OSHA Inspection: LYON, LLC

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $4,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.37(a)(4): Safeguard(s) designed to protect employees during an emergency (e.g., sprinkler systems, alarm systems, fire doors, exit lighting), were not in proper working order at all times:    Employees outside the oven by Paint Booth #2 were exposed to smoke inhalation and burns and the emergency "Exit" illuminated signage was not operational.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(4): Signs were not posted along the exit access indicating the direction of travel to the nearest exit and exit discharge when the direction of travel to the exit or exit discharge was not immediately apparent:    Employees were exposed to smoke inhalation and burn hazards from:    a)  the exit route between the office and Paint Booth #1 was not marked to indicate the nearest exit discharge.    b) the exit route between the cafeteria area and Paint Booth #2 was not marked to indicate the nearest exit discharge.    c) the exit routes to the west and east sides of the Paint Booth #2 room were not marked to indicate the nearest exit discharge.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $5,000 · Current $2,500 Reduced

General-duty citation text

29 CFR 1910.95(c)(1): The employer did not administer a continuing, effective hearing conservation program as described in 29 CFR 1910.9(c) through (o) whenever employee noise exposures equal or exceed an 8-hour time-weighted average sound level of 85 decibels measured on the A scale, or equivalently a dose of fifty percent:    The employer did not administer an effective hearing conservation program that included noise monitoring, required use of suitable hearing protectors, training, and recordkeeping for employees powder coating in Paint Booth #2 and:    a)  employee one was exposed to continuous noise levels at 129.1-percent of the permissible daily noise exposure, or an equivalent sound level of approximately 91.8 dBA, during the 480 minute sampling period on September 3, 2015; exposure calculations include a zero increment of 2-minutes not sampled.    b)  employee two was exposed to continuous noise levels at 396.6-percent of the permissible daily noise exposure, or an equivalent sound level of approximately 94.9 dBA, during the 475 minute sampling period on September 3, 2015; exposure calculations include a zero increment of 5-minutes not sampled.    c)  employee three was exposed to continuous noise levels at 112.7-percent of the permissible daily noise exposure, or an equivalent sound level of approximately 90.9 dBA, during the 483 minute sampling period on September 3, 2015; exposure calculations include a zero increment of 3-minutes not sampled.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $6,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.107(b)(5)(i): Visible gauges or audible alarm or pressure activated devices were not installed to indicate or ensure that the required air velocity is maintained.  Filters were not inspected to ensure proper replacement of filter media:    Employees were exposed to burn hazards and occupational exposure to total dust above the OSHA Permissible Exposure Limit and gauges or alarms were not used to indicate air velocity was maintained in the following equipment:    a) Paint Booth #1;    b) Paint Kitchen for Paint Booth #1;    c) Paint Booth #2;    d) Paint Kitchen for Paint Booth #2.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $6,000 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.107(b)(10): Illumination panels did not effectively isolate the spraying area from the area in which the lighting unit is located, and were not protected to ensure breakage was unlikely.      Employees were exposed to burn hazards and smoke inhalation when powder coating Powdura Hybrid Powder Coatings(combustible dusts) and the:    a) lens covers in Paint Booth #1 that projected into the walking/working surfaces were broken.    b) lens cover for an overhead light in Paint Booth #1 was missing.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $4,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.107(c)(9)(i): All metal parts of spray booths, exhaust ducts, and piping systems conveying flammable liquids or liquids with a flashpoint greater than 199.4 °F (93 °C) or aerated solids were not properly electrically grounded in an effective and permanent manner:    Employees were exposed to burn hazards and smoke inhalation when the hoppers of Powdura Hybrid Powder Coating were connected to the piping distribution for the powder coating guns and the hoppers were not electrically grounded.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $4,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.107(g)(4): Spray finishing employees' clothing was left on the premises overnight and not kept in metal lockers:    The employer did not provide lockers to the painters and the employees stored their personal protective equipment immediately outside the booths and within the powder coating areas overnight.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $6,000 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.107(h)(12):  All areas used for spraying, including the interior of the booth, were not protected by an automatic sprinklers or other approved automatic extinguishing equipment.    Employees were exposed to burn hazards and smoke inhalation and the employer did not provide automatic sprinkers or other automatic extinguishing equipment upstream and downstream of the powder coating process in the following areas:    a)  Paint Booth #1.    b)  Paint Booth #2.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $6,000 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.107(l)(4)(i):  All areas shall be kept free of the accumulation of powder coating dusts, particularly such horizontal surfaces as ledges, beams, pipes, hoods, booths, and floors.    The employer did not keep horizontal surfaces free of accumulated combustible Powdura Hybrid Powder Coatings in the following areas:    a) floor outside Paint Booths #1 and #2.    b) interior floor near the exhaust filters and partitions of Paint Booths #1 and #2.    c) suspended pipes, hoses, and wiring in the surrounding area of Paint Booths #1 and #2.    d) floor outside the Paint Booth Kitchen #2.    e) top of metal enclosure of Paint Booth #2 kitchen near the exhaust motor.    f) work tables and supply cabinet between Paint Booth #2 and the Paint Booth #2 Kitchen.    g) tool cabinet on east side of Paint Booth #2.    h) shelf on south side of Paint Booth #2.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.107(l)(4)(ii): Surfaces were not cleaned in such a manner as to avoid scattering dust to other places or creating dust clouds:    Employees were exposed to burn and smoke inhalation hazards, and exposure to total dust over the OSHA Permissible Exposure Limit, and the employees created dust clouds of Powdura Hybrid Powder Coatings when they used compressed air and dry sweeping methods to clean surfaces and equipment in the following:    a) Paint Booth #1 and surrounding area.    b) Paint Booth #2 and surrounding area.    c) Paint Booth #1 Kitchen and surrounding area.    d) Paint Booth #2 Kitchen and surrounding area.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $4,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.132(d)(2): The employer did not verify that the required workplace hazard assessment has been performed through a written certification that identifies the workplace evaluated, the person certifying that the evaluation has been performed, the date(s) of the hazard assessment, and, which identifies the document as a certification of hazard assessment:    The employer did not evaluate, develop and document a suitable personal protective equipment hazard assessment for the painting tasks, nor did they complete a written certification that included the name of the person who certified that the evaluation had been performed and the date that the hazard assessment was completed.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.133(a)(1): Protective eye equipment was not required where there was a reasonable probability of injury that could be prevented by such equipment:    Employees powder coating Powdura Hybrid Powder Coatings were not provided suitable protective equipment for the face and tight fitting eye protection to protect their eyes.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $6,000 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer did not identify and evaluate the respiratory hazard(s) in the workplace; including a reasonable estimate of employee exposures to respiratory hazards and identification of the contaminant's chemical state and physical form:    The employer did not evaluate the respiratory hazards and have a reasonable estimate of employee exposure to respiratory hazards nor identify chemical contaminants (state and form) for the employees powder coating metal parts.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(g)(1)(i)(A): Respirators with tight-fitting facepieces were worn by employees who had facial hair that came between the sealing surface of the facepiece and the face or that interfered with valve function:    Employees exposed to hazardous paints wore a tight-fitting respirator equipped with particulate cartridges and the employer did not prohibit employees with facial hair that interfered with the seal of the respirator from using a tight fitting respirator.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(k)(1):  The employer did not provide effective training that covered the required elements in 1910.134(k)(1)(i) through 1910.134(k)(1)(vii):    The employer required the painters to wear 3M tight-fitting half and full face piece respirator(s) with P100 filtration, supplied air hood(s), and supply air helmet(s), and the employer did not ensure employees were trained on the following at least annually:      a. Why respirator is necessary and how improper fit, usage, or maintenance can compromise the protective effect of the respirator;   b. What the limitations and capabilities of the respirator are;   c. How to use the respirator effectively in emergency situations, including situations in which the respirator malfunctions;    d. How to inspect, put on and remove, use, and check the seals of the respirator;   e. What the procedures are for maintenance and storage of the respirator;   f. How to recognize the medical signs and symptoms that may limit or prevent the effective use of respirators; and   g. The general requirements of this section.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(h)(4)(ii): Repairs were not made in accordance with the manufacturer's recommendations and specifications for the type and extent of repairs to be performed:    The employer provided employees helmet type supplied air respirators with duct tape used to repair the seals between the lens and hard shell face piece.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(i)(5)(iv): The employer did not ensure that compressors used to supply breathing air to respirators were constructed and situated so as to have a tag maintained at the compressor containing the most recent change date and the signature of the person authorized by the employer to perform the change:    The employees working at Paint Booth #1 wore respirators supplied by compressed air and a tag was not affixed to the filter bank showing the date of the most recent filter change and signed by the authorized person that performed the filter change.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $4,000 · Current $2,000 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:    Outside Paint Booth #1, employees were exposed to electrical shock and burn hazards and used fan with a flexible cord plugged into a non-secured metal outlet box.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $4,000 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.333(a)(2): Where exposed live parts were not deenergized, other safety related work practices were not used to protect employees who could be exposed to the electrical hazards involved:    The employer did not have safety related work practices to protect employees exposed to 460-volt, 6-amp arc flash hazards when resetting the Nordson Econo Coat Series II, Model EC3400, S/N 4002042-1,Paint Booth #2 exhaust because the unit deengergized approximate once per minute.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(1)(i): Employees working in areas where there were potential electrical hazards were not using electrical protective equipment that was appropriate for the specific parts of the body to be protected and for the work to be performed:    The employer did not provide electrical protective equipment to protect employees exposed to 460-volt, 6-amp arc flash hazards when resetting the Nordson Econo Coat Series II, Model EC3400, S/N 4002042-1,Paint Booth #2 exhaust because the unit deengergized approximate once per minute.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of copper dust and total dust listed in Table Z-1 in in excess of the eight-hour time-weighted average concentration for that substance in the table:    On September 24, 2015, employees were powder coating metal pieces in Paint Booth #1 and Paint Booth #2, which contained an airborne concentration of Particulates Not Otherwise Regulated at an eight-hour time-weighted average level in excess of the eight-hour time-weighted average concentration for Particulates Not Otherwise Regulated. The respiratory protection worn by several of those employees was not properly maintained, such that the employees with those respirators were exposed or had the potential to be exposed to an airborne concentration of Particulates Not Otherwise Regulated in excess of the eight-hour time-weighted average concentration for Particulates Not Otherwise Regulated.

Issued

Nov 30, 2015

Abate by

Apr 20, 2017

Penalty

Initial $0 · Current $2,000

General-duty citation text

29 CFR 1910.107(d)(3):  Each spray booth with more than one fan serving one booth, did not have the fans interconnected so that one fan cannot operate without all fans being operated.    Employees in Paint Booths #1 and #2 were exposed to burn and smoke inhalation hazards and the employer did not interconnect the exhaust fans to ensure one fan could not operate without all fans being operational.