OSHA Inspection: FUYAO GLASS AMERICA INC.

Issued

Oct 31, 2016

Abate by

Jun 1, 2017

Penalty

Initial $12,471 · Current $2,500 Reduced

General-duty citation text

29 CFR 1910.24(f): "Stair treads." All treads shall be reasonably slip-resistant and the nosings shall be of nonslip finish. Welded bar grating treads without nosings are acceptable providing the leading edge can be readily identified by personnel descending the stairway and provided the tread is serrated or is of definite nonslip design. Rise height and tread width shall be uniform throughout any flight of stairs including any foundation structure used as one or more treads of the stairs.    (a) The fixed industrial stairs by Posts AG 35, AH 35, Al 35 and AL 36 had treads that were not uniform and therefore exposed employees to falls as high as 70 inches.

Issued

Oct 31, 2016

Abate by

Jun 1, 2017

Penalty

Initial $12,471 · Current $10,000 Reduced

General-duty citation text

29 CFR 1910.37(b)(4): If the direction of travel to the exit or exit discharge is not immediately apparent, signs must be posted along the exit access indicating the direction of travel to the nearest exit and exit discharge. Additionally, the line-of-sight to an exit sign must clearly be visible at all times.    (a)  The exit sign on Post AE 4 did not indicate the direction of travel to the nearest exit, in that the exit sign pointed toward a fenced-in area that did not have an exit.

Issued

Oct 31, 2016

Abate by

Jun 1, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(5): Each doorway or passage along an exit access that could be mistaken for an exit must be marked "Not an Exit" or similar designation, or be identified by a sign indicating its actual use (e.g., closet).    (a)  The doorway leading into a fenced-in storage area on the factory floor, was not marked as "not an exit."

Issued

Oct 31, 2016

Abate by

Jun 1, 2017

Penalty

Initial $8,908 · Current $10,000

General-duty citation text

29 CFR 1910.135(a)(1): The employer shall ensure that each affected employee wears a protective helmet when working in areas where there is a potential for injury to the head from falling objects.    (a)  On or about May 25, 2016, two employees working at the entry to a gravity bin furnace by Post AG 47 in Lamination, were exposed to head injuries as the result of outside contractors working overhead in a JLG lift.

Issued

Oct 31, 2016

Abate by

May 1, 2017

Penalty

Initial $12,471 · Current $10,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section. Note: Exception: The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist: (1) The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; (2) the machine or equipment has a single energy source which can be readily identified and isolated; (3) the isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment; (4) the machine or equipment is isolated from that energy source and locked out during servicing or maintenance; (5) a single lockout device will achieve a locker-out condition; (6) the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; (7) the servicing or maintenance does not create hazards for other employees; and (8) the employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance:    (a)  There were no machine specific energy control procedures for the Krauss Mafei Horizontal Injection Molding Machine and the Haitian Horizontal Injection Molding machines.

Issued

Oct 31, 2016

Abate by

May 1, 2017

Penalty

Initial $12,471 · Current $0 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 shall be provided by the employer for isolating, securing or blocking of machines or equipment from energy sources.    (a)  Employees were not provided with locks and tags to attach to energy isolating devices prior to cleaning and setting up the Krauss Mafei Horizontal Injection Molding Machine and the Haitian Horizontal Injection Molding machines in the PVC Encapsulation Room.      (b)  There were grinder operators and bystronics operators who were not provided with locks and tags to attach to energy isolating devices prior to changing the belts on the grinder and prior to entering the robotic cell to clean and perform minor maintenance in the ARG Production Department.

Issued

Oct 31, 2016

Abate by

May 1, 2017

Penalty

Initial $12,471 · Current $0 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i): 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:    (a)  Employees were not adequately trained on the safe application, usage and removal of energy isolating devices prior to entering the injection molding machines in PVC Encapsulation Room to conduct mold changes.      (b)  Employees were not adequately trained on the safe application, usage and removal of energy isolating devices prior to changing the belts on the grinders on the grinding lines in ARG.      (c)  Employees were either not adequately trained, or not trained at all, on the safe application, usage and removal of energy isolating devices prior to entering the robotic cells on the Grinder lines in the ARG Production Department to performing cleaning and servicing.      (d)  An employee was not trained on the safe application, usage and removal of energy isolating devices, in that on or about June 26, 2016, an employee removed a guard covering the running chain and sprocket on the FBT 1 Tempering Furnace Line, in order to oil the chain.

Issued

Oct 31, 2016

Abate by

May 1, 2017

Penalty

Initial $12,471 · Current $0 Reduced

General-duty citation text

29 CFR 1910.147(d): The established procedures for the application of energy control (the lockout or tagout procedures) shall cover the following elements and actions and shall be done in the following sequence:    (a)  Employees who performed servicing on and around the robotic cells on the grinding lines in ARG prior to entering the robotic cells, failed to first:          (1)  turn off and shut down the machine,  (2)  physically locate and operate energy isolating devices in such a manner as to isolate the machine or equipment from the energy source,  (3)  affix lockout or tagout devices to each energy isolating device.      (b)  Employees who changed the belts on the grinders on the grinding lines in ARG, failed to first:      (1)  turn off and shut down the machine,  (2)  physically locate and operate energy isolating devices in such a manner as to isolate the machine or equipment from the energy source,  (3)  affix lockout or tagout devices to each energy isolating device.     (c)  Employees who setup the injection molding machines in the PVC Encapsulation Room prior to entering the injection molding machines, failed to first:    (1)  turn off and shut down the machine,  (2)  physically locate and operate energy isolating devices in such a manner as to isolate the machine or equipment from the energy source,  (3)  affix lockout or tagout devices to each energy isolating device.      (d)  On or about June 26, 2016, an employee who removed a guard covering the running chain and sprocket on the FBT 1 Tempering Furnace Line in order to oil the chain, failed to first:      (1)  turn off and shut down the machine,  (2)  physically locate and operate energy isolating devices in such a manner as to isolate the machine or equipment from the energy source,  (3)  affix lockout or tagout devices to each energy isolating device.

Issued

Oct 31, 2016

Abate by

May 1, 2017

Penalty

Initial $10,689 · Current $10,000 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)  Employees working on the plant floor, were exposed to unguarded belts and sprockets on the conveyor lines.    (b)  Employees working in the Print Room #1 and Print Room #2, were exposed to being struck by the moving squeegee.

Issued

Oct 31, 2016

Abate by

Jun 1, 2017

Penalty

Initial $12,471 · Current $10,000 Reduced

General-duty citation text

29 CFR 1910.303(g)(1)(i): Working space for equipment likely to require examination, adjustment, servicing, or maintenance while energized shall comply with the following dimensions, except as required or permitted elsewhere in this subpart:  The depth of the working space in the direction of access to live parts may not be less than indicated in Table S-1:    (a)  The distance between the front panel cover on the 600 VAC GE Heavy Duty Safety Switch by Post AA 35, and the metal fencing in front of it, did not comply with Table S-1, in that the distance between the front panel cover and the metal fencing was only 24 inches.    (b)  The distance between the front panel cover on the 600 VAC GE Heavy Duty Safety Switch by Post N 36, and the metal storage racks in front of it, did not comply with Table S-1, in that the distance between the front panel cover and the metal storage racks was only 27-1/2 inches.

Issued

Oct 31, 2016

Abate by

Jun 1, 2017

Penalty

Initial $12,471 · Current $0 Reduced

General-duty citation text

29 CFR 1910.304(f)(1)(iv): Overcurrent devices shall be readily accessible to each employee or authorized building management personnel. These overcurrent devices may not be located where they will be exposed to physical damage or in the vicinity of easily ignitable material:    (a)  The 480-VAC overcurrent device (electrical panel) was not readily accessible Post AH 36, in that access to the panel was blocked by a fixed control panel and a computer on wheels.

Issued

Oct 31, 2016

Abate by

Jun 1, 2017

Penalty

Initial $12,471 · Current $0 Reduced

General-duty citation text

29 CFR 1910.334(a)(4): Conductive work locations. Portable electric equipment and flexible cords used in highly conductive work locations (such a those inundated with water or other conductive liquids), or in job locations where employees are likely to contact water or conductive liquids, shall be approved for those locations.    (a)  On or about May 24, 2016, there was a standard podium fan standing in water, with its 110-VAC power cord running through water to reach an outlet on Post K-52, thereby exposing employees working in the area to electrical hazards.