OSHA Inspection: NATIONAL CYCLE, INC.

Issued

Dec 4, 2015

Abate by

Dec 10, 2015

Penalty

Initial $6,300 · Current $3,465 Reduced

General-duty citation text

29 CFR 1910.37(a)(3): Exits routes were not maintained to provide free and unobstructed access.    a) National Cycle, Inc.  -  The exit route located in the mold shop tool area along  the west wall was not kept free and unobstructed. The exit discharge was obstructed on the outside by a chain link fence and an overgrowth of vegetation which prevented the exit door from opening.

Issued

Dec 4, 2015

Abate by

Dec 10, 2015

Penalty

Initial $5,400 · Current $2,970 Reduced

Hazardous substances 0460156022102584

General-duty citation text

29 CFR 1910.106(e)(2)(ii)(b)(1):  The employer did not ensure the quantity of liquid located outside of an inside storage room or storage cabinet in a building or in any one fire area of a building did not exceed    (1)  25 gallons of Category 1 flammable liquids in containers  (2)  120 gallons of Category 2, 3, or 4 flammable liquids in containers  (3)  660 gallons of Category 2, 3, or 4 flammable liquids in a single portable tank.    a) National Cycle, Inc.- The employer did not ensure the quantity of liquid located in the Coating Department did not exceed 120 gallons of Category 2, 3, or 4 flammable liquids in a container.     There was a total of 220 gallons of Category 2 and Category 3 flammable liquids stored in the Coating Department including, one full 55 gallon drum of Isopropyl Alcohol,  one full 55 gallon drums of N- Butyl Alcohol, one full 55 gallon drum of VM & P Naphtha, and one full 55 gallon drum of 1-Methoxy-2-propanol.

Issued

Dec 4, 2015

Abate by

Dec 10, 2015

Penalty

Initial $5,400 · Current $2,970 Reduced

General-duty citation text

29 CFR 1910.151(c):   Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body shall be provided within the work area for immediate emergency use:     a) National Cycle, Inc.- The Fend-all Porta Stream II 16 gallon emergency eyewash station in the coating department, did not contain adequate water or a saline solution to flush the eyes in the event of an accidental splash to n-Butyl alcohol.     No abatement certification or documentation is required for this item.

Issued

Dec 4, 2015

Abate by

Sep 9, 2016

Penalty

Initial $6,300 · Current $3,625 Reduced

Hazardous substances 04601560

General-duty citation text

29 CFR 1910.1000(a)(2): Employees were exposed to an airborne concentration of n-Butyl alcohol listed in Table Z-1 in excess of the 8-hour Time-Weighted Average concentration of 100 parts per million particles of air (100 ppm) for any 8-hour work shift of a 40-hour work week.    The employer did not ensure that employee exposure to n-Butyl alcohol did not exceed 100 parts per million (ppm) of air, as an 8-hour time weighted average (TWA).     a) An employee in the coating department was exposed to n-Butyl alcohol at an 8-hour time-weighted average level of 171.12 ppm, approximately 1.7 times the permissible exposure limit of 100 ppm. This limit is established to prevent respiratory tract irritation, cardiovascular disturbances, central nervous system depression, and muscle weakness.     The sampling was performed for 452 min during one shift on November 19, 2015. Zero exposure was assumed for the unsampled time of 28 minutes.

Issued

Dec 4, 2015

Abate by

Sep 9, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 04601560

General-duty citation text

29 CFR 1910.1000(e): Feasible administrative or engineering controls are not determined and implemented to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d) and protective equipment or any other protective measures are not used to keep the exposure of employee to air contaminants within the limits prescribed:   National Cycle, Inc.- Feasible engineering controls and work practices were not instituted to reduce and maintain employee exposures to n-Butyl alcohol at or below the permissible exposure limit:   a) An employee in the coating department was exposed to n-Butyl alcohol at an 8-hour time-weighted average level of 171.12 ppm, approximately 1.7 times the permissible exposure limit of 100 ppm.  See instance description in item 4a of this citation.  Methods of engineering controls and work practices under these circumstances include, but are not limited to:    1) Seek the expertise of a competent individual such as an engineer or certified industrial hygienist to assess existing controls and work practices in the coating department; obtain recommendations to improve existing controls and work practices, and prepare design documentation for the successful installation of recommended equipment.    2) Ensure all containers of n-butyl are kept covered during the process of coating to prevent  evaporation of n-butyl into the ambient air.     3) Consider alternate means of coating the windshield instead of using a flow hose.   Abatement Schedule:  Step 1: Effective respiratory protection shall be provided and used by exposed employees as an interim protective measure until feasible engineering controls can be implemented or whenever such controls fail to reduce employee exposure to within permissible exposure limits.  Abatement Date: December 31, 2015  Step 2: A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering measures to control employee exposures to hazardous substances as referenced in this citation. This plan shall include, at a minimum, target dates for the following actions which must be consistent with abatement dates required by this citation:  1. Evaluation of engineering options; 2. Selection of optimum control methods and completion of design; 3. Procurement, installation, and operation of selected controls measures; and 4. Testing and acceptance or modifications/redesign of controls.  Note: All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.  Abatement Date: January 25, 2016  Step 3: Abatement shall have been completed by the implementation of feasible engineering controls upon verification of their effectiveness in achieving compliance.  Abatement Date: March 8, 2015

Issued

Dec 4, 2015

Abate by

Jan 29, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(a)(2): A respirator was not provided by the employer to each employee when such equipment was necessary to protect the health of the employee:    a) National Cycle, Inc.- The employer did not ensure that employee(s) in the coating department who were exposed to n-Butyl alcohol in excess of the permissible exposure limit were provided respirators.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $5,400 · Current $2,970 Reduced

Hazardous substances 0460156022102584

General-duty citation text

29 CFR 1910.1200(e)(1): The employer did not develop, implement, and/or maintain at each workplace, a written hazard communication program which describes how the criteria specified in paragraphs (f), (g), and (h) of this section for labels and other forms of warning, safety data sheets, and employee information and training will be met.    a) National Cycle, Inc. - The employer did not implement at the workplace a written hazard communication program in accordance with 29 CFR 1910.1200 that describes at least the following:    1) Requirement for labeling of containers or hazardous chemicals;    2) Safety data sheet(s) availability;    3) Training of employees;    4) A complete list of hazardous chemicals known to be in the workplace;    5) Methods to inform employees of the hazards of non-routine tasks; and,    6) Methods to inform other employee(s) of safety data sheets availability; the labeling system and any precautionary measures to protect employees.    The employees in the coating and polishing departments were exposed to hazardous chemicals, including, but not limited to combustible dust, 1-Methoxy-2-propanol, Isopropyl Alcohol, VM & P Naphtha and n-Butyl Alcohol.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 046015602584

General-duty citation text

29 CFR 1910.1200(f)(6): Workplace labeling.  Except as provided in paragraphs (f)(7) and (f)(8) of this section, the employer shall ensure that each container of hazardous chemicals in the workplace is labeled, tagged or marked with either:  (i) The information specified under paragraphs (f)(1)(I) through (v) of this section for labels on shipped containers; or,  (ii) Product identifier and words, pictures, symbols, or combination thereof, which provide at least general information regarding the hazards of the chemicals, and which, in conjunction with the other information immediately available to employees under hazard communication program, will provide employees with the specific information regarding the physical and health hazards of the hazardous chemical.  a) National Cycle, Inc. - The employer did not ensure each spray bottle in the Coating Department was labeled tagged or marked with both the identity of the hazardous chemical container and the general information regarding the hazards of the chemical. The labels on the spray bottles of the Isopropyl Alcohol, VM & P Naphtha, and n-Butyl Alcohol, only contained the product identifier but did not provide any information regarding hazards of the chemical.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 0460156022102584

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:  a) National Cycle, Inc. - The employees in the coating and polishing departments were not provided information and training on hazardous chemicals. The employees were exposed to hazardous chemicals, including, but not limited to combustible dusts,  1-Methoxy-2-propanol, Isopropyl Alcohol, VM & P Naphtha and n-Butyl Alcohol.