OSHA Inspection: DAEIL USA CORPORATION

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $3,960 · Current $2,600 Reduced

General-duty citation text

29 CFR 1910.141(a)(3)(ii): Floor(s) of workroom(s) were not maintained, so far as practical, in a dry condition:  a)  Chemical room;  On or about July 29, 2015 and at times prior; the employer exposed employees to slip and fall hazards in that employees were permitted to walk and work in an area where oil and water were present resulting in the presence of slippery floors.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $6,930 · Current $4,500 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(B): The energy control procedure did not clearly and specifically procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy:  a)  Robot cell (UMA Line); On or about July 29, 2015 and at times prior; the employer exposed employees to hazardous energies (including electrical, pneumatic), caught-in and amputations hazards in that the machine specific lockout/tagout procedure did not adequately outline the procedural steps for shutting down, isolating, blocking and securing machines or equipment to control all energy sources when employees perform service or maintenance inside the Robot cell at the UMA Line.  b)  Robot cell (ANA Line); On or about July 29, 2015 and at times prior;  the employer exposed employees to hazardous energies (including electrical, pneumatic), caught-in and amputations hazards in that the machine specific lockout/tagout procedure did not adequately outline the procedural steps for shutting down, isolating, blocking and securing machines or equipment to control all energy sources when employees perform service or maintenance inside the Robot cell at the ANA Line.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $6,930 · Current $4,500 Reduced

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)  Robotic Cell (UMA Line); On or about July 29, 2015 and at times prior; the employer exposed employees to potential hazardous energies in that employees were allowed to service and perform preventive maintenance following a procedure that had not been reviewed at least annually to correct any deviations or inadequacies identified.  b)  Robotic Cell (ANA Line); On or about July 29, 2015 and at times prior; the employer exposed employees to potential hazardous energies in that employees were allowed to service and perform preventive maintenance following a procedure that had not been reviewed at least annually to correct any deviations or inadequacies identified.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $6,930 · Current $4,500 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 are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees:  a) Robotic cells: On or about July 29, 2015, and at times prior; the employer exposed employees to potential hazardous energies in that employees were allowed to enter inside the robotic cell without first being trained to ensure those employees had the knowledge and skills for the safe application, usage, and removal of energy controls.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $6,930 · Current $4,500 Reduced

General-duty citation text

29 CFR 1910.147(f)(3)(ii)(D): Each authorized employee did not affix a personal lockout or tagout device to the group lockout device before working on the machine or equipment:  a) Robotic cells: On or about July 29, 2015, and at times prior; employer exposed employees to potential hazardous energies in that employees were allowed to clean inside the robotic cells together without all employees applying a personal lockout device on the energy control lockout point.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $4,950 · Current $3,200 Reduced

General-duty citation text

29 CFR 1910.151(c): Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use.   a)  Chemical room:  On or about July 29, 2015 and at times prior; employees dispensing, carrying and transferring Yumage WSW-60 (corrosive chemical) are not provided with a functional eye and body wash station.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $5,940 · Current $3,600 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): Point(s) of operation of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle.  a) Auto check machine (UMA Line):  On or about July 29, 2015 and at times prior; the employer exposed his employees to caught-in and amputation hazards in that employees were allowed to operate the auto check machine at the UMA line without been properly guarded.   b) Long bar machine:  On or about July 29, 2015 and at times prior; the employer exposed his employees to caught-in and amputation hazards in that employees were allowed to operate the long bar machine without been properly guarded.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $3,960 · Current $2,600 Reduced

General-duty citation text

29 CFR 1910.215(a)(4): Work rest(s) on grinding machinery were not adjusted closely to the wheel with a maximum opening of one eighth inch    a) Maintenance Shop; On or about July 29, 2015 and at times prior, the employer exposed employees to struck-by hazards in that they were allowed to operate a bench grinder with the work rest work rest exceeding one eighth inch.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.215(b)(9): The distance between the abrasive wheel periphery(s) and the adjustable tongue or the end of the safety guard peripheral member at the top exceeded one fourth inch.   a) Maintenance Shop ; On or about July 29, 2015 and at times prior, the employer exposed employees to struck-by hazards in that they were allowed to operate a bench grinder with the tongue guard missing.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.215(d)(3): The contact surface(s) of wheel(s), blotter(s) or flange(s) on grinding machine(s) were not flat and free or foreign matter:  a) Maintenance Shop ; On or about July 29, 2015 and at times prior, the employer exposed employees to struck-by hazards in that they were allowed to operate a bench grinder with a grinding wheel that's surface was not flat.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $5,940 · Current $3,600 Reduced

General-duty citation text

29 CFR 1910.242(b): Compressed air used for cleaning purposes was not reduced to less than 30 p.s.i.  a)  On or about July 29, 2015 and at times prior; the employer exposed his employees to compressed air hazards in that employees were permitted to use compressed air that was not reduced to less than 30 psi for cleaning and/or blow off themselves.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $4,950 · Current $3,200 Reduced

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There shall be no damaged parts that may adversely affect safe operation or mechanical strength of the equipment, such as parts that are broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating.  a)  Hose bracket Welding machine (UMA Line): On or about July 29, 2015, and at times prior, the employer exposed his employees to struck-by and caught-in hazards from broken stop buttons.  b)  Conveyor (ANA Line): On or about July 29, 2015, and at times prior, the employer exposed his employees to struck-by and caught-in hazards from broken stop buttons.  Daeil USA Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.144(a)(1)(iii), which was contained in OSHA inspection number 824881 citation number 1 item number 2 and was affirmed as a final order on May 15, 2013, with respect to a workplace located at 3509 45th St. SW Lanett, AL 36863.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $69,300 · Current $44,400 Reduced

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)  Stab bracket machine- UMA line;  On or about July 30, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the stab machine at the UMA line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  b)  Piercing machine- UMA line;  On or about July 30, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the piercing machine at the UMA line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  c)  Sizing machine- ANA line;  On or about July 30, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the sizing machine at the ANA line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  d)  Knuckle bracket machine- Lambda line;  On or about August 23, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the knuckle bracket machine at the Lambda line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  e)  Stab bracket machine- ANA line;  On or about September 7, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the stab bracket machine at the ANA line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  f)  Base cap welder machine- Lambda line;  On or about September 14, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the base cap welder machine at the lambda line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  g)  Spring seat welder machine- ANA line;  On or about September 14, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the spring seat welder machine at the ANA line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  h)  Stab bracket machine- Lambda line;  On or about September 21, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the stab bracket machine at the lambda line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  i)  Piercing machine- Lambda line;  On or about September 22, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the piercing machine at the lambda line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  j)  Spring seat welder machine- Lambda line;  On or about September 22, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the spring seat welder machine at the lambda line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  k)  Lot marker machine- LFA line;  On or about September 23, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the Lot marker machine at the LFA line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.  l)  Knuckle bracket machine- ANA line;  On or about September 23, 2015 and at times prior, the employer exposed his employees to potential hazardous energies in that employees were allowed to perform service and/or maintenance on the knuckle bracket machine at the ANA line without being provided with a lockout/tagout machine specific procedure to prevent the accidental start-up of the machine or the release of hazardous energy.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $200 · Current $130 Reduced

General-duty citation text

29 CFR 1910.95(d)(1): A representative monitoring program was not developed and implemented when information indicated that an employee's exposure may equal or exceed an 8 hour time weighted average of 85dBA.   a) On or about July 30, 2015 and at times prior; the employer exposed the employees to hi-noise hazards in that the employer failed to develop and implement a noise monitoring program when information indicates that any employee's exposure may equal or exceed an 8-hour time-weighted average of 85 decibels.  The Daeil USA Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.95(c)(1), which was contained in OSHA inspection number 824881 citation number 1, item number 1 and was affirmed as a final order on May 15, 2013, with respect to a workplace located at 3905 45th St. SW, Lanett, AL 36863

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $200 · Current $130 Reduced

General-duty citation text

29 CFR 1910.95(k)(3): The employer did not ensure that each employee exposed  to noise at or above  an 8-hour time weighted average of 85 decibels was trained and informed of the information included in sections k(3)(i) through k(3)(iii).   a)  Spring seat welder machine operator (UMA Line):  On July 30, 2015 and at times prior; the employer exposed the employee to noise at levels of 69.7% (equivalent to an 8 hour time weighted average TWA of 87.4 dBA) which is 1.4  times the action level of 50 % (equivalent to an 8 hour TWA of 85 dBA) while working in the UMA line at the facility.  Results were calculated for a 420 minutes sampling period with a zero concentration assumption for the remaining 60 minutes.  Annual training on the effects of noise, purpose of hearing protectors, advantages, disadvantages, instruction on selection and care purpose of audiometric testing and explain of the test procedures was not provided for the employee.   b)  Hose bracket machine operator (ANA Line):  On July 30, 2015 and at times prior; the employer exposed the employee to noise at levels of 62.4% (equivalent to an 8 hour time weighted average TWA of 86.6 dBA) which is 1.2  times the action level of 50 % (equivalent to an 8 hour TWA of 85 dBA) while working in the UMA line at the facility.  Results were calculated for a 479 minutes sampling period with a zero concentration assumption for the remaining 1 minutes.  Annual training on the effects of noise, purpose of hearing protectors, advantages, disadvantages, instruction on selection and care purpose of audiometric testing and explain of the test procedures was not provided for the employee.   c)  Spring seat welder machine operator (ANA Line):  On July 30, 2015 and at times prior; the employer exposed the employee to noise at levels of 83.2% (equivalent to an 8 hour time weighted average TWA of 88.6 dBA) which is 1.7 times the action level of 50 % (equivalent to an 8 hour TWA of 85 dBA) while working in the UMA line at the facility.  Results were calculated for a 478 minutes sampling period with a zero concentration assumption for the remaining 2 minutes.  Annual training on the effects of noise, purpose of hearing protectors, advantages, disadvantages, instruction on selection and care purpose of audiometric testing and explain of the test procedures was not provided for the employee.   d)  Leak test machine operator:  On July 30, 2015 and at times prior; the employer exposed the employee to noise at levels of 84.7% (equivalent to an 8 hour time weighted average TWA of 88.8 dBA) which is 1.7  times the action level of 50 % (equivalent to an 8 hour TWA of 85 dBA) while working in the UMA line at the facility.  Results were calculated for a 479 minutes sampling period with a zero concentration assumption for the remaining 1 minutes.  Annual training on the effects of noise, purpose of hearing protectors, advantages, disadvantages, instruction on selection and care purpose of audiometric testing and explain of the test procedures was not provided for the employee.   e)  Bubble check machine operator:  On July 30, 2015 and at times prior; the employer exposed the employee to noise at levels of 65.9% (equivalent to an 8 hour time weighted average TWA of 87.0 dBA) which is 1.3 times the action level of 50 % (equivalent to an 8 hour TWA of 85 dBA) while working in the UMA line at the facility.  Results were calculated for a 475 minutes sampling period with a zero concentration assumption for the remaining 5 minutes.  Annual training on the effects of noise, purpose of hearing protectors, advantages, disadvantages, instruction on selection and care purpose of audiometric testing and explain of the test procedures was not provided for the employee.   The Daeil USA Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.95(c)(1), which was contained in OSHA inspection number 824881 citation number 1, item number 1 and was affirmed as a final order on May 15, 2013, with respect to a workplace located at 3905 45th St. SW, Lanett, AL 36863.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $200 · Current $130 Reduced

General-duty citation text

29 CFR 1910.144(a)(1)(iii): Emergency stop bars, stop buttons or switches which letters or other markings appear, used for emergency stopping of machinery were not red.   a)  Hose bracket Welding machine (UMA Line): On or about July 29, 2015, and at times prior, the employer exposed his employees to struck-by and caught-in hazards from emergency stop buttons not being red.  b)  Conveyor (ANA Line): On or about July 29, 2015, and at times prior, the employer exposed his employees to struck-by and caught-in hazards from emergency stop buttons not being red.  Daeil USA Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.144(a)(1)(iii), which was contained in OSHA inspection number 824881 citation number 1 item number 2 and was affirmed as a final order on May 15, 2013, with respect to a workplace located at 3509 45th St. SW Lanett, AL 36863.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $13,860 · Current $8,900 Reduced

General-duty citation text

29 CFR 1910.147(c)(5)(i): Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware were not provided by the employer for isolating, securing or blocking of machines or equipment from energy sources:   a)    Robotic cells: On or about July 29, 2015: the employer exposed his employees to struck-by/caught-in hazards in that the employer had not provided locks for each of his employees to use to lockout the robotic cell prior enter to clean the area so that the robots could not accidentally start up.   Daeil USA Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(c)(5)(i), which was contained in OSHA inspection number 824881 citation number 1 item number 4 and was affirmed as a final order on May 15, 2013, with respect to a workplace located at 3509 45th St. SW Lanett, AL 36863.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $29,700 · Current $19,210 Reduced

General-duty citation text

29 CFR 1910.252(b)(2)(iii): Workers and other persons adjacent to the welding area were not protected from the rays by noncombustible or flameproof screens or shields:  a)  Hose bracket machine (ANA Line): On or about July 29, 2015 and at times prior; employees were exposed to eye injury hazards and skin burns from welding arc flashes and sparking due to the employers failure to ensure the shaded welding flash and spark shields were in place on the hose bracket machine at the ANA line.   The Daeil USA Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.252(b)(2)(iii), which was contained in OSHA inspection number 316304310 citation number 1, item number 1 and was affirmed as a final order on May 1, 2012, with respect to a workplace located at 3905 45th St. SW, Lanett, AL 36863.  The Daeil USA Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.252(b)(2)(iii), which was contained in OSHA inspection number 824881 citation number 2, item number 2 and was affirmed as a final order on May 15, 2013, with respect to a workplace located at 3905 45th St. SW, Lanett, AL 36863.

Issued

Jan 27, 2016

Abate by

Feb 8, 2016

Penalty

Initial $990 · Current $700 Reduced

General-duty citation text

29 CFR 1904.40(b): Employer did not provide government representative the requested records within 4 business hours.  a) Daeil USA Corporation:  On July 29, 2015 the employer did not provided to the OSHA Compliance Officer the OSHA 300 logs (2011-2015) within 4 business hours.