OSHA Inspection: KMK METAL FABRICATORS, INC

Issued

May 5, 2015

Abate by

Jul 17, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:     The employer did not ensure that procedures were developed for the control of potentially hazardous energy for employees who were performing serving operations on equipment such as, but not limited to, press brakes, part and full revolution presses, horizontal and vertical bandsaws, turret punch presses, resistance welders, pipe tube benders and milling machines.  Servicing operations included, but not limited to, die changing and blade changing.

Issued

May 5, 2015

Abate by

Jul 17, 2015

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirement of this standard were being followed:    The employer did not ensure that inspections of the energy control procedures were conducted at least annually.

Issued

May 5, 2015

Abate by

Jun 1, 2015

Penalty

Initial $2,100 · Current $1,470 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i)(B): Affected employee(s) was not instructed in the purpose and use of the energy control procedure:    Employees had not been provided with affected employee level of training in the purpose and use of energy control program.

Issued

May 5, 2015

Abate by

Jun 1, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.157(g)(2): The educational program to familiarize employees with the general principles of fire extinguisher use and the hazards involved with incipient stage fire fighting was not provided to all employees upon initial employment, and at least annually thereafter:    Annual training on fire extinguishers was not provided to employees.

Issued

May 5, 2015

Abate by

Jun 30, 2015

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): One or more methods of machine guarding was not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:    The following equipment was not adequately guarded to protect operators and other employees:    A.  Across from the welding area, a Fabrica horizontal bandsaw, unused portion of the blade.    B.  In the Press Break Area, A CNC machine (Cincinnati SABRE 100) had an Interlocked door bypassed.        C.  In the Press Break Area, The LaGuna Republic manual milling machine was not guarded to protect employees from flying chips.  There were no chip guards installed on the machine.    D.  In the Press Break Area, The Latour 3D wire bender uncoiler and reel was not guarded to protect employees from rotating and in-running nip points of wire through guide pulley.    E.  In the Press Break Area, The Latour 3D wire bender straightener section was not guarded to protect employees from in-running nip points.    F.  In the Press Break Area, The AIM wire former bending tube was not guarded to protect employees from the whipping action of the bent wire or the point of operation.  The point of operation is inset 32 inches.   Wire length may reach and expand beyond the 34 inch width table.    H.  In the Press Break Area, The AIM wire former rotating uncoiler on the straightening section was not guarded to protect employees from rotating and in-running nip points.     I.  In the old tool room, a Bridgepot Mill was not guarded to protect employees from flying chips.  There were no chip guards installed on the machine.    J.  In the old tool room, a Rockwell Model 20 vertical bandsaw had a 10 1/2 inch section of the blade that was exposed and not guarded.    K.  In the old tool room, a Cincinnati lathe had the chuck key left in place and was not guarded.    L.  In the old tool room, a Versa-Kut aluminum chop was guarded at the spindle end, nut and blade.    M.  In the wire way area, the guard on Amada PEGA-357 Turret Punch Press was missing a window section allowing an opening through the guard of 13 inches x 7 1/2 inches with the rotary turret 6 1/2 inches.    N.  In the Robot Area, the Dynamic Robot welding cell, DR-4000, was not properly guarded.  The 3 station welding cell had 3 door openings (41 1/2 inches wide x 74 inches tall) with welding operations conducted 16 inches inset form the door opening.    O.  In the wire way area, the back area of the Wysong Sheer was not guarded to prevent contact with moving back gauge.       P.  In the pipe bending area, South 3T Pines pipe tube bender had rotating adjustment controls that were not guarded.

Issued

May 5, 2015

Abate by

Sep 30, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): Point(s) of operation of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s):     The point of operation of the following equipment was not guarded in such a way as to prevent the operator from having any part of their body in the danger zone during the operating cycle:      A.  The Latour 3D wire bender perimeter barrier guard was not completely installed or secured and missing sections.      B.  The hinged point of operation guard on cut length section of the RNG Straightener had an opening in the guard 4 inches x 2 1/2 inches.  Nor was it fixed or interlocked with the machine controls.         C.  The die point of operation of the hydraulic MAC press had a 5/8 inch opening that was not guarded.      D.  The 5 Amada press brakes located in the press break area were not guarded.  Press brake die opening, from the North press break to the South press brake, were 3 1/2 inches, 3 1/2 inches, 1 inch, 3 1/2 inches and 4 1/4 inches.      E.  The Amada press brake located at the North end of the wire way area, next to the press brake area door, was not guarded.      F.  The blue Amana press brake located in the wire way area, next to the Amana PEGA 357 Turret Punch Press, had a die opening of 1 1/2 inches.      H.  The two 3T Pines tub pipe benders, located in the pipe bending area.

Issued

May 5, 2015

Abate by

May 29, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.217(b)(7)(ii): Mechanical power press(es) using part revolution clutches were not provided with a red color stop control, which would immediately deactivate the clutch and apply the brake, override any other control, and require use of the operating (tripping) means selected to reactivate the clutch:    A Bliss 21S OBI part revolution mechanical power press, located in the press area, did not have an emergency stop control.

Issued

May 5, 2015

Abate by

May 29, 2015

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.217(b)(7)(iv): The inch operating means on mechanical power press(es), using part revolution clutches, was not designed to prevent exposure of the worker's hands within the point of operation:    In the press area, Bliss OBI Part revolution mechanical power press inch controls were mounted 7 inches apart allowing actuation with one hand.

Issued

May 5, 2015

Abate by

May 29, 2015

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.219(b)(1): Flywheel(s) with parts seven feet or less above floor(s) or platform(s) were not guarded in accordance with the requirements specified in 29 CFR 1910.219(b)(1)(i) through (b)(1)(iv)(a):    In the press area, Bliss 21S OBI Part Revolution Mechanical Power Press flywheel was not guarded at the inner face and outer face, as well as the turnover bar slot.

Issued

May 5, 2015

Abate by

May 29, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.217(c)(2)(i)(a): Point of operation guard(s) on mechanical power press(es) did not prevent entry of hands or fingers into the point of operation by reaching through, over, under or around the guard(s):    The following equipment did not prevent the operator from reaching over, under, through or around the guard:    A.  In the press area, the Bliss 21S OBI part revolution press had a guard opening front was 7 1/2 inches x 4 1/2 inches and over the top and back of guard.  The guard was within 7 inches of the die hazards.    B.  In the press area, Toledo No 5A OBI full revolution mechanical power press guard was open along the top and back and had a 3 inch x 20 inch wide opening in the guard located 6 1/2 inches from the die hazards.

Issued

May 5, 2015

Abate by

Jun 1, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.217(d)(9)(i): The employer did not establish a die setting procedure for mechanical power press(es) that would ensure compliance with 29 CFR 1910.217(b)(c)(a):    The employer did not have die setting procedures established when employees where setting dies.

Issued

May 5, 2015

Abate by

Jun 1, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.217(e)(1)(i): A program of periodic and regular inspections of mechanical power press(es) was not established and followed to ensure that all parts, auxiliary equipment and safeguards were in a safe operating condition and adjustment:    The employer did not establish a program of periodic and regular inspections of mechanical power presses.

Issued

May 5, 2015

Abate by

Jun 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(e)(1)(ii): Mechanical power press(es) were not inspected and tested at least weekly to determine the condition of the clutch/brake mechanism, anti-repeat feature, and single stroke mechanism:   The employer did not inspect and test mechanical power presses weekly.

Issued

May 5, 2015

Abate by

Jun 1, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.217(e)(3): Original and continuing competence of personnel maintaining mechanical power press(es) was not insured:    The employer did not ensure that employees were trained to care for, inspect and maintain mechanical power presses.

Issued

May 5, 2015

Abate by

May 15, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.217(f)(2): Supervision to ensure that correct operating procedures were being followed on mechanical power press(es) was inadequate:    The keys for the hand/foot and mode selection controls were left in the controls and were not supervised on the Toledo No 5A OBI Full Revolution Mechanical Power Press, located in the press area.

Issued

May 5, 2015

Abate by

May 11, 2015

Penalty

Initial $2,800 · Current $1,960 Reduced

General-duty citation text

29 CFR 1910.242(b): Compressed air used for cleaning purposes was not reduced to less than 30 p.s.i.:    Compressed air nozzle located at CNC SABER 1000 was at 65psi.

Issued

May 5, 2015

Abate by

May 15, 2015

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

29 CFR 1910.253(b)(4)(iii): Oxygen cylinders in storage were not separated from fuel gas cylinders or combustible materials (especially oil or grease), a minimum distance of 20 feet (6.1 m) or by a noncombustible barrier at least 5 feet (1.5 m) high having a fire resistant rating of at least one-half hour:    Oxygen cylinders, located south of the press brake area, were stored with fuel gas cylinders.

Issued

May 5, 2015

Abate by

May 15, 2015

Penalty

Initial $2,800 · Current $1,960 Reduced

General-duty citation text

29 CFR 1910.255(a)(4): Controls of all automatic or air and hydraulic clamps were not arranged or guarded to prevent the operator from accidentally activating them:    In the welding area, the foot pedal of the H&H welder S/N H5723, was not arranged or guarded to prevent operator from accidently activating it.

Issued

May 5, 2015

Penalty

Initial $2,800 · Current $1,960 Reduced

General-duty citation text

29 CFR 1910.255(b)(3): All doors and access panels of all resistance welding machines and control panels were not kept locked and interlocked to prevent access, by unauthorized persons, to live portions of the equipment:    In the welding area, the control access door of the H&H welder, serial number H5723, was not kept locked and interlocked.  The control cabinet door was open.

Issued

May 5, 2015

Abate by

Jun 30, 2015

Penalty

Initial $2,800 · Current $0 Reduced

General-duty citation text

29 CFR 1910.255(e): Periodic inspection was not made by qualified maintenance personnel, and a certification record was not maintained:    Periodic inspections were not conducted and certified for the resistance welders, located in the welding department.

Issued

May 5, 2015

Abate by

Jun 30, 2015

Penalty

Initial $2,800 · Current $1,960 Reduced

General-duty citation text

29 CFR 1910.255(b)(4): All press welding machine operations, where there is a possibility of the operator's fingers being under the point of operation, were not effectively guarded by the use of a device such as an electronic eye safety circuit, two hand controls or protection similar to that prescribed for punch press operation.    The following equipment in the welding area, were not effectively guarded when operator's fingers could be in the point of operation:    A.  H&H resistance welder had a point of operation opening of 1/2 inch.    B.  H&H welder, serial number H5723, had a point of operation opening of 1 inch.    C.  Meritus Uniman welder had a point of operation had an opening of 7/8 inch.

Issued

May 5, 2015

Abate by

May 29, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.303(b)(1)(ii): Electrical equipment was not free from recognized hazards, based on the mechanical strength and durability, including, for parts designed to enclose and protect other equipment, the adequacy of the protection thus provided:    The following equipment was not free from recognized hazards:    A.  In the press brake area, on the Bliss 21S OBI part revolution mechanical power press, Outer semi-rigid conduit and electrical insulation on the foot control pedal was broken and damaged exposing internal conductors to damage.    B.  In the press brake area, on the Toledo No 5A OBI full revolution mechanical power press, Outer semi-rigid conduit and electrical insulation on the foot control pedal was broken and damaged exposing internal conductors to damage.    C.  In the press brake area, on the Latour 3D wire bender uncoiler, the door on the electrical cabinet containing equipment energized to 230VAC, was damaged and bent open on the lower left corner of the door.    D.  In the welding area, on the Versa-Kut Aluminum chop saw, the electrical junction box was broken and missing sections of the housing.

Issued

May 5, 2015

Abate by

May 29, 2015

Penalty

Initial $3,500 · Current $2,450 Reduced

General-duty citation text

29 CFR 1910.303(g)(2)(i): Except as elsewhere required or permitted by Subpart S of Part 1910, live parts of electric equipment operating  at 50 volts or more were not guarded against accidental contact by use of approved cabinets or other forms of approved enclosures or by any of the means identified in paragraphs (A), (B), (C), and (D) of 29 CFR 1910.303(g)(2)(i):    The following equipment was not guarded against accidental contact:    A.  In the press brake area, the door to the Latour 3D wire bender control cabinet, containing electrical equipment energized to 230VAC, was standing open.    B.  The RNG Straightener control panel was missing the 120VAC electrical connector cover.    C.  The electrical control cabinet door on the RNG Straightener was standing open and not secured closed.

Issued

May 5, 2015

Abate by

May 15, 2015

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:    In the welding area, an electrical knockout was missing on the Kimura Denuki Resistance welder, Serial Number 77736 240VAC disconnect box.

Issued

May 5, 2015

Abate by

May 15, 2015

Penalty

Initial $2,800 · Current $1,960 Reduced

General-duty citation text

29 CFR 1910.305(g)(2)(iii): Flexible cords and cables were not connected to devices and fittings so that strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws:    In the wire way area, next to the TruPunch press, the power cord for a 110VAC floor fan was missing the strain relieve device where the cable ran into the motor housing.

Issued

May 5, 2015

Abate by

Jun 1, 2015

Penalty

Initial $2,100 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1200(h)(1): Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:    Temporary employees were not provided with training on hazardous chemicals in the work area.  Employees utilize cutting fluids and lubricants.