OSHA Inspection: FIC AMERICA CORP.

Issued

Jul 1, 2015

Abate by

Nov 2, 2015

Penalty

Initial $7,000 · Current $5,250 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section:    Bloomingdale:     On or about January 6, 2015, the employer did not develop and document hazardous energy control procedures for utilization by employees who perform maintenance and servicing tasks on machine cells lines such as LH-2. Employees were exposed to amputation hazards.    Carol Stream: Stamping    The employer did not develop and document hazardous energy control procedures for utilization by employees who perform maintenance and servicing tasks on the SMG Feintool 630 #1 Mandrel. Employees were exposed to amputation hazards.      Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Nov 2, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii): The energy control procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, including, but not limited to items (a) through (d) of this section:    Carol Stream Stamping:    The energy control procedures did not identify how to isolate gravity which is listed under energy sources on the procedure for machines:     a) H&F 2500 Transfer #1     b) Komatsu 800 Blanker # 2.    c) SMG Feintool 630 #1     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Nov 2, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(5)(i): Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be provided by the employer for isolating, securing or blocking of machines or equipment from energy sources:    Operators assigned to perform job tasks such as die setting were not provided with locks for use on mechanical power presses.    a) SMG Feintool 630# 1    b) H&F 2500 Transfer #1     c) Komatsu 250T     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903(d).

Issued

Jul 1, 2015

Abate by

Nov 2, 2015

Penalty

Initial $5,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.217(c)(3)(iii)(f): Guards shall be used to protect all areas of entry to the point of operation not protected by the presence sensing device.    Bloomingdale- Employees working at the Komatsu 250 Ton and the Komatsu 300 Ton mechanical power presses were not protected while working in areas not guarded by presence sensing devices. Employees were exposed to amputation injuries resulting from pinch point and struck-by hazards.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Aug 18, 2015

Penalty

Initial $7,000 · Current $5,250 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees:    (a) Welding- The employer did not provide adequate training to ensure that employees assigned to perform servicing and maintenance understood the function of the hazardous energy control program.  Operators had not gained the knowledge and skills required for safe application and usage of energy controls such as, but not limited to energy isolating devices and hardware.    (b) Stamping- The employer did not provide adequate training to ensure that employees assigned to perform servicing and maintenance understood the function of the hazardous energy control program. Operators had not gained the knowledge and skills required for safe application, usage, and the removal of the energy controls such as, but not limited to energy isolating devices and hardware.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Nov 2, 2015

Penalty

Initial $7,000 · Current $5,250 Reduced

General-duty citation text

29 CFR 1910.147(d): The established procedures for the application of energy control (the lockout or tagout procedures) shall cover the following elements and actions and shall be done in the following sequence:    Employees who performed servicing and maintenance on and around welding robots were not required to:  (1) know the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy,   (2) turn off and shut down the machines,  (3) physically locate and operate energy isolating devices in such a manner as to isolate the machine or equipment from the energy source,  (4) affix lockout or tagout devices to each energy isolating device,  (5) prior to starting work on machines that have been locked out or tagged out, verify that isolation and deenergization of the machine or equipment have been accomplished.    Employees required to rely upon electronic control components were exposed to struck-by hazards from unexpected start-up and energizing of welders including, but not limited to Welder F-01 and Welders in E-Line.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Oct 1, 2015

Penalty

Initial $7,000 · Current $5,250 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:    Carol Stream:     (a) Stamping- Employees working at the SMG Feintool 630 #1 were exposed to injury from being struck by rotating equipment components during regular coil loading operations.    (b) Stamping- Employees working at the SMG Feintool 630 #1 were exposed to injury while clearing scrap from the cutoff shear. A movable guard on the scrap chute was provided a sensor that had been bypassed.    (c) Welding- Operators and other employees were exposed to being struck by flying sparks and chips from welding operations on the G-03 welder.     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Oct 1, 2015

Penalty

Initial $7,000 · Current $5,250 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefor, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.    (a) Employees feeding and removing parts from the point of operation in cell line machines including to LH-2 were exposed to pinch point hazards due to installation of ineffective electronic safeguarding devices.    (b) Employees feeding and removing parts from the point of operation at robotic welding stations including E-line process 3 were exposed to pinch point hazards due to installation of ineffective electronic safeguarding devices.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Aug 18, 2015

Penalty

Initial $7,000 · Current $5,250 Reduced

General-duty citation text

29 CFR 1910.333(a): Safety-related work practices were not employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contacts, when work was performed near or on equipment or circuits which were or could be energized.    An employee assigned to troubleshoot and/or perform voltage testing at equipment energized at up to 480 volts AC without employing adequate safety related work practices was exposed to electrical hazards likely to result in electrocution, shock and/or burns from contact with energized parts.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Aug 18, 2015

Penalty

Initial $7,000 · Current $5,250 Reduced

General-duty citation text

29 CFR 1910.335(a)(1): Employees working in areas where there were potential electrical hazards were not provided with, and did not use, electrical protective equipment that is appropriate for the specific parts of the body to be protected and for the work to be performed:    An employee was assigned to troubleshoot and/or perform voltage testing at equipment energized at up to 480 volts AC. The employer did not provide the employee with the adequate personal protective equipment exposing the employee to electrocution, shock and or burns from contact with energized parts.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Jul 28, 2015

Penalty

Initial $27,500 · Current $20,600 Reduced

General-duty citation text

29 CFR 1910.184(c)(7): Sling(s) were not padded or protected from sharp edges of their loads:    On 2/27/15 at the Carol Stream facility in the stamping area the employer did not protect chain slings from sharp edges of metal strip coils being hoisted near employees  on the SMG Feintool 630 #1. Employees were exposed to being crushed by falling/rolling metal coils.    FIC America Corp. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.184(c)(7), which was contained in OSHA inspection number 905809, citation number 1, item number 1 and was affirmed as a final order on November 5, 2013, with respect to a workplace located at 301 Long View Drive Bloomingdale IL, 60108.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jul 1, 2015

Abate by

Jul 28, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(j)(1)(i): Receptacles had live parts that were normally exposed to employee contact:  The employer provided a 120 Volt AC receptacle for use at the front of the SMG Feintool 630 mechanical power press that exposed employees to contact with live parts because the receptacle did not have a cover.  Abatement certification is required for this item in accordance with 29 CFR 1903.19(c).