OSHA Inspection: KENMODE TOOL AND ENGINEERING, INC.

Issued

Dec 18, 2015

Abate by

Feb 8, 2016

Penalty

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

General-duty citation text

29 CFR 1910.147(c)(4)(ii): The procedures shall 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, the following: (A) A specific statement of the intended use of the procedure; (B) Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy; (C) Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them; and (D) Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures:     (a) Press Room #4, Minster Press #62 - On or about June 30, 2015, a tooling maintenance employee performing repairs, adjustments and testing of an air-actuated slide on a open die (#15962) was exposed to pinch point hazard without adequate procedures that detailed techniques to secure the hazardous pneumatic energy for the slide.       There is no abatement documentation or certification required for instance a), which was Corrected During Inspection.    (b) Press Room #4 - Tooling maintenance employees performing repairs, adjustments and testing of dies in mechanical power presses were not provided adequate lockout/tagout procedures that contained a specific statement of the intended use of the procedure for such tasks.        (c) Press Room #7, Minster Press #63 - On or about August 21, 2015, a press setup operator performed setup adjustments to the press at the end of a material run in preparation for the next material run.  The employee removed piece parts by placing his hands inside the open die, and also used long-handled tools to cut and remove piece parts from the open die and was not provided adequate lockout/tagout procedures that contained a specific statement of the intended use of the procedure for such tasks.       (d) Press Room #3, Minster Press #58 - On or about August 20, 2015, a press setup operator was performing a coil lace up procedure.  The employee placed his hands inside the open die to make adjustments and was not provided adequate lockout/tagout procedures that contained a specific statement of the intended use of the procedure for such tasks.        Employees were exposed to crushing hazards likely to result in amputation and lacerations to hands and fingers from unexpected startup up and/or energy release.      Abatement documentation is required for instances (b), (c) and (d) in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Dec 18, 2015

Abate by

Feb 8, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d): Application of control. 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:       Tooling maintenance employees and press setup operators who performed servicing and maintenance tasks including setup and adjustments on mechanical power press(es) were not required to control hazardous energy sources in the following sequence:        1) turn off and shut down the machines,      2) physically locate and operate energy isolating devices in such a manner as to isolate the machines or equipment from the energy source(s),   3) affix lockout or tagout devices to each energy isolating device,      4) relieve, disconnect, restrain and otherwise render safe all hazardous residual or stored energy,    5) verify that isolation and de-energization of the machines or equipment have been accomplished.        (a) Press Room #4, Minster Press #62 - On or about June 30, 2015, a tooling maintenance employee performing repairs, adjustments and testing of an air-actuated slide on an open progressive die (#15962) was exposed to pinch point hazards.  The employee did not de-energize and lockout the pneumatic energy for the slide.     There is no abatement documentation or certification required for instance a), which was Corrected During Inspection.    (b) Press Room #4 - Tooling maintenance employees who performed repairs, adjustments and testing of dies in mechanical power presses did not isolate and lockout the energy sources on the presses.     (c)  Press Room #7, Minster Press #63 - On or about August 21, 2015, a press setup operator performed setup adjustments to the press at the end of a material run in preparation for the next material run.  The employee removed piece arts by placing his hands inside the open die, and also used long-handled tools to cut and remove piece parts from the open die.  The employee did not isolate and lockout the hazardous energy sources on the press.      (d) Press Room #3, Minster Press #58 - On or about August 20, 2015, a press setup operator was performing adjustments for a coil lace up procedure.  The employee placed his hands inside the open die to make adjustments and did not isolate and lockout the hazardous energy sources on the press.     Employees were exposed to crushing hazards likely to result in amputation to hands and fingers from unexpected start up and/or energy release.        Abatement documentation is required for instances (b), (c) and (d) in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Dec 18, 2015

Abate by

Feb 22, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(d)(9)(iv): The employer shall provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the press.     (a) Entire Facility-  On or about June 30, 2015 through August 21, 2015, tooling maintenance employees performing repairs and/or adjustments on open dies in mechanical power press(es) were not provided with or required to use safety blocks.  Employees were exposed to crushing hazards likely to result in amputation and lacerations to hands and fingers in the event of die closure.     (b) Entire Facility-  On or about June 30, 2015 through August 21, 2015, press setup operators performing setups and/or adjustments on open dies in mechanical power press(es) were not provided with or required to use safety blocks.  Employees were exposed to crushing hazards likely to result in amputation and lacerations to hands and fingers in the event of die closure.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Dec 18, 2015

Abate by

Apr 8, 2016

Penalty

Initial $4,500 · Current $2,466 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not provide training to ensure that the purpose and function of the energy control program were understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls were acquired by employees:      Entire Facility.  On or about June 30 through August 21, 2015, tooling maintenance employees and press setup operators who performed servicing and maintenance tasks including setup and adjustments on mechanical power press dies while open and in the presses were exposed to crushing hazards likely to result in amputation and lacerations to hands and fingers from unexpected start up and/or energy release. The employer did not ensure that lockout/tagout training, including the use of die blocks for the control of gravity hazards, was provided to all authorized and affected employees who were assigned such tasks, to ensure that the purpose and function of the energy control program were understood by employees and that the knowledge and skills required for the safe application, usage and removal of the energy controls were acquired by employees.     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d)

Issued

Dec 18, 2015

Abate by

Mar 22, 2016

Penalty

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

General-duty citation text

29 CFR 1910.217(c)(2)(i)(a): Point of operation guard(s) on mechanical power press(es) did not prevent entry of hands or fingers into the point of operation by reaching through, over, under or around the guard(s).     Employees who worked in the areas of the following mechanical power presses were exposed to amputation hazards where fixed barrier guards did not prevent entry into the points of operation over, under, around or through the guards:     (a) Press Room #7, Minster Press #63.  Employees removed piece parts by hand from the conveyor.  The opening under the fixed barrier guard at the discharge end of the press did not prevent entry into the point of operation.     (b) Press Room #5, Minster Press #46.  The press setup operator was working at the back of the press.  The opening under the fixed barrier guards on the front and back of the press were too large and did not prevent entry into the point of operation.       (c) Press Room #4, Minster Press #51.  Employees were working at the discharge conveyor in front of the press.  The openings under the fixed barrier guards on the front and back of the press were too large and did not prevent entry into the point of operation.  The machine opening on the side of the press was not guarded to prevent reaching through to the point of operation.     (d) Press Room #4, Minster Press #53.  Employees worked at the discharge conveyor on the side of the press.  The openings under the fixed barrier guards on the front and back of the press were too large and did not prevent entry into the point of operation.        (e) Press Room #6, Minster Press #6.  Employees worked in the area of the press.  The openings in fixed barrier guards on the front, back and sides of the press were too large and did not prevent entry under, around or through to the point of operation.       (f) Room #4, Minster Press #13.  The opening beneath the fixed barrier guard on the front of the press did not prevent entry under the guard into the point of operation.     Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).