OSHA Inspection: GENERAL ALUMINUM MFG. COMPANY

Issued

Sep 27, 2021

Abate by

Sep 27, 2023

Penalty

Initial $13,653 · Current $14,502

General-duty citation text

29 CFR  OSH ACT of 1970 Section (5)(a)(1):Section 5(a)(1) of the Occupational Safety and Health Act: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees, in that employees were exposed to burn hazards from fire and explosions due to the presence of water in locations where molten aluminum was being poured.  a. The employer is failing to protect employees from burn and explosion hazards due to the potential for molten aluminum contacting standing water underneath the tilt pour devices on turn table #2.   This was most recently documented  on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio. The water lines cooling the molds on the tilt pour devices are leaking, and water is being allowed to pool on the floor under the tilt pour devices.   b. The employer is failing to protect employees from burn and explosion hazards due to the potential for molten aluminum contacting standing water underneath the tilt pour devices on turn table #1B.   This was most recently documented  on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   The water lines cooling the molds on the tilt pour devices are leaking,  and water is being allowed to pool on the floor under the tilt pour devices.   Among other methods, feasible and acceptable means of abatement would be to implement a program to regularly repair and/or replace all sources of water leaks including, but not limited to, leaking water lines as needed and prior to aluminum pours.  Abatement Schedule:  STEP 1- A combination of administrative controls shall be implemented as an interim protective measure until feasible engineering and administrative controls can be permanently implemented.  STEP 2- A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to the hazardous condition as referenced in this citation. This plan shall include, at a minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation: (1) Evaluation of engineering/administrative control options; (2) Selection of optimum control methods and completion of design; (3) Procurement, installation and operation of selected control measures; and (4) Testing and acceptance or modification/redesign of controls;   STEP 3- Abatement shall have been completed by the implementation of feasible engineering and administrative controls upon verification of their effectiveness in achieving compliance.

Issued

Sep 27, 2021

Abate by

May 11, 2023

Penalty

Initial $13,653 · Current $14,502

General-duty citation text

29 CFR  1910.132(a):Protective equipment was not used when necessary whenever hazards capable of causing injury and impairment were encountered.  a. The employer is failing to protect quality control technicians from molten aluminum burn hazards to the torso, arms, and legs when the employee is taking quality control samples and adding alloys to the molten aluminum bath. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  Quality Control technicians are not being required to wear adequate PPE when near molten aluminum.

Issued

Sep 27, 2021

Abate by

May 11, 2023

Penalty

Initial $13,653 · Current $9,112 Reduced

General-duty citation text

29 CFR  1910.147(c)(7)(i)(A): Authorized employee(s) did not receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation.   a. The employer is failing to protect operators from pinch point hazards by ensuring employees are trained as authorized employees under the company's lockout program when performing work such as, but not limited to, core box prep and core box maintenance activities on the #2 core machine located in the Core Department. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   b. The employer is failing to protect operators from pinch point hazards by ensuring employees are trained as authorized employees under the company's lockout program when performing work such as, but not limited, to core box prep and core box maintenance activities on the #3143 core machine located in the Core Department. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   c. The employer is failing to protect operators from pinch point hazards by ensuring employees are trained as authorized employees under the company's lockout program when performing work such as, but not limited to, mold prep activities, performing maintenance on the equipment, and when unjamming stuck parts from the upper die at the robot catching station on Tilt Pour Turntable #2 located in the foundry area. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   d. The employer is failing to protect operators from pinch point hazards by ensuring employees are trained as authorized employees under the company's lockout program when performing work such as, but not limited to, mold prep activities, performing maintenance on the equipment, and when unjamming stuck parts from the upper die at the robot catching station on Tilt Pour Turntable #1B located in the foundry area. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   e. The employer is failing to protect operators from pinch point hazards by ensuring employees are trained as authorized employees under the company's lockout program when performing work such as, but not limited to, mold prep activities, performing maintenance on the equipment, and when unjamming stuck parts from the upper die at the robot catching station on Tilt Pour Turntable #4a located in the foundry area. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   f. The employer is failing to protect operators from pinch point hazards by ensuring employees are trained as authorized employees under the company's lockout program when performing work such as, but not limited to, mold prep activities, performing maintenance on the equipment, and when unjamming stuck parts from the upper die at the robot catching station on Tilt Pour Turntable #5 located in the foundry area. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   g. The employer is failing to protect operators from pinch point hazards by ensuring employees are trained as authorized employees under the company's lockout program when performing work such as, but not limited to, mold prep activities, performing maintenance on the equipment, and when unjamming stuck parts from the upper die at the robot catching station on Tilt Pour Turntable #6 located in the foundry area. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.

Issued

Sep 27, 2021

Abate by

Oct 22, 2021

Penalty

Initial $13,653 · Current $0 Reduced

General-duty citation text

29 CFR  1910.178(a)(4):Modifications or additions which affect capacity and safe operation of powered industrial truck were performed by the employer without the manufacturer's prior written approval.  a. The employer is failing to ensure the manufacturer's approval is obtained prior to using an aftermarket boom attachment with a Caterpillar R9141 forklift. Employees are exposed to crushing hazards while using the aftermarket boom attachment to remove  fixtures from the knockout machine #2616.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   b. The employer is failing to ensure the manufacturer's approval is obtained prior to using an aftermarket boom attachment with a Caterpillar GC55K forklift. Employees are exposed to crushing hazards while using the aftermarket boom attachment to load scrap aluminum into furnaces #5 and #6.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   c. The employer is failing to ensure the manufacturer's approval is obtained prior to using an aftermarket boom attachment with a Mitsubishi FGC60K forklift. Employees are exposed to crushing hazards while using the aftermarket boom attachment to dross off furnaces #5 and #6.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.

Issued

Sep 27, 2021

Abate by

Mar 27, 2024

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.178(a)(5):The powered industrial truck was equipped with front-end attachments other than factory installed attachments, however the employer did not request that the truck be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered.  a. The employer is failing to ensure the forklift data plate for the Caterpillar R9141 forklift is updated to show the identity and approximate weight of the truck and attachment combination prior to using the boom attachment. Employees are exposed to crushing hazards while using the aftermarket boom attachment to remove fixtures from the knockout machine #2616.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   b. The employer is failing to ensure the forklift data plate for the Caterpillar GC55K forklift is updated to show the identity and approximate weight of the truck and attachment combination prior to using the boom attachment. Employees are exposed to crushing hazards while using the aftermarket boom attachment to load scrap aluminum into furnaces #5 and #6. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   c. The employer is failing to ensure the forklift data plate for the Mitsubishi FGC60K forklift is updated to show the identity and approximate weight of the truck and attachment combination prior to using the boom attachment. Employees are exposed to crushing hazards while using the aftermarket boom attachment to dross off furnaces #5 and #6.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.

Issued

Sep 27, 2021

Abate by

Nov 15, 2021

Penalty

Initial $136,532 · Current $0 Reduced

General-duty citation text

29 CFR  1910.147(c)(4)(i):Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:  a. The employer is failing to protect operators from pinch point hazards by ensuring employees utilized lockout procedures when performing work such as but not limited to core box prep and core box maintenance activities on the #2 core machine located in the Core Department.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   b. The employer is failing to protect operators from pinch point hazards by ensuring employees utilized lockout procedures when performing work such as but not limited to core box prep and core box maintenance activities on the #3143 core machine located in the Core Department.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   c. The employer is failing to protect operators from pinch point hazards by ensuring operators utilized lockout procedures when working on the Tilt Pour Turntable #2 located in the foundry area. Employees perform mold prep activities, maintenance on the equipment, and unjam stuck parts from the upper die at the robot catching station. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   d. The employer is failing to protect operators from pinch point hazards by ensuring operators utilized lockout procedures when working on the Tilt Pour Turntable #1B located in the foundry area. Employees perform mold prep activities, maintenance on the equipment, and unjam stuck parts from the upper die at the robot catching station.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   e. The employer is failing to protect operators from pinch point hazards by ensuring operators utilized lockout procedures when working on the Tilt Pour Turntable #4A located in the foundry area. Employees perform mold prep activities, maintenance on the equipment, and unjam stuck parts from the upper die at the robot catching station.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   f. The employer is failing to protect operators from pinch point hazards by ensuring operators utilized lockout procedures when working on the Tilt Pour Turntable #5 located in the foundry area. Employees perform mold prep activities, maintenance on the equipment, and unjam stuck parts from the upper die at the robot catching station.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.   g. The employer is failing to protect operators from pinch point hazards by ensuring operators utilized lockout procedures when working on the Tilt Pour Turntable #6 located in the foundry area. Employees perform mold prep activities, maintenance on the equipment, and unjam stuck parts from the upper die at the robot catching station.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.

Issued

Sep 27, 2021

Abate by

Oct 22, 2021

Penalty

Initial $136,532 · Current $0 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. The employer is failing to protect operators from pinch point hazards created by the movement of the Hall Permanent Mold Tilt Pour Devices for turntable #2, located in the foundry area, while performing various tasks such as, but not limited to, attaching hoses to the equipment, placing floor dry around the bottom of the tilt pours, blowing water off the rotating pouring deck, shoveling up floor dry from around the base of the tilt pours, and checking water flow gages to the molds. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  b. The employer is failing to protect operators from pinch point hazards created by the movement of the Hall Permanent Mold Tilt Pour Devices for turntable #lB, located in the foundry area, while performing various tasks such as, but not limited to, attaching hoses to the equipment, placing floor dry around the bottom of the tilt pours, blowing water off the rotating pouring deck, shoveling up floor dry from around the base of the tilt pours, and checking water flow gages to the molds. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  c. The employer is failing to protect operators from pinch point hazards created by the movement of the Hall Permanent Mold Tilt Pour Devices for turntable #5, located in the foundry area, while performing various tasks such as, but not limited to, attaching hoses to the equipment, placing floor dry around the bottom of the tilt pours, blowing water off the rotating pouring deck, shoveling up floor dry from around the base of the tilt pours, and checking water flow gages to the molds. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  d. The employer is failing to protect operators from pinch point hazards created by the movement of the catcher cell robot for turntable #5, located in the foundry area, employees are exposed to pinch point hazards between the robot catcher table and the employee's workstation. The workstation is equipped with light curtains but there is a 33-inch gap between the work station light curtain and the robot cell metal enclosure which allows employees to reach around the guarding and enter the robot's operational envelope. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  e. The employer is failing to protect operators from pinch point hazards created by the movement of the Hall Permanent Mold Tilt Pour Devices for turntable #6, located in the foundry area, while performing various tasks such as, but not limited to, attaching hoses to the equipment, placing floor dry around the bottom of the tilt pours, blowing water off the rotating pouring deck, shoveling up floor dry from around the base of the tilt pours, and checking water flow gages to the molds. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  f. The employer is failing to protect operators from pinch point hazards created by the movement of the catcher cell robot for turntable #6, located in the foundry area, employees are exposed to pinch point hazards between the robot catcher table and the employee's workstation. The workstation is equipped with light curtains but there is a 36 inch gap between the work station light curtain and the robot cell metal enclosure which allows employees to reach around the guarding and enter the robot's operational envelope. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  g. The employer is failing to protect operators from pinch point hazards created by the movement of the Hall Permanent Mold Tilt Pour Devices for turntable #4a, located in the foundry area, while performing various tasks such as, but not limited to, attaching hoses to the equipment, placing floor dry around the bottom of the tilt pours, blowing water off the rotating pouring deck, shoveling up floor dry from around the base of the tilt pours, and checking water flow gages to the molds. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  h. The employer is failing to protect operators from pinch point hazards on the #2 core machine located in the Core Department while performing various tasks including, but not limited to, monitoring the operation of core machine #2. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  i. The employer is failing to protect operators from pinch point hazards on the #3143 core machine and associated picker table located in the Core Department while performing various tasks including, but not limited to, monitoring the operation of core machine 3143, cleaning between cycles, and removing cores from the picker table. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.

Issued

Sep 27, 2021

Abate by

Oct 22, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.212(a)(3)(ii):Point(s) of operation of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s).  a.  The employer is failing to protect operators from crushing hazards on the Hall Permanent Mold Tilt Pour Devices for turntable #2, located in the foundry area. Employees are exposed to crushing hazards created by the upper and lower molds as the mold halves close. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  b.  The employer is failing to protect operators from crushing hazards on the Hall Permanent Mold Tilt Pour Devices for turntable #lB, located in the foundry area. Employees are exposed to crushing hazards created by the upper and lower molds as the mold halves close. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  c. The employer is failing to protect operators from crushing hazards on the Hall Permanent Mold Tilt Pour Devices for turntable #5, located in the foundry area. Employees are exposed to crushing hazards created by the upper and lower molds as the mold halves close. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.                                                                                                                d.  The employer is failing to protect operators from crushing hazards on the Hall Permanent Mold Tilt Pour Devices for turntable #6, located in the foundry area. Employees are exposed to crushing hazards created by the upper and lower molds as the mold halves close. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  e.  The employer is failing to protect operators from crushing hazards on the Hall Permanent Mold Tilt Pour Devices for turntable #4A, located in the foundry area. Employees are exposed to crushing hazards created by the upper and lower molds as the mold halves close. This was most recently documented on May 6, 2021, at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.

Issued

Sep 27, 2021

Abate by

Oct 22, 2021

Penalty

Initial $75,092 · Current $0 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.   The employer is failing to protect operators from pinch point hazards created by the movement of the chuck and tooling of the Bridgeport mill, located in the quality control department.   This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  b.   The employer is failing to protect operators from struck-by hazards created by the movement of the skip hoist used to load aluminum scrap into furnace #2.  The barrier guarding around the base of the skip hoist is not equipped with a functioning interlock.  This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  c.     The employer is failing to protect operators from pinch point hazards created by the movement of the chuck and tooling of the Cubic Lathe 5-712, located adjacent to the heat treat department.  The barrier guard is not equipped with a functioning interlock. This was most recently documented on May 6, 2021 at the General Aluminum Mfg. Company facility located in Rootstown Township, Ohio.  General Aluminum Mfg. Company was previously cited for a violation of this occupational safety and health standard or its equivalent standard  1910.212.a.1, which was contained in OSHA inspection number 1060722, citation number 1, item number 1b and was affirmed as a final order on February 27, 2017, with respect to a workplace located at 13663 Short Rd., Wapakoneta, OH 45895.