OSHA Inspection: MELOON FOUNDRIES, LLC

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $8,192 · Current $4,100 Reduced

General-duty citation text

29 CFR  1910.95(g)(5)(i):Within 6 months of an employee's first exposure at or above the action level, the employer did not establish a valid baseline audiogram against which subsequent audiograms can be compared:  a) Knockout area, on or about 2/16/21: A knockout area employee was  exposed to an 8-hr TWA  of noise at 93.0 dBA, for the 341 minutes sampled. A zero increment was included for the 139 minutes not sampled. No baseline audiogram during the calendar year 2020 was performed.  The employee was hired on 2/12/2020.   b) Grinding area, on or about 3/10/21: A grinding area employee was exposed to an 8-hr TWA  of noise at 91.5 dBA, for the 360 minutes sampled. A zero increment was included for the 120 minutes not sampled. No baseline audiogram during the calendar year 2020 was performed. The employee was hired on 3/9/20.  Abatement certification must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.95(g)(6): At least annually after obtaining the baseline audiogram, the employer did not obtain a new audiogram for each employee exposed at or above an 8-hour time-weighted average (8-hr TWA) of 85 decibels (dBA):  a) Grinding area, on or about 2/11/21: Grinding area employees were exposed to an 8-hr TWA  of noise at 91.5 dBA, for the 360 minutes sampled. A zero increment was included for the 120 minutes not sampled. Annual audiograms during the calendar year 2020 were not performed.    b) Melt room, on or about 2/11/21: Melt room employees were  exposed to an 8-hr TWA  of noise at 87.7 dBA, for the 372 minutes sampled. A zero increment was included for the 108 minutes not sampled. Annual audiograms during the calendar year 2020 were not performed.  Abatement certification must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.95(k)(1): The employer did not train each employee who is exposed to noise at or above an 8-hour time-weighted average of 85 decibels in accordance with the requirements of 29 CFR 1910.95(k):   a) Knockout area, on or about 2/11/21: Knockout area employees were  exposed to an 8-hr TWA  of noise at 93.0 dBA, for the 341 minutes sampled. A zero increment was included for the 139 minutes not sampled. No noise training was performed in calendar year 2020.  b) Grinding area, on or about 2/11/21: Grinding area employees were exposed to an 8-hr TWA  of noise at 91.5 dBA, for the 360 minutes sampled. A zero increment was included for the 120 minutes not sampled. No noise training was performed in calendar year 2020.  c) Melt room, on or about 2/11/21: Melt room employees were  exposed to an 8-hr TWA  of noise at 87.7 dBA, for the 372 minutes sampled. A zero increment was included for the 108 minutes not sampled. No noise training was performed in calendar year 2020.  Abatement certification must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.95(k)(2): The training program was not repeated annually for each employee included in the hearing conservation program:   a) Grinding area, on or about 2/11/21: Grinding area employees were exposed to an 8-hr TWA  of noise at 91.5 dBA, for the 360 minutes sampled. A zero increment was included for the 120 minutes not sampled. No annual noise training was performed in calendar year 2020.  b) Melt room, on or about 2/11/21: Melt room employees were  exposed to an 8-hr TWA  of noise at 87.7 dBA, for the 372 minutes sampled. A zero increment was included for the 108 minutes not sampled. No annual noise training was performed in calendar year 2020.  Abatement certification must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jun 22, 2021

Penalty

Initial $8,192 · Current $4,100 Reduced

General-duty citation text

29 CFR  1910.132(d)(2): The employer did not verify that the required workplace hazard assessment has been performed through a written certification that identifies the workplace evaluated; the person certifying that the evaluation has been performed; the date(s) of the hazard assessment; and, which identifies the document as a certification of hazard assessment:    a) Melt area, on or about 12/3/20: A certification of hazard assessment was not performed for personal protective equipment required to be worn by employees in the melt area.  Abatement certification must be submitted for this item.

Issued

Jun 2, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.132(f)(1): The employer did not provide training to each employee who is required by this section to use PPE:  a) Melt area, on or about 12/3/20:  An employee was not trained on the personal protective equipment that is necessary such as aprons and leggings to protect against burns to the legs from molten metal.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $6,827 · Current $3,417 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR 1910.134(f)(2): The employer did not ensure that an employee using a tight-fitting facepiece respirator is fit tested prior to initial use of the respirator, whenever a different respirator facepiece (size, style, model or make) is used, and at least annually thereafter:   a) Green Sand Molding West, on or about 2/11/21: A green sand molder wearing an N95 respirator was overexposed to respirable quartz (silica) at 61.8 micg/m^3 or 1.2 times the permissible exposure limit of 50 micg/m^3 for the 456 minutes sampling period. A zero increment was included for the 24 minutes not sampled. This employee was not fit-tested for a respirator.  Abatement certification must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(k)(3): The employer did not provide the training prior to requiring the employee to use a respirator in the workplace:  a) Green sand molding area, on or about 2/11/21: A green sand molder required to wear an N95 respirator was not provided with training on respirators.  b) Green sand mixing area, on or about 2/11/21: A green sand mixer required to wear an N95 respirator was not provided with training on respirators.  Abatement certification must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jan 3, 2022

Penalty

Initial $9,557 · Current $4,782 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR  1910.1053(c): The employer did not ensure that any employee was exposed to an airborne concentration of respirable crystalline silica in excess of 50 g/m3, calculated as an 8-hour TWA.   a) Green Sand Molding West, on or about 2/11/21: A green sand molder was overexposed to respirable quartz (silica) at 61.8 micg/m^3 or 1.2 times the permissible exposure limit of 50 micg/m^3 for the 456 minutes sampling period. A zero increment was included for the 24 minutes not sampled.  Abatement must be done according to the following:  1) Employees must be placed in proper respirators complying with medical evaluation, fit-testing and training provision of the OSHA Respiratory Protection Standard, 29 CFR 1910.134. (30 days)  2) A plan must be developed to reduce exposures below the PEL, through engineering controls, work practice controls, administrative controls or any combination thereof. (60 days)  3) The above controls must be tested and implemented. (90 days)  Abatement documentation must be submitted for these items.

Issued

Jun 2, 2021

Abate by

Jun 22, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.1053(e)(1): . The employer did not establish a regulated area wherever an employee's exposure to airborne concentrations of respirable crystalline silica is, or can reasonably be expected to be, in excess of the PEL.    a) Green Sand Molding West, on or about 2/11/21: A green sand molder was overexposed to respirable quartz (silica) at 61.8 micg/m^3 or 1.2 times the permissible exposure limit of 50 micg/m^3 for the 456 minutes sampling period. A zero increment was included for the 24 minutes not sampled. A regulated area including posting  signage, demarcating the area and prohibiting access to unauthorized employees was not established.  Abatement documentation must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jan 3, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 9010

General-duty citation text

29 CFR  1910.1053(f)(1):  The employer did not use engineering and work practice controls to reduce and maintain employee exposure to respirable crystalline silica to or below the PEL, unless the employer could demonstrate that such controls are not feasible:      a) Green Sand Molding West, on or about 2/11/21: A green sand molder was overexposed to respirable quartz (silica) at 61.8 micg/m^3 or 1.2 times the permissible exposure limit of 50 micg/m^3 for the 456 minutes sampling period. A zero increment was included for the 24 minutes not sampled.  Engineering and work practice controls were not used to reduce exposures at or below the PEL.  Abatement documentation must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Aug 6, 2021

Penalty

Initial $0 · Current $0

Hazardous substances 9010

General-duty citation text

29 CFR  1910.1053(f)(2)(i): The employer did not establish and implement a written exposure control plan that contains at least the following elements:  - a description of tasks in the workplace that involve employee exposure to respirable crystalline silica. - engineering controls, work practice controls and respiratory protection that limit employee exposure to respirable crystalline silica, and - a description of housekeeping measures that limit employee exposure to respirable crystalline silica.     a) Green Sand Molding West, on or about 2/11/21: A green sand molder was overexposed to respirable quartz (silica) at 61.8 micg/m^3 or 1.2 times the permissible exposure limit of 50 micg/m^3 for the 456 minutes sampling period. A zero increment was included for the 24 minutes not sampled.  No written exposure control plan was developed.  Abatement documentation must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.1053(i)(1)(i): The employer did not make medical surveillance available at no cost to the employee, and at a reasonable time and place, for each employee who was occupationally exposed to respirable crystalline silica at or above the action level for 30 or more days per year:    a) No Bake Molding Area, on or about 2/11/21: A no bake molder was exposed to respirable quartz (silica) at  55.6 micrograms per cubic meter (mcg/m^3) or 2.2 times the action level (AL) of 25 micg/m^3 for the 445 minute sampling period. A zero increment was included for the 35 minutes not sampled.   b) Green sand mixing area, on or about 2/11/21: A green sand mixer was exposed to respirable quartz (silica) at  54.5 micrograms per cubic meter (mcg/m^3) or 2.2 times the action level (AL) of 25 micg/m^3 for the 408 minute sampling period. A zero increment was included for the 72 minutes not sampled.   Abatement documentation must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1053(j)(3)(i): The employer did not ensure that each employee covered by this section could demonstrate knowledge and understanding of the following:  (A) the health hazards associated with exposure to respirable crystalline silica;  (B) specific tasks in the workplace that could result in exposure to respirable crystalline silica;  (C) specific measures the employer has implemented to protect employees from exposure to respirable crystalline silica, including engineering controls, work practices, and respirators to be used;  (D) the contents of this section; and,  (E) the purpose and a description of the medical surveillance program required by paragraph (i) of this section:   a) Green Sand Molding West, on or about 2/11/21: A green sand molder was overexposed to respirable quartz (silica) at 61.8 micg/m^3 or 2.5 times the action level of 25  micg/m^3 for the 456 minutes sampling period. A zero increment was included for the 24 minutes not sampled. No training on silica including information contained in the OSHA Respirable Crystalline Silica standard, 29 CFR 1910.1053, was provided for employees. Information not provided included information on medical surveillance, regulated areas, silica exposure control plan , and measures used for protection such as work practice controls and engineering controls.  b) No Bake Molding Area, on or about 2/11/21: A no bake molder was exposed to respirable quartz (silica) at  55.6 micrograms per cubic meter (mcg/m^3) or 2.2 times the action level (AL) of 25 micg/m^3 for the 445 minute sampling period. A zero increment was included for the 35 minutes not sampled. No training on silica including information contained in the OSHA Respirable crystalline Silica standard  silica standard, 29 CFR 1910.1053, was provided for employees. Information not provided included information on medical surveillance, regulated areas, silica exposure control plan, and measures used for protection such as work practice controls and engineering controls.  c) Green sand mixing area, on or about 2/11/21: A green sand mixer was exposed to respirable quartz (silica) at  54.5 micrograms per cubic meter (mcg/m^3) or 2.2 times the action level (AL) of 25 micg/m^3 for the 408 minute sampling period. A zero increment was included for the 72 minutes not sampled. No training on silica including information contained in the OSHA Respirable Crystalline Silica standard, 29 CFR 1910.1053, was provided for employees. Information not provided included information on medical surveillance, regulated areas, silica exposure control plan and measures used for protection such as work practice controls and engineering controls.     Abatement documentation must be submitted for this item.

Issued

Jun 2, 2021

Abate by

Jun 17, 2021

Penalty

Initial $16,384 · Current $8,200 Reduced

General-duty citation text

29 CFR  1910.132(a) Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, were not provided, used, and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment, chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact:  a) Melt area, on or about 12/3/20: An employee incurred a burn on his leg when an apron that protects the legs and torso was not worn.  Abatement documentation must be submitted for this item.  Meloon Foundries LLC was previously cited for a violation of this occupational safety and health standard or its equivalent standard, 29 CFR 1910.132(a),  which was contained in OSHA inspection number 1172484, citation number 1, item number 1a, and was affirmed as a final order on 10/18/2016, with respect to a workplace located at  1841 Lemoyne Avenue, Syracuse, NY 13208.

Issued

Jun 2, 2021

Abate by

Jul 7, 2021

Penalty

Initial $19,114 · Current $9,565 Reduced

General-duty citation text

29 CFR  1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee is fit tested or required to use the respirator in the workplace. The employer may discontinue an employee's medical evaluations when the employee is no longer required to use a respirator:  a) Green sand molding area, on or about 2/11/21: A green sand molder required to wear an N95 respirator was not provided with a medical evaluation assessing the ability to wear a respirator.   b) Green sand mixing area, on or about 2/11/21: A green sand mixer required to wear an N95 respirator was not provided  with a medical evaluation assessing the ability to wear a respirator.  Abatement Documentation must be submitted for this item.  Meloon Foundries LLC  was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.134(e)(1), which was contained in OSHA inspection number 1283599, citation number 2,  item number 1b  and was affirmed as a final order on 6/15/18, with respect to a workplace located at 1841 Lemoyne Avenue, Syracuse, NY 13208.