OSHA Inspection: STAR MANUFACTURING COMPANY

Issued

Jan 8, 2018

Abate by

Mar 21, 2018

Penalty

Initial $9,054 · Current $4,527 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:      On or about 24 July 2017, the employer did not ensure adequate documented energy control procedures were developed and utilized for employees assigned to perform servicing or maintenance on all company machines to include the Williams White Moline S2-500-60-48, Machine #125. Employees were exposed to unexpected start-up and release of stored energy (spinning flywheel) while performing servicing or maintenance when they did not use Lockout/Tagout on all sources of potential energy (kinetic/pneumatic). Employees were exposed to caught-in/crushing hazards.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Mar 21, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii): The procedures shall 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, the following:    On or about 24 July 2017, documented procedures in the employer's lockout/tagout program did not adequately outline the scope, purpose, authorization, rules, and techniques to be utilized for the prevention of unexpected energizing, start-up or release of stored energy on all company machines, to include the Williams White S2-500-60-48, Machine #125. Employees were exposed to unexpected start-up when they were observed performing maintenance on Machine #125 without properly securing all potential sources of stored energy (kinetic/pneumatic). The employees did not install the ram block, secure the pneumatic air supply, or wait until the flywheel came to a complete stop prior to placing their hands inside of the die area and performing maintenance.     All employees who gain access to equipment, including shears, power presses, plasma cutter, upsetters, saws, mills, furnaces, and bull dozers who perform servicing and maintenance were exposed to caught-in hazards.     Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 31, 2018

Penalty

Initial $0 · Current $0

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.    On or about 24 July 2017, the employer did not conduct a periodic inspection of the energy control procedures at least annually to ensure that the procedures and the requirement of this standard were being followed. Employees utilizing undocumented procedures were exposed to caught-in hazards and amputation hazards.     Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Mar 21, 2018

Penalty

Initial $9,054 · Current $4,527 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:     On or about 24 July 2017, the employer failed to effectively train employees to identify each potential energy source and isolate those sources during servicing and maintenance operations on all company equipment, including shears, power presses, plasma cutter, upsetters, saws, mills, furnaces, and bull dozers. Employee(s) were exposed to a caught-in hazard.    This exposed employees to amputation and/or crushing injuries from unexpected start-up.     Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Mar 21, 2018

Penalty

Initial $9,054 · Current $4,527 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.     On or about 24 July 2017, the employer failed to provide machine guarding to protect operator(s) and other employees from hazard(s) created by all production equipment to include the following machines:    a. Machine #98 & #102 Williams & White Bar Shear. The machine did not have a guard on the side of the machine that completely guarded the shearing action of the machine. This allowed the employees to gain access during the operation of the machine.     b. Machine #101 Clearing Cold Work Press. The side of the machine did not have guarding to prevent employees from gaining access to the machine while it was in operation.    c. Machine #200 Clearing Hot Work Press. The guarding on the side of the machine was pulled back to allow employees to place larger parts into the machine. The guarding was not adjusted properly to allow larger pieces of product.     d. Machine #98 Warco Hot Work Press. The side of the machine did not have any kind of guarding to prevent employees from gaining access to the moving parts of the machine.     e. Machine #114 Blow Hot Press. The machine did not have any form of guarding on the rear of the machine. Employees pass behind the machine and the lack of guarding allows the employees to gain access during the operation of the machine. Behind the machine is a walk way where employees pass by throughout the day.     f. The Johnson Press near the Verson Press #110 did not have guarding in the front of the machine where employees would load/unload parts. Employees used a foot pedal to control presses.     g. The Warco Press near the Verson Press #110 did not have guarding in the front of the machine where employees would load/unload parts. Employees used a foot pedal to control presses.    This exposes employees to caught-in, and struck by hazards.     Abatement documentation is required in accordance with the 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 23, 2018

Penalty

Initial $9,054 · Current $4,527 Reduced

General-duty citation text

29 CFR 1910.218(f)(1): Mechanical forging presses. When dies are being changed or maintenance is being performed on the press, the following shall be accomplished:    (i). The power to the press shall be locked out.  (ii). The flywheel shall be at rest.  (iii). The ram shall be blocked with a material the strength of which shall meet or exceed the specifications or dimensions shown in Table O-11.    On or about 24 July 2017, the employer did not ensure that the employees were protected from injuries when they were required to perform maintenance on the William White Moline S2-500-60-48, Machine #125. The following was not accomplished:    (i). The power to the press was not locked out. The operator of the press applied his lockout device on the electrical power source only. The maintenance mechanics did not apply their locks or shut down the remaining power sources for the machine.  (ii). The flywheel was not at rest. The maintenance mechanics did not allow the flywheel to come to a complete stop prior to beginning maintenance on the forging press.  (iii). The ram was not blocked with a material the strength of which shall meet or exceed the specifications or dimensions shown in Table O-11. The maintenance employees were observed performing maintenance on the forging press without a ram block being used..    Employees were exposed to crushing, caught-in, and amputation hazards.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 31, 2018

Penalty

Initial $6,467 · Current $3,238 Reduced

General-duty citation text

29 CFR 1910.332(b)(1): Employees shall be trained in and familiar with the safety-related work practices required by 1910.331 through 1910.335 that pertain to their respective job assignments:    On or about 10 July 2017 and on dates prior, employee were required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing.       The employees were not trained in and familiar with safety-related work practices, such as the use of special precautionary techniques, personal protective equipment (PPE), and insulating and shielding materials. The employees were exposed to shock and arc flash hazards.     Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 31, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.333(c)(2): Only qualified persons may work on electric circuit parts or equipment that have not been deenergized under the procedures of paragraph (b) of this section. Such persons shall be capable of working safely on energized circuits and shall be familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools.     On or about 10 July 2017 and on dates prior, an employee was required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing.    The employee was not trained in and familiar with safety-related work practices such as the use of special precautionary techniques, Personal Protective Equipment (PPE) and insulating and shielding materials. The employee was exposed to shock hazards.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 31, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.334(c)(1): Only qualified persons may perform testing work on electric circuits or equipment.     On or about 10 July 2017 and on dates prior, an employee was required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing.    Employees were exposed to shock hazards.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Mar 1, 2018

Penalty

Initial $9,054 · Current $4,527 Reduced

General-duty citation text

29 CFR 1910.333(a): Safety-related work practices shall be employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contacts, when work is performed near or on equipment or circuits which are or may be energized. The specific safety-related work practices shall be consistent with the nature and extent of the associated electrical hazards.     On or about 10 July 2017 and on dates prior, an employee was required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing    Electrically insulated rubber gloves were not provided to prevent direct or indirect contract with live electrical parts. Employees were exposed to electrocution and shock hazards.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Mar 1, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.333(b)(2)(i): The employer shall maintain a written copy of the procedures outlined in paragraph (b)(2) and shall make it available for inspection by employees and by the Assistant Secretary of Labor and his or her authorized representatives.     The employer did not maintain written procedures to ensure parts were de-energized, locked out and tagged in accordance with paragraph (b).     On or about 10 July 2017 and on dates prior, an employee was required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing.    This exposed employee(s) assigned to perform work on up to 480v circuits to electric shock, and electrocution.     Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 31, 2018

Penalty

Initial $9,054 · Current $4,527 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.    The employer failed to provide electrical protective equipment for the employees to use when they were assigned tasks in areas where they have the potential to come into contact with energized equipment.    On or about 10 July 2017 and on dates prior, an employee was required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing.    Employees did not wear appropriate electrical protective equipment, including but not limited to the following, to protect against electrical shock injuries:      a) Rubber insulating gloves with leather protectors.      b) Arc-Rated clothing such as arc-rated long-sleeve shirt and pants, or arc-rated coverall.      c) Hearing protection (canal inserts).      d) Arc-Rated flash suit, hood or balaclava.      Abatement documentation is required of this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 31, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(1)(iv): Employees shall wear nonconductive head protection wherever there is a danger of head injury from electric shock or burns due to contact with exposed energized parts.    Maintenance employee(s) did not wear nonconductive head protection, such as a hard hat with dielectric properties to protect against electrical shock or injuries in case of contact with energized equipment.    On or about 10 July 2017 and on dates prior, an employee was required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing.    This exposed employees to shock hazards.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 31, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(1)(v): Employees shall wear protective equipment for the eyes or face wherever there is danger of injury to the eyes or face from electric arcs or flashes or from flying objects resulting from electrical explosion.    Maintenance employee(s) did not wear appropriate protective equipment, such as safety glasses and an arc-rated face shield, to protect the eyes and face against electrical arc flash/blast injuries.    On or about 10 July 2017 and on dates prior, an employee was required to work live on electrical equipment up to 480 volts. The employee was required to gain access to the 480 volt control panel for the Blow Press #124 and perform voltage testing. This exposed employees to shock hazards.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 8, 2018

Abate by

Jan 23, 2018

Penalty

Initial $6,467 · Current $0 Reduced

General-duty citation text

29 CFR 1904.39(a)(2): Basic Requirement. Within twenty-four (24) hours after the in-patient hospitalization of one or more employees or an employee's amputation or an employee's loss of an eye, as a result of a work-related incident, you must report the in-patient hospitalization, amputation, or loss of an eye to OSHA.    On or about 24 July 2017, the employer failed to inform OSHA of an employee being hospitalized within 24 hours as is required. The accident occurred on July 15, 20017, OSHA was informed on July 17, 2017 by the local Fire Chief and not by the employer.     There is no abatement certification or documentation required for this item.