OSHA Inspection: MAGNA SEATING OF AMERICA

Issued

Nov 10, 2016

Abate by

Jan 15, 2018

Penalty

Initial $12,471 · Current $7,000 Reduced

Hazardous substances 8300

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1): The employer did not furnish employment and a place of employment which was free from recognized hazards that were causing or likely to cause death or serious physical harm to employees who were assigned to perform work at the Excelsior Springs Seating Systems location on "Transit" van seats specifically on Cells 6080 (6081), and 6130 which required forceful exertion and awkward postures for extended periods of time that may be consistent with the development of MSDs.    On or about May 17, 2016 at times prior to and since, the employer is exposing employees in the Front and Rear Cell area to the hazards of developing musculoskeletal disorders (MSDs) while performing prolonged repetitive movements, awkward working postures, high perceived force applications, wrist deviations, or repeated/continued use of a specific body part of the upper extremities.    This was most recently observed at the plant located at 301 South McCleary Road, Excelsior Springs, Missouri 64024. The following listing includes but is not limited to examples of jobs observed to have hazards which may develop musculoskeletal disorders:      a) Cell 1040A-D: On or about May 17, 2016 and at times prior and since, employees using Stanley hog ring guns to attach foam to frame covers, complete close out, and placing covers over the foam, are exposing employees to forceful exertions.  Inserting the hog rings results in awkward postures as well as extended reaches for extended periods of time exposing employees to ergonomic stressors causing MSDs.       b) Cell 6130: On or about May 17, 2016 and at times prior and since, employees closing the rear seat back covers and steaming seats surfaces requires forceful exertions, awkward postures as well as extended reaches for prolonged periods of time exposing employees to ergonomic stressors causing MSDs.     c) Cell 6055 (6056):  On or about May 17, 2016 and at times prior and since, employees using Stanley hog ring guns on the rear seat cushion top and bottom requires forceful exertions. Inserting the hog rings results in awkward postures for extended periods of time exposing employees to ergonomic stressors causing MSDs.     d) Cell 6080 (6081):  On or about May 17, 2016 and at times prior and since, employees rolling trim over the seat and finessing the cover over the foam requires forceful exertion and awkward posture for extended periods of time exposing employees to ergonomic stressors causing MSDs.      Recommendations for Abatement:    While some ergonomic related risk factors can be reduced or eliminated by implementing a single means of abatement, in most cases a process that includes analysis of the worksite, medical management, training, education and participation of employees (in both recognition of injury and avoidance of injury), procedural and engineering controls, and hazard prevention and control will provide the most effective method of addressing the factors.  Examples of such measures include, but are not limited to the following:      Engineering Controls    Evaluate and implement alternative hog ring guns that would reduce the force necessary to initiate.      Evaluate and implement positioners that allow employees to make quick adjustments in multiple planes to quickly adjust the seat orientation. Include a place for the hog ring gun to be attached to the positioners while not in use.      Evaluate and implement mechanical methods to compress seat foam for Trim Close-Out tasks.     Evaluate and implement adjustable-height platforms along conveyor assembly lines to reduce extended reaches.     Evaluate and implement additional steam trim warmers, to ensure that trim is fully warmed before the skinning step in the seat building process. This will make the trim more pliable and reduce the amount of force needed to attach the trim to the frame.    Administrative Controls     Evaluate and implement rotations within the Front and Rear Cells based on the results from the Strain Index or another assessment tool to eliminate or reduce to the extent feasible employees rotating to positions with similar muscle and tool use.      Evaluate and implement a comfort survey as one method for identifying areas or jobs where potential MSD problems exist. The major strength of the survey approach is in collecting data on the number of workers that may be experiencing some form of MSD. This often is achieved through comfort surveys, in which individuals are asked to indicate any discomfort or soreness they experience, around a body part, and its magnitude. Reported pain symptoms by several workers on a specific job would indicate the need for further investigation of that job.    Provide and implement training for all employees on proper techniques to perform each task on the line for their specific rotation. Train employees on the use and benefit existing adjustable workstations.       Ensure that employees provide feedback on ergonomic program changes especially any changes to the cell tasks and rotations.      Ergonomic Program      Provide an ergonomic assessment, by a certified professional ergonomist of the workstations and tasks included in Front and Rear rotations. The ergonomist, or other qualified professional, shall provide a job hazard analysis and recommendations for reducing or eliminating ergonomic risk factors from the work of the employees performing repetitive hand activity or use of the hog ring gun. The company must implement controls to eliminate the hazard or reduce the hazard to acceptable levels (e.g. job strain index). The ergonomics assessment should be repeated whenever conditions change (i.e. new layout, new product, new equipment or hand tools, or reported MSD injury or illness).      Have a certified professional ergonomist, or other competent person, review the ergonomics training to ensure its effectiveness.      Provide more decision authority to the participatory ergonomics team. The team should be responsible for implementing and sustaining the ergonomics program. The composition of the team should be multi-disciplinary, including at least four hourly employees, union representation, plant management, engineering, maintenance, medical and safety. The multi-disciplinary composition will facilitate problem solving and implementation since all of the key people are on the team. The team will solicit employee suggestions and follow-up on resolution to the suggestions. The team will provide input to changes in layout and hand tool selection. Team leadership and management support are key to reducing hazards and MSD injuries.      An outside expert in medical management protocols should review the medical management protocols for treating musculoskeletal injuries and education for employees on early reporting. The review of the protocol must include recommendations for alternate duty for employees who report musculoskeletal pain. The expert should conduct initial plant healthcare provided training and follow-up training. The expert should provide an annual review of trends in the injury log and symptoms reports. The expert should recommend changes in the protocol based on the trends.