OSHA Inspection: VFORGE, INC.

Issued

Sep 20, 2018

Abate by

Sep 28, 2018

Penalty

Initial $9,054 · Current $4,527 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, (c)(4)(ii)[A], (c)(4)(ii)[B], (c)(4)(ii)[C] and (c)(4)(ii)[D]:    a) On or about March 23, 2018, and at times prior, press operators and helpers were exposed to crushing hazards while performing die change, maintenance and set up while utilizing the "SSM Lockout/Tag-out" procedure which was inadequate to inform and protect workers in that its scope, purpose, rules, and means to enforce compliance were not clear, it did not achieve a locked-out condition, and the procedure did not include the following:        1.  The intended use, such as including if it should be used for die change and/or other hazardous tasks.      2.  Specific procedural steps for electrical isolation of control switches and the hydraulic pump.      3.  Specific procedural steps for isolation and lockout of compressed air hazards.      4.  Specific procedural steps for the application, removal and transfer of locks.      5.  A means to verify or test the effectiveness of the isolation and lockout methods.    b) On or about March 23, 2018, and at times prior, the Lockout Safety Procedure for VFE/SSM (Press 1) did not specifically address transfer of locks and verifying hazardous air pressure was effectively isolated.      Abatement Note: Abatement certification and documentation are required for this item (see enclosed Certification of Corrective Action Worksheet).

Issued

Sep 20, 2018

Abate by

Oct 10, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirement of this standard were being followed (see substeps [A], [B], and [C]):  a) On or about March 23, 2018, and at times prior, managers did not ensure that a periodic inspection was conducted in a timely manner in that the program titled, SSM Lockout / Tag-out had not received an annual review since April 30, 2008.    b) On or about March 23, 2018, and at times prior, managers did not ensure that the Lockout Safety Procedures, including, but not limited to VFE/SSM (Press 1) for engineering personnel received a timely, annual review in that the binder containing these procedures was most recently inspected on January 10, 2017.  c) On or about March 23, 2018, and at times prior, managers did not ensure the most recent review of LOTO procedures was performed by a person who does not utilize the specific LOTO procedure, did not identify and correct deficiencies, and did not include a review between the inspector and each authorized employee (see substeps [A], [B], and [C]).     Abatement Note: Abatement certification and documentation are required for this item (see enclosed Certification of Corrective Action Worksheet).

Issued

Sep 20, 2018

Abate by

Sep 28, 2018

Penalty

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

General-duty citation text

29 CFR 1910.212(a)(1): One or more methods of machine guarding was not 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:    a) SSM presses: On or about March 28, 2018, and at times prior, workers were exposed to severe crushing injuries while routinely entering the area beyond the protective enclosure doors of the IDRA and IDRA Prince presses, including Model OL/320 I PRP; Ser. No.: 7110, during operation in the full automatic mode for tasks including part retrieval and die-cleaning while the presses were fully operational and could cycle unexpectedly due to operator's panel input and/or equipment malfunction.    Abatement Note: Abatement certification and documentation are required for this item (see enclosed Certification of Corrective Action Worksheet).

Issued

Sep 20, 2018

Abate by

Sep 28, 2018

Penalty

Initial $103,469 · Current $51,735 Reduced

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 and did not include all the training elements listed under Items A-C of 29 CFR 1910.147(c)(7)(i):     a) SSM Presses: On or about March 23, 2018, and at times prior, workers without the ability to speak, read and/or comprehend the English language were exposed to severe crushing hazards while being untrained or effectively untrained respective to roles, responsibilities and hazards during machine servicing and maintenance due to the employer's Lockout/Tagout training being presented only in English.  A worker with almost no ability to communicate in the English language was exposed to crushing injuries while assigned to perform servicing and maintenance on SSM Press 1 prior to receiving any Lockout/Tagout training.  The worker sustained fatal injuries.       Abatement Note: Abatement certification and documentation are required for this item (see enclosed Certification of Corrective Action Worksheet).

Issued

Sep 20, 2018

Abate by

Sep 28, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(1): The authorized employees did not have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy before the authorized or affected employees turned off the machine or equipment:    a)  SSM Presses: On or about March 23, 2018, and at times prior, workers were not provided with specific information regarding the types and magnitude of hazardous energy, potential hazards and the means to perform a full and effective removal of hazardous energy present in the IDRA and IDRA Prince presses, including Model OL/320 I PRP; Serial No. 7110, such as electrical, mechanical, hydraulic, and pressurized air.    Abatement Note: Abatement certification and documentation are required for this item (see enclosed Certification of Corrective Action Worksheet).

Issued

Sep 20, 2018

Abate by

Sep 28, 2018

Penalty

Initial $103,469 · Current $51,735 Reduced

General-duty citation text

29 CFR 1910.218(f)(2)(i): Electrical power apparatus to hydraulic forging presses was not locked out when dies were being changed or maintenance was being performed on the presses:    a) SSM presses: On or about March 23, 2018, and at times prior, press operators and trimmers were exposed to severe crushing injuries when they performed die changes on IDRA and IDRA Prince presses, including Model OL/320 I PRP; Serial No 7110, without shutting off and locking out power using the electrical apparatus for the presses.  A fatal injury resulted from this condition.         Abatement Note: Abatement certification and documentation are required for this item (see enclosed Certification of Corrective Action Worksheet).

Issued

Sep 20, 2018

Abate by

Sep 28, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(3): All energy isolating devices that were needed to control the energy to the machine or equipment were not physically located and operated in such a manner as to isolate the machine or equipment from the energy sources:    a) SSM presses: On or about March 23, 2018, and at times prior, press operators and trimmers were exposed to severe crushing injuries while performing die changes on IDRA and IDRA Prince presses, including Model OL/320 I PRP; Serial No. 7110, when the air supply line providing more than 100 p.s.i. air pressure to enclosure door pneumatic actuators was not locked in the closed position and residual pressure bled off.        Abatement Note: Abatement certification and documentation are required for this item (see enclosed Certification of Corrective Action Worksheet).