OSHA Inspection: INGERSOLL MACHINE TOOLS, INC.

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $0 · Current $12,932

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):    MES department, MES 1, MES 2, MES 3 - on or about October 18, 2016, employees performing setup tasks (servicing) in the point-of-operation and associated danger zones were not required to apply energy controls in the following sequence prior to starting work:     (a) prepare for shut down by recognizing energy hazards and its controls,  (b) turn off and shut down the machines,  (c) physically locate and operate energy isolating devices in such a manner as to isolate the machine or equipment from the energy source,  (d) affix lockout or tagout devices to each energy isolating device,  (e) render safe all potentially hazardous stored or residual energy,  (f) verify that isolation and de-energization of the machine or equipment have been accomplished.    Operators assigned to perform setup (servicing) on energized equipment were exposed to machine struck-by and caught-in hazards likely to result in serious injury because hazardous energy controls (lockout) were not implemented.    Alternative measure, such as, but not limited to relying on a stopped cycle and/or program to prevent unexpected start-up on energized machines did not ensure equivalent safety. Other safeguards were not provided to prevent operators' access and/or disable hazardous operations start-up prior to exposure.     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $8,149 · Current $12,932

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not 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:    MES department, MES 1, MES 2, MES 3 - on or about October 18, 2016, each authorized and/or affected employee did not receive adequate workplace-specific and job-specific hazardous energy control training to ensure competency prior to performing servicing tasks. Operators were regularly entering machining areas (danger zones) to perform energized equipment setup in the point-of-operation, inspections, adjustments, and to maintain housekeeping. Operators were exposed to unexpected machine start-up likely to result in serious injuries due to struck-by and caught in-between hazards.     Alternative measure, such as, but not limited to relying on a stopped cycle and/or program to prevent unexpected start-up on energized machines did not ensure equivalent safety. Other safeguards were not provided to prevent operators' access and/or disable hazardous operations start-up prior to exposure.     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d)

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $6,519 · Current $1,356 Reduced

General-duty citation text

29 CFR 1910.22(a)(2): The floor of every workroom shall be maintained in a clean and, so far as possible, a dry condition. Where wet processes are used, drainage shall be maintained, and false floors, platforms, mats, or other dry standing places should be provided where practicable.    MES department, MES 2, machining area: on or about October 18, 2016, employees performing regular setup and production tasks were exposed to slip and fall hazards likely to result in serious injury due to excessive accumulation of coolant and metal chips where floor drainage was not provided.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d). 29 CFR 1910.136(a): General requirements. The employer shall ensure that each affected employee uses protective footwear when working in areas where there is a danger of foot injuries due to falling or rolling objects, or objects piercing the sole, or when the use of protective footwear will protect the affected employee from an electrical hazard, such as a static-discharge or electric-shock hazard, that remains after the employer takes other necessary protective measures.  MES department, MES 1, MES 2, MES 3 machining areas: on or about October 18, 2016, adequate work boots with specific work environment resistant properties were not provided to operators. Foot injuries resulting from direct exposure to sharp metal chips were likely due to coolant and metal chips damaging and deteriorating soles and outer shells faster than expected replacement.  Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $9,778 · Current $1,356 Reduced

General-duty citation text

29 CFR 1910.23(d)(1): Every flight of stairs having four or more risers shall be equipped with standard stair railings or standard handrails as specified in paragraphs (d)(1)(i) through (v) of this section, the width of the stair to be measured clear of all obstructions except handrails:    MES department, MES 1, MES 2, MES 3: on or about October 18, 2016, employees were using stairways to access equipment's machining areas for regular setup and production tasks, and to return to operator's cabs. Operators were exposed to fall hazards over 4 feet likely to result in serious injury where standard stair railings were not provided on each open side.      Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $8,149 · Current $1,356 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii): Procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, 29 CFR 1910.147(c)(4)(ii)(A), (c)(4)(ii)(B), (c)(4)(ii)(C) and (c)(4)(ii)(D):    MES department, MES 1, MES 2, MES 3 - on or about October 18, 2016, operators assigned to perform regular setup tasks (servicing) on energized equipment in the point-of-operation and associated danger zones were not provided with adequately developed and documented machine-specific hazardous energy control (lockout tagout) procedures to ensure safety in accordance with the standard. Operators were exposed to unexpected machine start-up likely to result in serious injuries due to struck-by and caught in-between hazards.     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $8,149 · Current $1,356 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct an annual or more frequent inspection of the energy control procedure to ensure that the procedure and requirements of this standard were followed:     MES department, MES 1, MES 2, MES 3 - on or about October 18, 2016, the employer did not inspect hazardous energy control (lockout) procedures periodically (at least once per year) to ensure they were adequate and being followed in accordance with the requirements of 29 CFR 1910.147. Operators assigned to perform setup (servicing) on energized equipment were exposed to machine struck-by and caught-in hazards likely to result in serious injury.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $11,408 · Current $1,356 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) MES department, MES 1 and MES 2: on or about October 18, 2016, operators were regularly entering machining areas (danger zones) from the operators' cabs to perform quality checks on parts being actively produced, and to maintain housekeeping in the area. Safeguards were not provided to prevent operators' access and/or disable hazardous operations prior to exposures. Operators were exposed to machine struck-by and caught in-between hazards likely to result in serious injuries. Operators cab doors were not designed and constructed as adequate safeguards due to damages, lack of safety interlocks, and otherwise not being properly secured and/or affixed to function as physical barrier guards.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).    (b) MES department, MES 3: on or about October 18, 2016, operators were regularly entering machining area (danger zone) from the operator's cab to perform quality checks on parts being actively produced and to maintain housekeeping in the area. Provided door safety interlocks were bypassed and not functioning as intended to prevent operators' access and/or disable hazardous operations prior to exposure. Operators were exposed to machine struck-by and caught in-between hazards likely to result in serious injuries.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Mar 7, 2017

Abate by

Apr 17, 2019

Penalty

Initial $6,519 · Current $1,356 Reduced

General-duty citation text

29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:    (a) MES department, MES 2, time station, Belkin temporary relocatable power tap: on or about October 18, 2016, employees were exposed to fire and electrical hazards where an energized relocatable power tap was used in an industrial setting as a substitute for fixed wiring of an electronic time station, and suspended over a pipe. This equipment is not intended for such use.    (b) MES department, MES 2, operator's cab, black and white relocatable power taps: on or about October 18, 2016, employees were exposed to fire and electrical hazards where energized relocatable power taps were used in an industrial setting as a substitute for fixed wiring of electronic devices. Relocatable power taps were not directly connected to a permanently installed branch-circuit receptacle outlet and were connected in series to each other and an extension cord. Relocatable power taps were zip tied to a work bench and guardrail. This equipment is not intended for such use.    (c) MES department, MES 1, operator's cab, white relocatable power tap: on or about October 18, 2016, employees were exposed to fire and electrical hazards where an energized relocatable power tap was used in an industrial setting as a substitute for fixed wiring of electronic devices. Relocatable power tap was not directly connected to a permanently installed branch-circuit receptacle outlet and was connected in series to an extension cord. Relocatable power tap was zip tied to a work bench. This equipment is not intended for such use.    There is no abatement certification or documentation required for these items.