OSHA Inspection: FERRO MAGNETICS CORPORATION

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $3,500 · Current $4,500

General-duty citation text

29 CFR 1910.133(a)(1): The employer did not ensure that each affected employee used appropriate eye or face protection when exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially injurious light radiation:    a/  Inside of the Storage Area, employee(s) replenishing the water levels inside of the battery cells belonging to industrial fork trucks such as the Caterpillar Fork Truck, m/n EP18T, s/n 6MM02656, were not provided with or used suitable eye and face protection.    b/  Inside of the Assembly Area, employee(s) using portable power tools such as the Ryobi Hand Drill, unknown m/n, s/n CS123611N100088, to assemble transformers were not provided with or used suitable eye and/or face protection.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.151(c): Where the eyes or body of any person was exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:    a/ Shipping Department at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044:  Employees who manually add potable water to the individual battery cells belonging to forklifts such as the Caterpillar Forklift, m/n EP18T, s/n 6MM02656, were not provided with suitable facilities for quick drenching or flushing of the eyes and body. 29 CFR 1910.132(d)(1): The employer did not assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of personal protective equipment (PPE):    The employer did not adequately assess:    a/  Shipping Department on the lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044:  Employees were required to replenish the water level inside of battery cells belonging to fork trucks and were exposed to contact with battery acid.    b/  Assembly Area on the lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044:  Employees were required to operate a variety of portable power hand tools and were exposed to struck-by injuries.    c/  Testing station for the fabrication process on the lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: Employees were required to test transformer components using power supply sources and were exposed to contact with electrical current.     d/  Dip station on the lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: Employees were required to test transformer lead components using a Slaughter AC HIPOT tester (model 1101-2.5) and were exposed to contact with electrical current.    e/  Dip station on the lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: Employees were required to dip transformers using a basket into a container holding product number TC0118-06 and were exposed to contact with toxic, caustic or noxious substances.     f/  High frequency testing area on the lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: Employees were required to test transformer components using Tenma 72-7675 power supply source and were exposed to contact with electrical current.     g/  Assembly line final testing station on the lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: Employees were required to test industrial battery chargers using power supply sources and were exposed to contact with electrical current.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $3,500 · Current $4,500

General-duty citation text

29 CFR 1910.138(a): The employer did not select and require employees to use appropriate hand protection when employees' hands are exposed to hazards such as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasions; punctures; chemical burns; thermal burns; and harmful temperature extremes:    a/  Dip station at the Lamination Area (lower level of facility at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044): The employer failed to provide suitable gloves for employees who use product TC0118-06, which includes irritation of the eyes and potential harm if skin absorption occurs (rash, itching or dermatitis all listed on the chemical safety data sheet).    b/ Shipping Department at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044:  Employees who manually add potable water to the individual battery cells belonging to forklifts such as the Caterpillar Forklift, m/n EP18T, s/n 6MM02656, were not wearing suitable hand protection.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $4,900 · Current $4,500 Reduced

General-duty citation text

29 CFR 1910.147(c)(1):  The employer did not establish a program consisting of energy control procedures, employee training, and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment was not isolated from the energy source and rendered inoperative:    a/  Transformer Department (lower level of facility at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044):  The employer did not develop or implement a lockout/tagout program for employee(s) who service the T & B Crimper Machine, m/n C13600, s/n 1602PP37705.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

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 are engaged in the activities covered by this section:    a/  Transformer Department (lower level of facility at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044):  The employer did not develop or implement specific lockout/tagout procedures for employee(s) who service the T & B Crimper Machine, m/n C13600, s/n 1602PP37705.  This machine operates off of 120 volts, 10,000 p.s.i. hydraulics, and a die return spring.  One employee received an amputation on 07/09/14 while changing out the die belonging to this machine.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $4,900 · Current $4,500 Reduced

General-duty citation text

29 CFR 1910.178(l)(2)(ii): Training did not consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace:    a/ Lower working level at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: The employer did not ensure employees who operate forklifts such as the Caterpillar Fork Truck, m/n EP18T, s/n 6MM02656, received training that consisted of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator's performance.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $4,900 · Current $3,700 Reduced

General-duty citation text

29 CFR 1910.178(p)(1): If at any time a powered industrial truck was found to be in need of repair, defective, or in any way unsafe, the truck was not taken out of service until it had been restored to safe operating condition:    a/ Lower working level at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: The front right solid rubber tire belonging to the Caterpillar Forklift, m/n EP18T, s/n 6MM02656, was badly damaged in that large chunks of rubber were missing throughout its circumference.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $4,900 · Current $4,500 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii):  Point(s) of operattion (P.O.O.) of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycles:    a/  Transformer Department (lower level of facility at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044):  The P.O.O. belonging to the T & B Crimper Machine, m/n C13600, s/n 1602PP37705, was unguarded.  The opening of the die belonging to this machine was approximately one inch.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $3,500 · Current $4,500

General-duty citation text

29 CFR 1910.303(a): The conductors and/or equipment required or permitted by this subpart were not approved:    a/  Inside of the high frequency testing department (lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044):  The employer failed to provide employees with an approved step-up transformer that was part of the equipment used during the high frequency testing of BIAS Transformers. The voltage generated by the Step-Up Transformer reached 1,200 volts.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $3,500 · Current $4,500

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in cabinets, boxes, and fittings were not effectively closed.    Old Welding Area of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044 (lower level):    a/  The 220 volt receptacle box was missing a knockout.    Assembly Area of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044 (lower level):    b/  The electrical disconnect box overlooking the test bench was missing a knockout.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(2)(i): Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:     Lamination Area of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044 (lower level):      a/  A quad-receptacle box was missing its face plate.    b/  A light switch was missing its face plate.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $4,900 · Current $4,500 Reduced

General-duty citation text

29 CFR 1910.332(b)(1): Employees were not trained in and familiar with the safety-related work practices required by 1910.331 through 1910.335 that pertained to their respective job assignments:     a/  High frequency testing department (lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044): The employer failed to provide adequate instruction to employees in safety-related work practices while working with live leads during the high frequency testing of BIAS Transformers. The voltage amounted to be 1,200 volts.  One employee performing this task was electrocuted on or about November 11, 2014.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $3,500 · Current $4,500

General-duty citation text

29 CFR 1910.334(a)(2)(ii): If there was a defect or evidence of damage that might expose an employee to injury, the defective or damaged flexible cord was not removed from service, and no employee may use it until repairs and tests necessary to render the equipment safe have been made:    a/ Old Welding Area of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044 (lower level):  The outer insulation belonging to an orange, flexible cord was badly damaged.  This flexible cord was supplying 120 volt electrical power to a Dewalt Abrasive Wheel Grinder, m/n DW756, s/n 2010-44-YL-4996.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $2,100 · Current $4,500

General-duty citation text

29 CFR 1910.1200(e)(1): The employer did not develop, implement, and/or maintain at the workplace a written hazard communication program which describes how the criteria specified in 29 CFR 1910.1200(f), (g), and (h) will be met:    a/  Dip station of lamination process (lower level of facility at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044): The employer failed to provide a written hazard communication program that details how labeling (f), safety data sheets (g), or employee training (h) were to be managed.  The hazards associated with employee use of  product TC0118-06 includes irritation of the eyes and potential harm if skin absorption occurs to include rash, itching or dermatitis.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(e)(1)(i): A list of the hazardous chemicals known to be present using a product identifier that was referenced on the appropriate safety data sheet (the list may be compiled for the workplace as a whole or for individual work areas) was not prepared:    a/  A list of hazardous materials used by employees was not prepared.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(f)(5)(i): The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged, or marked with the identity of the hazardous chemical(s) contained therein:    a/  Lamination area of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044 (lower level): The container partially filled with up to 110 gallons of Epic Resin was not labeled with the appropriate identity of this hazardous chemical.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(f)(5)(ii): Appropriate hazard warnings, or alternatively, words, pictures, symbols, or combination thereof, which provided at least general information regarding the hazards of the chemicals, and which, in conjunction with the other information immediately available to employees under the hazard communication program, did not provide employees with the specific information regarding the physical and health hazards of the hazardous chemical:    a/  Lamination area of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044 (lower level): The container partially filled with up to 110 gallons of Epic Resin was not labeled with the appropriate hazard warning.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(h)(3)(iv): The employer did not train employees regarding the new label elements and safety data sheets format:    a/  Lamination area of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044 (lower level): Employees using product number TC0118-06 were not adequately trained in the new label elements and safety data sheets format as of November 11, 2014.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $49,000 · Current $4,500 Reduced

General-duty citation text

29 CFR 1910.333(a)(2): Where exposed live parts were not deenergized, other safety related work practices were not used to protect employees who could be exposed to the electrical hazards involved:    a/  High frequency testing department (lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044): The employer failed to provide employees with adequate safety related work practices while working with live leads during the high frequency testing of bias transformers. The voltage amounted to be 1,200 volts.  One employee performing this task was electrocuted on or about November 11, 2014.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(1)(i): Employees working in areas where there were potential electrical hazards were not provided with electrical protective equipment that was appropriate for the specific parts of the body that needed to be protected and for the work being performed:    a/  High frequency testing department (lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044): The employer failed to provide employees with adequate personal protective equipment for the hands while working with live leads during the high frequency testing of bias transformers. The voltage amounted to be 1,200 volts.  One employee performing this task was electrocuted on or about November 11, 2014.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(2)(ii): Protective shields, protective barriers, or insulating materials were not used to protect each employee from shock, burns, or other electrically related injuries while that employee was working near exposed energized parts:    a/  High frequency testing department (lower level of 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044): The employer failed to provide employees with adequate engineering controls while working with live leads during the high frequency testing process.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.132(d)(2): The employer did not verify that the required workplace hazard assessment has been performed through a written certification that identifies the workplace evaluated; the person certifying that the evaluation has been performed; the date(s) of the hazard assessment; and, which identifies the document as a certification of hazard assessment:    a/  The workplace hazard assessment was not certified.

Issued

May 1, 2015

Abate by

Oct 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(l)(6):  The employer did not certify that each operator had been trained and evaluated as required by this paragraph (l). The certification did not include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation:    a/ Lower working level at 4328 Bridgeton Industrial Park Drive, Bridgeton, MO 63044: The employer did not certify employees who operate forklifts such as the Caterpillar Fork Truck, m/n EP18T, s/n 6MM02656.