OSHA Inspection: KAPCO, INC.

Issued

Jul 31, 2015

Abate by

Oct 2, 2015

Penalty

Initial $7,000 · Current $7,000

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:    (a) Welding area; Energy isolation procedures were not utilized when the machine operators and setup personnel performed cleaning and servicing tasks on welders such as, but not limited to:      (i) The Fanic Robotic Welder #PL301,     (ii) The OTC Welding Robot #PL302,     (iii) The ArcWorld by Motoman 100 welding robot #PL303,    (iv) The High Weld spot welder #PL350, and     (v) The T.J. Snow spot welder #PL351.

Issued

Jul 31, 2015

Abate by

Oct 2, 2015

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(B): Lockout and tagout devices were not standardized within the facility in at least one of the following criteria: color; shape; or size:    (a) Metal Stamping Area; Lockout devices used during die changing operations on metal stamping machinery were not standardized, similar types of silver banded locks were used for security purposes.

Issued

Jul 31, 2015

Abate by

Oct 2, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): Authorized employee(s) do not receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control:    (a) Throughout the facility; Operator and set-up personnel were not trained as authorized employees for the control of hazardous energy including, but not limited to:    (i) Mechanical Press #PL115; The operator was not trained as an authorized employee for the control of hazardous energy, prior to affixing a lock out device, and    (ii) Welding area; Operators and setup personnel were not trained as authorized employees for the control of hazardous energy prior to performing servicing and set up activities.

Issued

Jul 31, 2015

Abate by

Oct 2, 2015

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(d)(4)(i): Lockout or tagout devices are not affixed to each energy isolating device by authorized employees:     (a) Welding area; Lockout or tagout devices were not applied to isolate all energy sources while the machine operators and setup personnel performed cleaning and servicing tasks on welders such as, but not limited to:    (i) The Fanic Robotic Welder #PL301,    (ii) The OTC Welding Robot#PL302,    (iii) The ArcWorld by Motoman 100 welding robot #PL303,    (iv) The High Weld spot welder #PL350, and    (v) The T.J. Snow spot welder #PL351.

Issued

Jul 31, 2015

Abate by

Aug 28, 2015

Penalty

Initial $70,000 · Current $70,000

General-duty citation text

29 CFR 1910.255(b)(4): All press welding machine operations, where there was a possibility of the operator's fingers being under the point of operation, were not effectively guarded by use of a device such as an electronic eye safety circuit, two hand controls or protection similar to that prescribed for punch press operation:    (a) T.J. Snow spot welder #PL351; On or about February 5, 2015, the point of operation was not effectively guarded.

Issued

Jul 31, 2015

Abate by

Aug 28, 2015

Penalty

Initial $70,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.255(b)(4): All press welding machine operations, where there was a possibility of the operator's fingers being under the point of operation, were not effectively guarded by use of a device such as an electronic eye safety circuit, two hand controls or protection similar to that prescribed for punch press operation:    (a) Hi-Weld spot welder #PL350; On or about February 5, 2015 the point of operation was not effectively guarded.

Issued

Jul 31, 2015

Abate by

Aug 28, 2015

Penalty

Initial $38,500 · Current $70,000

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:    (a) Throughout the facility; Operators were not effectively protected from rotating parts and flying chips such as, but not limited to:    (i) The Bridgeport milling machine, in the maintenance area; The rotating chuck and tooling shaft were not guarded from accidental contact and the operator was not protected from flying metal shavings,      (ii) The metal straightener on the Komatsu 250 ton mechanical press #PL122; The discharge rollers on the metal straightener were not effectively guarded, and      (iii) The Rowe metal straightener on the Clearing 200 ton mechanical press line #PL110; The ingoing feed rollers and the discharge rollers on the metal straightener were not effectively guarded.    KAPCO, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.212(a)(3)(ii), which was contained in OSHA inspection # 961283, Citation 1, Item 1 issued on June 14, 2014, and was affirmed as a final order on July, 9 2014, with respect to a workplace located at 805 Seminole Avenue, Osceola, WI.

Issued

Jul 31, 2015

Penalty

Initial $7,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1904.39(a)(2): The employer did not report an in-patient hospitalization, amputation, or loss of an eye as a result of a work-related incident to OSHA within twenty-four (24) hours:    (a) KAPCO, Inc. Osceola, WI; The employer did not report a right index finger amputation to OSHA within 24 hours.

Issued

Jul 31, 2015

Abate by

Oct 2, 2015

Penalty

Initial $1,100 · Current $1,100

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:    (a) Throughout the facility; The employer did not conduct periodic inspections of the energy control procedures and conduct a review with authorized employees to ensure there were no deficiencies.