OSHA Inspection: PAYSON CASTERS, INC.

Issued

May 20, 2016

Abate by

Jul 29, 2016

Penalty

Initial $4,900 · Current $2,450 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) Throughout the facility - Specific Hazardous Energy Control Procedures (Lockout/Tagout) were not developed, documented and utilized for machines and equipment including; mechanical power presses, press brakes, shears, and lathes. On January 26, 2016 a mechanical power press was observed undergoing maintenance with a lock on the electrical disconnect.

Issued

May 20, 2016

Abate by

Jul 29, 2016

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not provide adequate training to ensure that the purpose and function of the energy control program was understood by employees:    (a) On or about January 22, 2016 - Employees that perform limited service activities to machines and equipment, such as set-up and die changes, were not trained and authorized to perform lockout/tagout procedures on the machines and equipment they are servicing, including mechanical power presses and shears.

Issued

May 20, 2016

Abate by

Jul 8, 2016

Penalty

Initial $4,200 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): One or more methods of machine guarding was not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:    (a) Roll-A-Way Department - On January 26, 2016, the HydMech PLC 100 Horizontal band saw running in continuous mode was not provided with guards over the unused portion of the rotating saw blade exposing workers to laceration hazards.     (b) Caster Department - On January 22, 2016, the unidentified drill press equipped with a reamer was allowed to operate continually with out a guard or other device to protect the operator from being entangled in the rotating chuck/reamer. The employee was wearing a loose fitting long sleeve shirt that enhanced the probability of entanglement.

Issued

May 20, 2016

Abate by

Oct 28, 2016

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): Point of operation guards were not designed and constructed as to prevent the operator from having any part of their body in the danger zone during the operating cycle:    (a) Roll-A-Way Department - On or about January 26, 2016, the Chicago Dreis & Krump mechanical break press, which is foot operated and equipped with a punch die, did not have a guard over the point of operation to prevent the operator's hands from entering the point of operation.

Issued

May 20, 2016

Abate by

Oct 28, 2016

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.217(c)(1)(i): The employer did not provide and ensure the usage of point of operation guards or properly applied point of operation devices on every operation performed on mechanical power press(es):    (a) Roll-A-Way Department -  On January 26, 2016, the Johnson Machine and Press Corp. foot operated full revolution mechanical power press (employer asset #R-121) was operated with inadequate point of operation guarding that did not meet the requirements in Table O-10. Guard openings were (right side) 5.5" x 4.0", 5.5" to point of operation, (left side) 4.75" x 5.5", 5.125" to point of operation, and (front) 7" x 6", 6" to point of operation.    (b) Roll-A-Way Department -  On January 26, 2016, the Niagara foot operated full revolution mechanical power press (employer asset #R-230) had been operated with inadequate point of operation guarding that did not meet the requirements of Table O-10. Guard openings were (left and right) 4" x 4", 11" to point of operation.    (c) Roll-A-Way Department - On January 26, 2016, the Bliss 75-ton part revolution mechanical power press (employer asset #R-31) was equipped to be operated by either a two-handed control system or foot control. The point of operation was equipped with an inadequate guard that did not met the requirements of Table O-10. Guard openings on both the left and right sides were 15.75" wide x 7.75" high, 5" to point of operation.

Issued

May 20, 2016

Abate by

Jul 8, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(c)(3)(vii)(b): Two hand controls on mechanical power presses utilizing part revolution clutches did not meet the construction requirements of paragraph (b)(7)(v) of this section.  (a) Roll-A-Way Department - On January 26, 2016, a Bliss 75-ton part revolution mechanical power press (employer asset #R-31) was equipped to be operated by either a two-handed control system or foot control. The two-handed control system was not adequate and did not meet the requirements of section (b)(7)(v), in that the palm buttons were not equipped with "ring guards" to ensure the concurrent use of both hands while operating the press.

Issued

May 20, 2016

Abate by

Jun 2, 2016

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.217(c)(3)(iv)(d): Mechanical power press(es) using pullout devices on mechanical power press(es) were not properly adjusted were permitted to be operated before necessary maintenance or repair was performed and record(s) of inspections and maintenance were not kept in accordance with paragraph (e):    (a) Caster Department - On January 22, 2016, on the Marshalltown #7 OBI full revolution mechanical power press (S/N1895, asset #P-7), the pull-out device used to protect the operator from point of operation hazards was not checked for proper adjustment at the beginning of the shift and properly maintained. On the first day of the inspection, the operator was observed utilizing the pull-out device with the wristlet straps unsecured. The straps appeared to have not been cleaned and were stiff making proper fitting difficult.

Issued

May 20, 2016

Abate by

Oct 28, 2016

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.217(d)(3): Scrap cutters used with scrap handling systems on mechanical power presses were not safeguarded in accordance with paragraph (c) of this standard and 29 CFR 1910.219:    (a) Caster Department - On January 22, 2016, the scrap trimmer on a Niagara E150 part-revolution mechanical power press, which was coil fed and ran continuously, was not guarded to protect workers from laceration hazards.

Issued

May 20, 2016

Abate by

Jul 8, 2016

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.217(e)(1)(i): A program of periodic and regular inspections of mechanical power press(es) was not established and followed to ensure that all parts, auxiliary equipment and safeguards were in a safe operating condition and adjustment:    (a) On January 22 and 26, 2016, the employer did not have a program of documented periodic and regular inspections to ensure that all press parts, auxiliary equipment and safeguards were in safe operating condition and adjustment, as indicated by the lack of adequate guards and or guarding devices on mechanical punch presses, including press #R-230, R-121, R-40 and the Niagara E-150 press in the Caster Department (no asset number).

Issued

May 20, 2016

Abate by

Oct 28, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(e)(1)(ii): Mechanical power press(es) were not inspected and tested at least weekly to determine the condition of the clutch/brake mechanism, anti-repeat feature and single stroke mechanism(s), and a certification record of the inspection(s) was not maintained:  (a) On January 22 and 26, 2016, weekly inspections and tests of the brake/clutch mechanisms, anti-repeat and single stroke mechanisms were not conducted and/or documented for mechanical power presses in the facility.