OSHA Inspection: MAL-BER MANUFACTURING COMPANY

Issued

Oct 13, 2015

Abate by

Dec 1, 2015

Penalty

Initial $2,200 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii): Procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, 29 CFR 1910.147(c)(4)(ii)(A), (c)(4)(ii)(B), (c)(4)(ii)(C) and (c)(4)(ii)(D):    (a) Throughout Facility - On or about June 9, 2015, where servicing and maintenance is performed on equipment with hazardous energy sources, to include saws and presses, specific procedural steps for shutting down, isolating, blocking, and securing machines or equipment to control hazardous energy were not developed as required in paragraph (c)(4)(ii)(B) of this section.    (b) Throughout Facility - On or about June 9, 2015, where servicing and maintenance is performed on equipment with hazardous energy sources, to include saws and presses, specific procedural steps for the placement, removal, and transfer of lockout devices or tagout devices, and the responsibility for them were not developed as required in paragraph (c)(4)(ii)(C) of this section.    (c)  Throughout Facility - On or about June 9, 2015, where servicing and maintenance is performed on equipment with hazardous energy sources, to include saws and presses, specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures were not developed as required in paragraph (c)(4)(ii)(D) of this section.

Issued

Oct 13, 2015

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

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 Facility - On or about June 9, 2015, where a written lockout/tagout program with a generic energy control procedure was developed, a periodic inspection of the procedure was not conducted at least annually.

Issued

Oct 13, 2015

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(7)(i): The training program of the employer did not include all the training elements listed under Items A-C of 29 CFR 1910.147(c)(7)(i):  (a)  Throughout Facility - On or about June 9, 2015, each employee who performs servicing and maintenance, to include set-up, on equipment with hazardous sources of energy, did 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 as required in paragraph (c)(7)(i)(A) of this section.  (b)  Throughout Facility - On or about June 9, 2015, each employee, who operates equipment with hazardous energy sources on which servicing and maintenance is performed, was not trained to the level required for an affected employee in that they were not instructed in the purpose and use of the energy control procedure as required in paragraph (c)(7)(i)(B) of this section.  (c)  Throughout Facility - On or about June 9, 2015, where servicing and maintenance on equipment with hazardous sources of energy is performed, other employees whose work operations were in an area where energy control procedures were utilized were not instructed about the prohibition relating to attempts to restart or reenergize machines as required in paragraph (c)(7)(i)(C) of this section.  Abatement Note:  a.  Training must meet the minimum requirements outlined in 1910.147(c)(7). b.  Retraining shall be provided for all authorized and affected employees whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard or when there is a change in the energy control procedures or whenever a periodic inspection under paragraph (c)(6) of this section reveals, or whenever the employer has reason to believe that there are deviations from or inadequacies in the employee's knowledge or use of the energy control procedures; c.  The employer shall certify that employee training has been accomplished and is being kept up to date. The certification shall contain each employee's name and dates of training.

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $3,080 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.217(b)(6)(i): Two hand trip(s) on mechanical power press(es) using full revolution clutches did not have the individual operator's hand controls protected against unintentional operation:    (a) Production Area - On or about August 20, 2015, the hand controls on the two-hand trip used to operate the 90-Ton Johsnon Mechanical Power Press were not protected from unintentional operation; in that the buttons were not shrouded.

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(b)(7)(iii): Mechanical power press(es) using part revolution clutches were not provided with a means of selecting Off, Inch, Single Stroke, and Continuous with the clutch/brake control to select type of operation of the press.  And or/the fixing of selection was not capable of supervision by the employer.  (a) Production Area - On or about August 20, 2015, the 50-Ton Warco Part-Revolution Mechanical Power Presses, did not have means to select the operation mode which was capable of supervision by the supervisor, in that there was not a stroking selector switch.  (b) Production Area - On or about August 20, 2015, the 60-Ton Warco Part-Revolution Mechanical Power Presses, did not have means to select the operation mode which was capable of supervision by the supervisor, in that there was not a stroking selector switch.

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(b)(7)(v)(a): Each two-hand control for single stroke operations on mechanical power press(es) using part revolution clutches was not protected against unintended operation:  (a) Production Area - On or about August 20, 2015, the hand controls on the two-hand control used to operate the 400-Ton Niagara Mechanical Power Press were not protected from unintentional operation; in that the buttons were not shrouded.  (b) Production Area - On or about August 20, 2015, one of the hand controls on the two-hand control used to operate the 110-Ton Clearing Mechanical Power Press was not protected from unintentional operation; in that the right palm button was not shrouded.

Issued

Oct 13, 2015

Abate by

Dec 1, 2015

Penalty

Initial $3,080 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.217(c)(1)(i): The employer did not provide and ensure the usage of point of operation guards or properly applied point of operation devices on every operation performed on mechanical power press(es):    (a) Production Area - On or about August 20, 2015, the point of operation on the 250-Ton Verson Mechanical Power Press was not guarded, thereby exposing employees to the hazards created by the point of operation when walking behind the press during operating cycle.    (b) Production Area - On or about August 20, 2015, the point of operation on the 400-Ton Niagara Mechanical Power Press was not guarded, thereby exposing employees to the hazards created by the point of operation when walking behind the press during operating cycle.    (b) Production Area - On or about August 20, 2015, the point of operation on the 250-Ton Bliss Mechanical Power Press was not guarded, thereby exposing employees to the hazards created by the point of operation when walking behind the press during operating cycle.

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $2,200 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.217(c)(3)(vii)(d): Two hand controls used with mechanical power press(es) were not fixed in position so that only a supervisor or safety engineer was capable of relocating the controls:     (a) Production Area - On or about August 20, 2015, the two-hand control device used as a means to safeguard the point of operation on the 50-Ton Warco Mechanical Power Press was not in a fixed position where only a supervisor or safety engineer is capable of relocating the controls.     (b) Production Area - On or about August 20, 2015, the two-hand control device used as a means to safeguard the point of operation on the 60-Ton Warco Mechanical Power Press was not in a fixed position where only a supervisor or safety engineer is capable of relocating the controls.     (c) Production Area - On or about August 20, 2015, the two-hand control device used as a means to safeguard the point of operation on the 400-Ton Niagara Mechanical Power Press was not in a fixed position where only a supervisor or safety engineer is capable of relocating the controls.     (d) Production Area - On or about August 20, 2015, the two-hand control device used as a means to safeguard the point of operation on the 250-Ton Bliss Mechanical Power Press was not in a fixed position where only a supervisor or safety engineer is capable of relocating the controls.     (e) Production Area - On or about August 20, 2015, the two-hand control device used as a means to safeguard the point of operation on the 110-Ton Clearing Mechanical Power Press was not in a fixed position where only a supervisor or safety engineer is capable of relocating the controls.      Abatement Note:    One method of abatement is to fix the control device at the appropriate safety distance determined by the formula outlined in 29 CFR 1910.217(c)(3)(vii)(c).

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(c)(3)(viii)(d): Two hand trip devices of mechanical power press(es) were not fixed in position so that only a supervisor or safety engineer was capable of relocating the controls:   (a) Production Area - On or about August 20, 2015, the two-hand trip device used to operate the 90-Ton Johnson Mechanical Power Press was not in a fixed position where only a supervisor or safety engineer is capable of relocating the controls.   (a) Production Area - On or about August 20, 2015, the two-hand trip device used to operate the 250-Ton Verson Mechanical Power Press was not in a fixed position where only a supervisor or safety engineer is capable of relocating the controls.   Abatement Note: One method of abatement is to fix the control device at the appropriate safety distance determined by the formula outlined in 29 CFR 1910.217(c)(3)(iii)(e).

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $3,080 · Current $2,000 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:    (a) Production Area - On or about August 20, 2015, where employees operate Bliss, Clearing, Johnson, Niagara, Verson, and Warco Mechanical Power Presses, the employer did not establish an inspection program to ensure that all of the partts, auxiliary equipment, and safeguards, including the clutch/brake mechanism, antirepeat feature, and single-stroke mechanism, on each of the presses are in a safe operating condition and adjustment.

Issued

Oct 13, 2015

Abate by

Nov 6, 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, antirepeat feature, and single-stroke mechanism;  (a) Production Area - On or about August 20, 2015, where employees operate Niagara, Bliss, Johnson, Warco, Clearing and Verson Mechanical Power Presses, the employer did not inspect and test the presses to determine the condition of the clutch/brake mechanism, antirepeat feature, and single-stroke mechanism  Abatement Note: In addition to inspecting the equipment, the employer must: a.  Perform and complete necessary maintenance or repair, or both, on the clutch/brake mechanism, antirepeat feature, and single-stroke mechanism before operating the press; and  b.  Maintain a certification record of each maintenance task performed under the directed component of the inspection program that includes the date of the maintenance task, the signature of the person who performed the maintenance task, and the serial number, or other identifier, of the power press maintained.  Note to paragraph (e)(1)(ii): Inspections of the clutch/brake mechanism, antirepeat feature, and single-stroke mechanism conducted under the directed component of the inspection program are exempt from the requirement to maintain certification records specified by paragraph (e)(1)(i)(C) of this section, but inspections of the clutch/brake mechanism, antirepeat feature, and single-stroke mechanism conducted under the general component of the inspection program are not exempt from this requirement.repairs must be made as necessary, and a certification document must be created

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $2,640 · Current $2,316 Reduced

General-duty citation text

29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:    (a)  Production Area - On or about August 20, 2015, a job made extension cord used to supply power to a portable floor fan was made with equipment for which is was not listed or labeled.

Issued

Oct 13, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:(a)   (a)  Shop - On or about June 9, 2015, unused openings on the front of the control panel of the 250T Verson Power Press were not effectively closed.

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $0 · Current $0

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:  (a)  Shop Area - On or about August 20, 2015, strain relief was not provided for the power cord on the control unit for the 60T Warco Mechanical Press in that the outer insulation was pulled away from the control unit exposing the internal insulated conductors.  (b) Shop Area - On or about August 20, 2015, strain relief was not provided on the 60T Warco Mechanical Press power cord, in that the outer insulation was pulled away from the adapter plug and exposed the internal insulated conductors.

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $2,200 · Current $2,200

General-duty citation text

29 CFR 1910.179(j)(2): The following items were not be inspected for defects at intervals as defined in paragraph (j)(1)(ii) of this section or as specifically indicated, including observation during operation for any defects which might appear between regular inspections:     (a)  Shop - On or about August 20, 2015, all functional operating mechanisms of the Morris-Wheeler 10T Overhead Bridge Crane were not inspected daily for maladjustment interfering with proper operation as required in paragraph (j)(2)(i) of this section or for excessive wear of components as required in paragraph (j)(2)(vi) of this section.     (b)  Shop - On or about August 20, 2015, the Morris-Wheeler 10T Overhead Bridge Crane was not inspected daily for deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems as required in paragraph (j)(2)(ii) of this section.     (c)  Shop - On or about August 20, 2015, hooks on the Morris-Wheeler 10T Overhead Bridge Crane were not visually inspected daily for deformation or cracks.  Nor was a monthly inspection with a certification record which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook inspected as required in paragraph (j)(2)(iii) of this section.     (d)  Shop - On or about August 20, 2015, hooks on the Morris-Wheeler 10T Overhead Bridge Crane were not inspected monthly with a certification record which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook inspected as required in paragraph (j)(2)(iii) of this section.     (e)  Shop - On or about August 20, 2015, hoist chains, including end connections of the Morris-Wheeler 10T Overhead Bridge Crane were not visually inspected daily for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer's recommendations as required in paragraph (j)(2)(iv) of this section.     (f)  Shop - On or about August 20, 2015, hoist chains, including end connections, of the Morris-Wheeler 10T Overhead Bridge Crane were not inspected monthly with a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier of the chain which was inspected completed as required in paragraph (j)(2)(iv) of this section.     (g)  Shop - On or about August 20, 2015, rope reeving on the Morris-Wheeler 10T Overhead Bridge Crane was not inspected for noncompliance with manufacturer's recommendations as required in paragraph (j)(2)(vii) of this section

Issued

Oct 13, 2015

Abate by

Nov 6, 2015

Penalty

Initial $2,200 · Current $0 Reduced

General-duty citation text

29 CFR 1910.179(j)(3): A complete periodic inspection of crane(s) had not been conducted in the past 12 months:    (a)  Shop - On or about August 20, 2015, employees were using a Morris-Wheeler 10T Overhead Bridge Crane which had not received a complete inspection in the past 12 months.