OSHA Inspection: FOLDEDPAK, INC.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $5070.00 · Current $2294.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(1): Energy control program. The employer shall establish a program consisting of energy control procedures, employee training and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative.    a. On or about October 4, 2016, located on the production line, employees performed service/maintenance activities.  The employer had not established an energy control program and training to protect the employees from unexpected energization, startup or release of stored energy, thereby exposing the employees to electrical, struck-by and/or caught-in/caught-between hazards.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

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.     a. On or about October 4, 2016, located on the production line, employees had guards removed and servicing the B-Bunch machine to replace a bearing without having a specific documented procedure for the control of hazardous energy, which exposed employees to electrical shock and/or caught-in hazards of the unexpected start-up of the production line. The employer failed to develop, document and utilize specific procedures to include a specific statement of intended use [1910.147(c)(4)(I)(A)], specific procedural steps for shutting down, isolating, blocking, and securing machines or equipment to control hazardous energy [1910.147(c)(4)(I)(B)], specific procedural steps for the placement, removal and transfer of lockout devices and the responsibility of them [1910.147(c)(4)(I)(C)], and specific requirement for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures [1910.147(c)(4)(I)(D)].

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(d): Application of control. 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. On or about October 4, 2016, employees were exposed to machine hazards associated with moving parts and ingoing nip points when replacing a bearing on the B-Bunch machine on the production line. The employer failed to implement energy control application steps as authorized employees were not knowledgeable of the type, magnitude, hazards, and the method or means to control the hazardous energy [per 1910.147(d)(1).The employer did not implement energy control application steps as the machine was not turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4), dissipation of residual energy [(d)(5)(I)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $5070.00 · Current $2294.00 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 October 4, 2016, located on the production line at the Bernal rotary die, serial number 0229432, there was a 6-3/16 by 27 inch opening in the guarding that did not prevent employee exposure to the machines rollers, thereby exposing the employees to a caught-in hazard.       b. On or about October 6, 2016, located on the production line at the front and back of the B-Bunch folder B-Bunch, model number 1250, serial number 42142650,  there were unguarded rotating knives that exposed the employees to laceration and/or caught-in hazards.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.212(a)(2): General requirements for machine guards. Guards shall be affixed to the machine where possible and secured elsewhere if for any reason attachment to the machine is not possible. The guard shall be such that it does not offer an accident hazard in itself.   a. On or about October 4, 2016, located on the production line at the Bernal rotary die, serial number 0229432, the Plexiglas guarding installed was not secured to the machine to prevent employee access to the ingoing nip points of the rollers, thereby exposing the employees to a caught-in hazard.       b. On or about October 6, 2016, located at the paint station on the production line at the rotary paint machine, there was guarding over the rollers that was not secured to the machine which did not prevent employee exposure to the ingoing nip points of the paint rollers, thereby exposing the employees to a caught-in hazard.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $3622.00 · Current $2294.00 Reduced

General-duty citation text

29 CFR 1910.219(c)(2)(i): All exposed parts of horizontal shafting seven (7) feet or less from floor or working platform, excepting runways used exclusively for oiling, or running adjustments, shall be protected by a stationary casing enclosing shafting completely or by a trough enclosing sides and top or sides and bottom of shafting as location requires.          a. Located in the paint station, there was a horizontal shaft that was  approximately 40 inches from the floor that did not have guarding on the bottom of the shaft, thereby exposing the employees to caught-in hazards.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.219(c)(4)(i): Projecting shaft ends shall present a smooth edge and end and shall not project more than one-half the diameter of the shaft unless guarded by nonrotating caps or safety sleeves.  a. Located at the end of a two inch diameter rotating shaft at the paint station, there was an unguarded three inch protruding shaft end that was not guarded, thereby exposing the employees to a caught-in hazard.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $3622.00 · Current $2294.00 Reduced

General-duty citation text

29 CFR 1910.219(e)(3)(i): Vertical and inclined belts shall be enclosed by a guard conforming to standards in paragraphs (m) and (o) of this section.    a. On or about October 6, 2016, located between a rotary die machine and the B-Bunch folding machine, employees worked around an unguarded one inch belt where the bottom of the belt was 38-3/4 inches from the floor and the top of the belt was 41-3/4 inches from the floor which went to a series of pulleys, thereby exposing the employees to a caught-in hazard.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.219(f)(1): Gears. Gears shall be guarded in accordance with one of the following methods:  29 CFR 1910.219(f)(1)(i): By a complete enclosure; or   a. On or about October 6, 2016, located at the top of the paint stations rotary paint machine, there was an unguarded 5-1/2 inch diameter gear where employees worked on the production line, thereby exposing the employees to caught-in hazards.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.219(f)(3): Sprockets and chains. All sprocket wheels and chains shall be enclosed unless they are more than seven (7) feet above the floor or platform. Where the drive extends over other machine or working areas, protection against falling shall be provided. This subparagraph does not apply to manually operated sprockets.  a. On or about October 6, 2016, located on the back of the B-Bunch machine on the production line, there was an unguarded chain with seven unguarded sprockets that were used in part to drive the B-Bunch, thereby exposing the employees to a caught-in hazard.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.219(i)(2): Couplings. Shaft couplings shall be so constructed as to present no hazard from bolts, nuts, setscrews, or revolving surfaces. Bolts, nuts, and setscrews will, however, be permitted where they are covered with safety sleeves or where they are used parallel with the shafting and are countersunk or else do not extend beyond the flange of the coupling.  a. On or about October 6, 2016, located on the production line there was a total of six inches of unguarded coupling that was approximately 42 inches off the floor between an induction motor to a rotary die machine, thereby exposing the employees to a caught-in hazard.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $5070.00 · Current $2294.00 Reduced

General-duty citation text

29 CFR 1910.307(c): Electrical installations. Equipment, wiring methods, and installations of equipment in hazardous (classified) locations shall be intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location.     a. Located behind the production line, the electrical equipment including, but not limited to, three 480 volt electrical disconnects, 480 volt electrical cabinet, 240 volt electrical panel, 208 volt electrical motors, wall-mounted transformer, and an extension cord to a light on the B-Bunch machine were in a Class II, Division 2 location which were not intrinsically safe, approved for a Class II, Division 2 location, or safe for a Class II, Division 2 location.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.303(g)(2)(i): Except as elsewhere required or permitted by this standard, live parts of electric equipment operating at 50 volts or more shall be guarded against accidental contact by use of approved cabinets or other forms of approved enclosures or by any of the following means:  29 CFR 1910.303(g)(2)(i)(B): By suitable permanent, substantial partitions or screens so arranged so that only qualified persons will have access to the space within reach of the live parts. Any openings in such partitions or screens shall be so sized and located that persons are not likely to come into accidental contact with the live parts or to bring conducting objects into contact with them;  a. On or about October 4, 2016, located behind the production line, there was a 480 volt electrical cabinet that had its doors left open with fans placed in the middle in an effort to cool the cabinets electrical components. There were no partitions or screens in place so that only qualified persons would have access to the cabinet, thereby exposing the employees to an electrical shock and/or arc flash hazard.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(b)(1)(i): Conductors entering cutout boxes, cabinets, or fittings shall be protected from abrasion, and openings through which conductors enter shall be effectively closed.  a. On or about October 4, 2016, there was an electrical terminal box on a Baldor 208 VAC, 3-phase electric motor, model number VM31561 that had its flexible conduit disconnected at its fitting approximately one foot from the floor leaving the conductors exposed to abrasion, thereby exposing the employees to an electrical shock hazard of 208 volts.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

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 October 6, 2017, located behind the production line, there was a 240 volt electrical panel that had an unused opening that was not closed, thereby exposing the employees to burn injuries if an arc flash occurred.

Issued

2017-02-22 00:00:00

Abate by

2017-03-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.178(l)(1)(ii): Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph (l), except as permitted by paragraph (l)(5).  a. Located throughout the facility, the employer had not trained an employee that operated forklifts to move equipment and materials on the safe operation of powered industrial vehicles.