OSHA Inspection: SUNFIELD, INC.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $5,500 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.137(c): In-service care and use of electrical protective equipment:       29 CFR 1910.137(c)(2): Specific requirements. The following specific requirements apply to rubber insulating blankets, rubber insulating covers, rubber insulating line hose, rubber insulating gloves, and rubber insulating sleeves:       29 CFR 1910.137(c)(2)(viii): Electrical protective equipment shall be subjected to periodic electrical tests. Test voltages and the maximum intervals between tests shall be in accordance with Table I-4 and Table I-5:      a. On or about March 3, 2016, the employer failed to perform periodic electrical tests on rubber insulating gloves. Due this condition, maintenance employees required to use this equipment were exposed to electrical hazards and an increased risk for electrocution while trouble shooting energized 480 volt electrical equipment.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $7,000 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements of this standard are being followed:     1910.147(c)(6)(i)(C): Where lockout is used for energy control, the periodic inspection shall include a review, between the inspector and each authorized employee, of that employee's responsibilities under the energy control procedure being inspected:    a. On or about February 23, 2016, in the production plant where lockout/tagout was to be used to de-energize equipment, the employer did not include a review of the energy control procedures with each authorized employee to identify deficiencies within the program and review the knowledge of the authorized employee for the energy control procedure being inspected.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $7,000 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): Types of guarding. One or more methods of machine guarding shall be 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. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc:    a. On or about February 18, 2016, on the RY-3 press line between press 3 and press 4, the employer did not provide a method of machine guarding to protect employees from entering the point of operation of the robotic arm that moves parts out of press 3, onto the idler station table and into press 4. The light curtains did not protect employees from the point of operation in that the light curtains were not installed correctly and could be reset automatically by initiating the presses while employees were in the danger zone.

Issued

Jun 29, 2016

Abate by

Aug 4, 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. On or about February 18, 2016, on the RY-3 press line, the employer did not ensure that light curtain presence sensing devices, of the adjacent idler station, were adjusted so that entry from the side of press 3 into the point of operation would be detected at all times and the press could not cycle. The light curtains did not protect employees from the point of operation in that the light curtains were not installed correctly and could be reset automatically by initiating the presses while employees were in the danger zone.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $7,000 · Current $6,000 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. On or about April 6, 2016, the 480 volt energized electrical box located behind K-5 was damaged and had openings to energized parts, thereby exposing employees to an electrical hazard.

Issued

Jun 29, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in cabinets, boxes, and fittings shall be effectively closed:  a.  On or about March 24, 2016, in the plant on the main walkway used by employees to enter the office area, the 480 volt cabinet had two fuses open to the main buss, thereby exposing employees to a fire/explosion hazard.  b. On or about April 7, 2016, in the plant behind press A-2 and A-3, there were two missing circuit breakers in the 480 volt energized electrical panel where employees entered to turn equipment on and off, thereby exposing employees to an electrical hazard.

Issued

Jun 29, 2016

Abate by

Jul 12, 2016

Penalty

Initial $7,000 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.333(a)(1): "Deenergized parts." Live parts to which an employee may be exposed shall be deenergized before the employee works on or near them, unless the employer can demonstrate that deenergizing introduces additional or increased hazards or is infeasible due to equipment design or operational limitations. Live parts that operate at less than 50 volts to ground need not be deenergized if there will be no increased exposure to electrical burns or to explosion due to electric arcs.  Note 1: Examples of increased or additional hazards include interruption of life support equipment, deactivation of emergency alarm systems, shutdown of hazardous location ventilation equipment, or removal of illumination for an area.  Note 2: Examples of work that may be performed on or near energized circuit parts because of infeasibility due to equipment design or operational limitations include testing of electric circuits that can only be performed with the circuit energized and work on circuits that form an integral part of a continuous industrial process in a chemical plant that would otherwise need to be completely shut down in order to permit work on one circuit or piece of equipment.  Note 3: Work on or near deenergized parts is covered by paragraph (b) of this section:    a. On or about April 6, 2016, two Sunfield employees were observed performing work inside a 480 volt electrical panel (the control box for the weld side K-5 press) without deenergizing the equipment. Due to this condition, employees were exposed to live electrical parts and associated hazards.

Issued

Jun 29, 2016

Abate by

Jul 6, 2016

Penalty

Initial $5,500 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.335(a)(1)(i): Employees working in areas where there are potential electrical hazards shall be provided with, and shall use, electrical protective equipment that is appropriate for the specific parts of the body to be protected and for the work to be performed.  Note: Personal protective equipment requirements are contained in subpart I of this part:    a. On or about April 6, 2016, two employees, who were inspecting a 480 volt electrical panel box to the K-5 press, were not provided hand, neck, ear and face protection when working in the energized panel. Due to this condition, employees were exposed to electrical hazards, potential arc flash hazards and increased risk for electrocution.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $5,500 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.1030(f)(1)(i): The employer shall make available the hepatitis B vaccine and vaccination series to all employees who have occupational exposure, and post-exposure evaluation and follow-up to all employees who have had an exposure incident:    a. On or about February 18, 2016, four Sunfield employees were required to clean blood, bodily fluids and other potentially infectious materials from equipment involved in a mechanical power press accident.  The employees had not received and had not been offered the hepatitis B vaccination series, thus exposing the employees an increased risk of illness.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $70,000 · Current $50,400 Reduced

General-duty citation text

29 CFR 1910.147(d): The established procedure for the application of energy control (the lockout or tagout procedures) did not cover the actions listed in and was not done in sequence as required by 29 CFR 1910.147(d)(1)-(6):    The employer does not protect employees from the hazardous energy of machinery or equipment by turning off or shutting down machinery or equipment as required by energy control procedures, ensuring energy isolation devices are operated to isolate machinery or equipment from their energy source(s), and affixing lockout devices to energy isolation devices by authorized employees:      a.  On or about February 18, 2016, the employer did not ensure that employees implemented energy control procedures on mechanical power presses prior to allowing them to enter the point of operation to remove scrap. Press 3 of the RY-3 robotic press line was not isolated from energy sources prior to engaging in this servicing and maintenance activity.  A mechanical power press operator was in the point of operation, removing scrap when the press cycled, crushing the employee's right arm. The employee's arm was later surgically amputated.    As a result, the remaining applicable energy control elements, involving machine isolation [1910.147(d)(3)], lock-out/tag-out device application [1910.147(d)(4)], dissipation of residual energy [1910.147(d)(5)(i)], and verification of isolation [1910.147(d)(6)], were not implemented to protect employees from machine servicing hazards, such as removing scrap from the point of operation.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(7)(i): General.  Training and communication.  The employer shall 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. The training shall include the following:  29 CFR 1910.147(c)(7)(i)(A): Each authorized employee shall 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. The employer does not protect employees from the hazardous energy of machinery or equipment by providing lockout/tagout (hazardous energy control) training that includes facility/process specific information,  such as (but not limited to) the recognition of hazardous energy sources, the type and magnitude of energy available and the methods necessary to isolate and control such energy:     On or about February 18, 2016, the employer failed to provide authorized employee training for the employee, a mechanical power press operator on RY-3 line, prior to the employee engaging in servicing and maintenance activities, such as, but not limited to, scrap removal, die cleaning, die repair, and die changing.  The employee performed servicing and maintenance activities without isolating and controlling hazardous energy sources, exposing the employee to struck-by, crushing and amputation hazards.  The employee is a full time associate.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(f):  Operation of power presses:  29 CFR 1910.217(f)(2): Instruction to operators. The employer shall train and instruct the operator in the safe method of work before starting work on any operation covered by this section. The employer shall insure by adequate supervision that correct operating procedures are being followed:  a. The employer does not protect employees from the hazards associated with mechanical power press operation by providing safe method of operation training that includes equipment specific information, such as, but not limited to, machine specific hazards, hazards of interconnected equipment, the operational controls, basic major component knowledge regarding dies, flywheels and air valves, safe die changing procedures and machine safeguarding methods:    On or about February 18, 2016, the employer failed to provide training on the safe operation (method of work) of mechanical power presses prior to assigning an employee to perform work as an operator on RY-3 line mechanical power presses.  The employee was a full time associate.

Issued

Jun 29, 2016

Abate by

Jul 20, 2016

Penalty

Initial $70,000 · Current $50,400 Reduced

General-duty citation text

29 CFR 1910.217(c)(3): Safeguarding the point of operation - Point of operation devices:    29 CFR 1910.217(c)(3)(iii): A presence sensing point of operation device shall protect the operator as provided in paragraph (c)(3)(i)(a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator's hand or other part of his body is within the sensing field of the device during the downstroke of the press slide:    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:  The employer does not use guards to protect all areas of entry to the point of operation or any other entry points not protected by presence sensing devices.   a. On or about March 17, 2016, on the RY-4 press line, press 1, approximately six to seven inches of duct tape was used to blank out the bottom right side of the light curtain.  This prohibited the presence sensing device from properly guarding the point of operation for the press, and the blanked area was not protected with additional guarding. Due to this condition, employees were exposed to struck-by, crushing and amputation hazards.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $70,000 · Current $50,400 Reduced

General-duty citation text

29 CFR 1910.217(c)(3): Safeguarding the point of operation - Point of operation devices:    29 CFR 1910.217(c)(3)(iii): A presence sensing point of operation device shall protect the operator as provided in paragraph (c)(3)(i)(a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator's hand or other part of his body is within the sensing field of the device during the downstroke of the press slide:    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:  The employer does not use guards to protect all areas of entry to the point of operation or any other entry points not protected by presence sensing devices.   a. On or about March 17, 2016, on the RY-4 press line, press 2, approximately six to seven inches of electrical tape was used to blank out the bottom, right side of the light curtain.  This prohibited the presence sensing device from properly guarding the point of operation for the press, and the blanked area was not protected with additional guarding. Due to this condition, employees were exposed to struck-by, crushing and amputation hazards.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $70,000 · Current $50,400 Reduced

General-duty citation text

29 CFR 1910.217(c)(3): Safeguarding the point of operation - Point of operation devices:    29 CFR 1910.217(c)(3)(iii): A presence sensing point of operation device shall protect the operator as provided in paragraph (c)(3)(i)(a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator's hand or other part of his body is within the sensing field of the device during the downstroke of the press slide:    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:  The employer does not use guards to protect all areas of entry to the point of operation or any other entry points not protected by presence sensing devices.   a. On or about March 17, 2016, on the RY-4 press line, press 6, approximately six to seven inches of electrical tape was used to blank out the bottom, right side of the light curtain.  This prohibited the presence sensing device from properly guarding the point of operation for the press, and the blanked area was not protected with additional guarding. Due to this condition, employees were exposed to struck-by, crushing, and amputation hazards.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $70,000 · Current $50,400 Reduced

General-duty citation text

29 CFR 1910.217(c)(3): Safeguarding the point of operation - Point of operation devices:    29 CFR 1910.217(c)(3)(iii): A presence sensing point of operation device shall protect the operator as provided in paragraph (c)(3)(i)(a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator's hand or other part of his body is within the sensing field of the device during the downstroke of the press slide:    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:  The employer does not use guards to protect all areas of entry to the point of operation or any other entry points not protected by presence sensing devices.   a. On or about March 17, 2016, on the RY-4 press line, press 7, approximately seven and one half inches of electrical tape was used to blank out the bottom, right side of the light curtain.  This prohibited the presence sensing device from properly guarding the point of operation for the press, and the blanked area was not protected with additional guarding. Due to this condition, employees were exposed to struck-by, crushing and amputation hazards.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $70,000 · Current $50,400 Reduced

General-duty citation text

29 CFR 1910.217(c)(3): Safeguarding the point of operation - Point of operation devices:    29 CFR 1910.217(c)(3)(iii): A presence sensing point of operation device shall protect the operator as provided in paragraph (c)(3)(i)(a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator's hand or other part of his body is within the sensing field of the device during the downstroke of the press slide:    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:  The employer does not use guards to protect all areas of entry to the point of operation or any other entry points not protected by presence sensing devices.   a. On or about March 24, 2016 on the RY-6 press line, press 1, approximately six inches of electrical tape was used to blank out the bottom, right side of the light curtain.  This prohibited the presence sensing device from properly guarding the point of operation for the press, and the blanked area was not protected with additional guarding. Due to this condition, employees were exposed to struck-by, crushing, and amputation hazards.

Issued

Jun 29, 2016

Abate by

Aug 4, 2016

Penalty

Initial $70,000 · Current $50,400 Reduced

General-duty citation text

29 CFR 1910.217(c)(3): Safeguarding the point of operation - Point of operation devices:    29 CFR 1910.217(c)(3)(iii): A presence sensing point of operation device shall protect the operator as provided in paragraph (c)(3)(i)(a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator's hand or other part of his body is within the sensing field of the device during the downstroke of the press slide:    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:  The employer does not use guards to protect all areas of entry to the point of operation or any other entry points not protected by presence sensing devices.   a. On or about March 24, 2016, on the RY-6 press line, press 5, approximately eight inches of electrical tape was used to blank out the bottom, left side of the light curtain.  This prohibited the presence sensing device from properly guarding the point of operation for the press, and the blanked area was not protected with additional guarding. Due to this condition, employees were exposed to struck-by, crushing, and amputation hazards.

Issued

Jun 29, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(f)(2)(i): Whenever outside servicing personnel are to be engaged in activities covered by the scope and application of this standard, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures:  a.  On or about March 17, 2016, in the RY press area where Aida press contractors were installing a part revolution mechanical power press, Sunfield failed to share their hazardous energy control program and did not inform the contractor before starting the shutdown and lockout of the electrical power, thereby exposing employees to an electrical hazard.