OSHA Inspection: D&D MANUFACTURING, INC.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $6,930 · Current $4,504 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) On or about October 5, 2015, at the above located workplace, a set-up employee was required to perform work under punch press ram and between the upper and lower dies of mechanical punch press 21 (USI/Clearing, 150 ton, part revolution mechanical punch press). The employer had not provided the set-up employee a lock and an approved ram block to properly lock out the press.     b) On or about October 7, 2015, at the above located workplace, a set-up employee was required to perform work under punch press ram and between the upper and lower dies of mechanical punch press 22 (Dreis & Krump, 200 ton, part revolution mechanical punch press). The employer had not provided the set-up employee a lock and an approved ram block to properly lock out the press.      c) On or about October 15, 2015, at the above located workplace, a set-up employee was required to perform work under punch press ram and between the upper and lower dies of mechanical punch press 2 (Niagara, 100 ton, part revolution mechanical punch press). The employer had not provided the set-up employee a lock and an approved ram block to properly lock out the press.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $6,930 · Current $4,504 Reduced

General-duty citation text

29 CFR 1910.217(d)(9)(i): The employer did not establish a diesetting procedure that insured compliance with paragraph (c) of this section:      a) On or about October 5, 2015, at the above located workplace, a set-up employee was required to perform work under punch press ram and between the upper and lower dies of mechanical punch press 21 (USI/Clearing, 150 ton, part revolution mechanical punch press). The employer had not established a diesetting procedure to address safeguarding the point of operation as specified in paragraph 29 CFR 1910.217(c).      b) On or about October 7, 2015, at the above located workplace, a set-up employee was required to perform work under punch press ram and between the upper and lower dies of mechanical punch press 22 (Dreis & Krump, 200 ton, part revolution mechanical punch press). The employer had not established a diesetting procedure to address safeguarding the point of operation as specified in paragraph 29 CFR 1910.217(c).      c) On or about October 15, 2015, at the above located workplace, a set-up employee was required to perform work under punch press ram and between the upper and lower dies of mechanical punch press 2 (Niagara, 100 ton, part revolution mechanical punch press).  The employer had not established a diesetting procedure to address safeguarding the point of operation as specified in paragraph 29 CFR 1910.217(c).

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(d)(9)(iv): The employer did not enforce the use of safety blocks whenever dies were being adjusted or repaired in the press:   a) On or about October 15, 2015, at the above located workplace, punch press set-up employees/operators were required to perform work (adjusting or repairing) under punch press rams #2, #21, and #22. The employer did not require employees to use safety blocks to prevent rams from falling.

Issued

Mar 30, 2016

Abate by

Apr 5, 2016

Penalty

Initial $4,950 · Current $3,217 Reduced

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There were damaged parts that adversely affected the safe operation or mechanical strength of electric equipment, such as parts that were broken, bent, cut or deteriorated by corrosion, chemical action, or overheating:       a) On or about October 7, 2015, at the above located workplace, a General Electric heavy duty 480 Volt service disconnect box on the east wall was missing its handle. The box was in the on position and was providing 480 volt to a transformer. Employees were thereby exposed to an electrical shock hazard.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $4,950 · Current $3,217 Reduced

General-duty citation text

29 CFR 1910.303(f)(2): Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, was not legibly marked to indicate its purpose:     a) On or about October 15, 2015 at the above located workplace, employees were required to work with and around punch presses. The punch press disconnects were not marked to indicate their purpose.

Issued

Mar 30, 2016

Penalty

Initial $3,960 · Current $2,574 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(i): Conductors entering cutout boxes, cabinets, or fittings were not protected from abrasion, and openings through which conductors enter were not effectively closed.        a) On or about February 3, 2016, at the above located workplace, at Punch Press Number 17, employees were required to work with and around a Littell uncoiler. The uncoiler had a broken strain relief and exposed energized (120 volt) wires. Employees were exposed to an electrical shock hazard.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $13,860 · Current $9,240 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) On or about October 15, 2015, at the above located workplace punch press set-up employees performed set-up, servicing and maintenance. The punch press set-up employees did not lockout the punch presses before performing the work. The employer did not develop, document and utilize specific procedures for controlling hazardous energy for mechanical punch presses.           The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(c)(4)(ii), which was contained in OSHA inspection number 979337, citation number 1, item number 4 and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $13,860 · Current $9,009 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): Each authorized employee 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 and control.      a) On or about October 15, 2015, at the above located workplace, punch press set-up employees/operators  were required to perform work between the bolster plates and the rams. The employer had not trained the employees to ensure that the purpose and function of the energy control program was understood by employees and that the skills required for the safe application, usage, and removal of the energy controls are acquired by employees.      The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(c)(7)(i)(A), which was contained in OSHA inspection number 979337, citation number 1, item number 5 and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $9,900 · Current $6,435 Reduced

General-duty citation text

29 CFR 1910.217(b)(7)(iii): Fixing of the selection was not by means capable of supervision by the employer:          a) On or about October 7, 2015, at the above located workplace, the means of selecting the mode (inch, single stroke, continuous) of operating press number 2 was not capable of supervision by the employer. The control keys were left in the control buttons and were not in the custody of the employer or a trained and experienced supervisor or foreman. When the press was not in use, it was not locked off. The employer's lack of supervision allowed the unauthorized use of the keys and exposed employees to amputation hazards.        b) On or about October 15, 2015, at the above located workplace, the means of selecting the mode (inch, single stroke, continuous) of operating press number 5 was not capable of supervision by the employer. The control keys were left in the control buttons and were not in the custody of the employer or a trained and experienced supervisor or foreman. When the press was not in use, it was not locked off. The employer's lack of supervision allowed the unauthorized use of the keys and exposed employees to amputation hazards.      c) On or about October 7, 2015, at the above located workplace, the means of selecting the mode (inch, single stroke, continuous) of operating press number 16 was not capable of supervision by the employer. The control keys were left in the control buttons and were not in the custody of the employer or a trained and experienced supervisor or foreman. When the press was not in use, it was not locked off. The employer's lack of supervision allowed the unauthorized use of the keys and exposed employees to amputation hazards.        d) On or about October 5, 2015, at the above located workplace, the means of selecting the mode (inch, single stroke, continuous) of operating press number 21 was not capable of supervision by the employer. The control keys were left in the control buttons and were not in the custody of the employer or a trained and experienced supervisor or foreman. When the press was not in use, it was not locked off. The employer's lack of supervision allowed the unauthorized use of the keys and exposed employees to amputation hazards.        e) On or about October 7, 2015, at the above located workplace, the means of selecting the mode (inch, single stroke, continuous) of operating press number 22 was not capable of supervision by the employer. The control keys were left in the control buttons and were not in the custody of the employer or a trained and experienced supervisor or foreman. When the press was not in use, it was not locked off. The employer's lack of supervision allowed the unauthorized use of the keys and exposed employees to amputation hazards.        f) On or about October 21, 2015, at the above located workplace, the means of selecting the mode (inch, single stroke, continuous) of operating press number 26 was not capable of supervision by the employer. The control keys were left in the control buttons and were not in the custody of the employer or a trained and experienced supervisor or foreman. When the press was not in use, it was not locked off. The employer's lack of supervision allowed the unauthorized use of the keys and exposed employees to amputation hazards.        The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.217(b)(7)(iii), which was contained in OSHA inspection number 979337, citation number 1, item number 14 and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $13,860 · Current $9,009 Reduced

General-duty citation text

29 CFR 1910.217(c)(1)(i): The employer did not provide and insure the usage of "point of operation guards" or properly applied and adjusted point of operation devices on every operation performed on mechanical power presses. See Table O-10.      a) Press 23 -- On or about October 5, 2015, employees were required to work with Punch Press Number 23, a Niagara, 110 ton part revolution press in in single stroke mode. The right side of the press was unguarded. The unguarded right side allowed nearby employees to reach into the point of operation and was not a properly applied and effective method of guarding.             b) Press 25 -- On or about October 5, 2015, employees were required to work with Punch Press Number 25, a USI/Clearing, 75 ton part revolution press in single stroke mode. The right side of the press was unguarded. The unguarded right side allowed nearby employees to reach into the point of operation and was not a properly applied and effective method of guarding.                         c) Press 27 -- On or about October 5, 2015, employees were required to work with Punch Press Number 27, a Niagara, 75 ton part revolution press in single stroke mode. The right side of the press was unguarded. The unguarded right side allowed nearly employees to reach into the point of operation and was not a properly applied and effective method of guarding.                The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.217 (c)(3)(iii)(f), which was contained in OSHA inspection number 979337, citation number 1, item number 16 and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(c)(3)(iii)(f): Guards shall be used to protect all areas of entry to the point of operation not protected by the presence sensing device.    a) Press 5 -- On or about October 15, 2015, employees were required to work with Punch Press Number 5, a USI/Clearing, 75 ton part revolution press, in continuous mode.  The press had a light curtain on the front and left side. The right side of the press was unguarded. The unguarded right side allowed the operator and other employees to reach into the point of operation.           b) Press 21 -- On or about October 15, 2015, employees were required to work with Punch Press Number 21, a USI/Clearing, 150 ton part revolution press in continuous mode. The press had a light curtain on the front. The right side of the press was unguarded. The unguarded right side allowed the operators and other employees to reach into the point of operation.          The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.217 (c)(3)(iii)(f), which was contained in OSHA inspection number 979337, citation number 1, item number 16 and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $13,860 · Current $9,009 Reduced

General-duty citation text

29 CFR 1910.217(c)(3)(iii)(c): The presence sensing point of operation device was not constructed so that a failure within the system did not prevent the normal stopping action from being applied to the press when required, but did prevent the initiation of a successive stroke until the failure is corrected:       a) Press 10 -- On or about October 15, 2015, employees were required to work with Punch Press Number 10, a Bruder, 35 ton part revolution press, in continuous mode. The method used to guard the back was an improperly applied, light curtain system. The light curtain system was an on-site made (homemade) system that included Takex Takenaka NA TR20R sensors that were not properly spaced and were not approved for protection of humans. The light curtain system was not a properly applied and effective method of guarding.                b) Press 11 ? on or about December 9, 2015,  employees were required to work with Punch Press Number 11, a Danley, 500 ton part revolution press, in continuous mode. The method used to guard the front was an improperly applied light curtain system that allowed employees to reach under the curtain and into the point of operation. The method used to guard the back was an improperly applied light curtain system that was an on-site made (homemade) system that included Takex Takenaka NA TR20R sensors that were not properly spaced, allowed employees to reach under and were not approved for protection of humans. The improperly applied light curtain system allowed employees to reach into the point of operation.                     c) Press 12 -- On or about October 15, 2015, employees were required to work with Punch Press Number 12, a Verson, 300 ton part revolution press, in continuous mode. The method used to guard the front was an improperly applied, light curtain system. The light curtain system was an on-site made (homemade) system that included Takex Takenaka NA TR20R sensors that were not properly spaced, allowed employees to reach under and were not approved for protection of humans. The improperly applied light curtain system allowed employees to reach into the point of operation.             d) Press 18 -- On or about October 15, 2015, employees were required to work with Punch Press Number 18, a Niagara, 200 ton part revolution press, in continuous mode. The method used to guard the front of the point of operation was an improperly applied, light curtain system. The light curtain system allowed employees to reach under the curtain and into the point of operation. The method used to guard the back of the point of operation was an improperly applied, light curtain system. The light curtain system was an on-site made (homemade) system that included Takex Takenaka NA TR20R sensors that were not properly spaced and were not approved for protection of humans. The improperly applied light curtain systems allowed employees to reach into the point of operation.                      e) Press 22 -- On or about October 5, 2015, employees were required to work with Punch Press Number 22, a Dreis & Krump, 200 ton part revolution press in continuous mode. The method used to guard the front was an improperly applied, light curtain system. The light curtain?s control box was open and unlocked. The open and unlocked box allowed employees to disable sections of the light curtain and reach into the point of operation.  The method used to guard the back of the point of operation was an improperly applied, light curtain system. The light curtain system was an on-site made (homemade) system that included Takex Takenaka NA TR20R sensors that were not properly spaced and were not approved for protection of humans. The improperly applied light curtain systems allowed employees to reach into the point of operation.                f) Press 24 -- On or about October 5, 2015, employees were required to work with Punch Press Number 24, a USI/Clearing, 75 ton part revolution press in continuous mode. The method used to guard the front was an improperly applied, light curtain system. The light curtain's control box was open and unlocked. The open and unlocked box allowed the operator and other employees to disable sections of the light curtain and reach into the point of operation. The light curtain was not a properly applied and effective method of guarding.               g) Press 26 -- On or about October 5, 2015, employees were required to work with Punch Press Number 26, a USI/Clearing, 75 ton part revolution press in continuous mode. The method used to guard the front was an improperly applied, light curtain system. The light curtain's control box was open and unlocked. The open and unlocked box allowed the operator and other employees to disable sections of the light curtain and reach into the point of operation. The light curtain was not a properly applied and effective method of guarding.              The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.217(c)(3)(iii)(f), which was contained in OSHA inspection number 979337, citation number 1, item number 16 and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Penalty

Initial $7,920 · Current $5,148 Reduced

General-duty citation text

29 CFR 1910.219(d)(1): Pulley(s) with part(s) seven feet or less from the floor or work platform were not guarded in accordance with the requirements specified in 29 CFR 1910.219(m) and (o):             a) On or about October 15, 2015, at the above located workplace, employees at Punch Press 5 were required to work with and around a W. W. Richardson, Uncoiler (Number 319). The uncoiler had a pulley that was not guarded. The pulley was less than seven feet from the floor. The unguarded pulley exposed employees to a caught-between hazard.     The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.219(d)(1), which was contained in OSHA inspection number 979337, citation number 1, item number 19a and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(e)(3)(i): Vertical and inclined belts were not enclosed by a guard conforming to standards in paragraphs (m) and (o) of this section:  a) On or about October 15, 2015, at the above located workplace, employees at Punch Press 5 were required to work with and around a W. W. Richardson, uncoiler (Number 319). The uncoiler had a power belt that was not guarded. The belt was less than seven feet from the floor. The unguarded belt exposed employees to a caught-between hazard.   The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.219(e)(1)(i), which was contained in OSHA inspection number 979337, citation number 1, item number 19b and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Abate by

Apr 5, 2016

Penalty

Initial $200 · Current $200

General-duty citation text

29 CFR 1910.253(b)(2)(ii): Cylinders were not stored in definitely assigned places where they would not be knocked over or damaged by passing or falling objects, or subject to tampering by unauthorized persons.   a) On or about October 5, 2015, at the above located workplace there were two compressed gas cylinders stored just outside the maintenance shop. The cylinders were not secured and stored to prevent damaged or subject to tampering by unauthorized persons.    The D&D Manufacturing, Inc. was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.253(b)(2)(ii), which were contained in OSHA inspection number 979337, citation number 1, item number 22a and was affirmed as a final order on 12/23/2014, with respect to a workplace located at 1330 Pullman Drive, El Paso, TX 79936.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(5)(ii): Lockout devices and tagout devices were not singularly identified; the only devices(s) used for controlling energy, and/or used for other purposes and did not meet items A-D of this section:   a) On or about October 15, 2015, at the above located workplace, two maintenance employees, a tool man and the plant manager preformed work that required locking out equipment. The locks provided by the employer and used for lockout were not standardized and did not indicate the identity of the employee using the device.

Issued

Mar 30, 2016

Abate by

Apr 25, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.255(e): Periodic inspection of resistance welding machines was not made by qualified maintenance personnel, and certification records maintained:   a) On or about October 15, 2015 at the above located workplace, employees were required to work with and around resistance welding machines. The employer did not maintain welding machine inspection records that included the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, for the equipment inspected.

Issued

Dec 9, 2015

Abate by

Dec 15, 2015

Penalty

Initial $6,930 · Current $6,930

General-duty citation text

29 CFR 1910.217(c)(3)(vii)(a): When used in press operations requiring more than one operator, separate two hand controls were not provided for each operator, and designed to require concurrent application of all operators' controls to activate the slide:    a) On or about June 13, 2015, two employees (operators) were required to operate Punch Press Number 11, a Danley, 500 ton part revolution press, in single stroke mode. Only one press operator was provided with and used two hand controls when operating the punch press. The second employee was not provided with separate two hand controls. The second employee was exposed to the point of operation and experienced an amputation.

Issued

Dec 9, 2015

Abate by

Jan 6, 2016

Penalty

Initial $1,000 · Current $1,000

General-duty citation text

29 CFR 1904.29(b)(1): A Log of all recordable work-related injuries and illnesses (OSHA Form 300 or equivalent), was not completed in detail as required by the regulation:      a) On or about October 5, 2015, at the above located workplace, the employer's OSHA 300 form for 2015 was not completed in detail as required by 1904.4 through 1904.12. In that:    An employee working with a punch press experienced an amputation on 6/13/2015 that resulted in more than 37 days away from work. The OSHA 300 Log for 2015 had the injury listed as a laceration caused by a tool. There was a check in Column I (Job transfer or restriction) without a number of days in column L (number of restricted days) or column H (number days away from work).

Issued

Dec 9, 2015

Abate by

Jan 6, 2016

Penalty

Initial $1,000 · Current $1,000

General-duty citation text

29 CFR 1904.39(a)(2):  The employer did not report an in-patient hospitalization, amputation, or loss of an eye as a result of a work work-related incident to OSHA within twenty-four hours:               a) On or about June 13, 2015, the employer did not contact OSHA within 24 hours when an employee at the facility sustained a work-related amputation.