OSHA Inspection: CHAPPELL DOOR MANUFACTURING, LLC

Issued

2021-08-17 00:00:00

Penalty

Initial $4096.00 · Current $9000.00

General-duty citation text

29 CFR 1910.22(a)(1): All places of employment, passageways, storerooms, service rooms, and walking-working surfaces are kept in a clean, orderly, and sanitary condition.  a) On or about May 6, 2021, employees were exposed to electrical cables, hoses, and cords found on the floor which created tripping hazards in areas such as but not limited to the Challoner 723 Tenoner Trim Saw and the Electric Panel Saw.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $9557.00 · Current $0.00 Reduced

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: (A) A specific statement of the intended use of the procedure; (B) Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy; (C) Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them; and (D) Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures.  a) On or about May 6, 2021, the Lite Machine lockout procedure lacked specific information to lockout the machine.  There wasn't statement of intended use for the procedure. The procedure did not address the location of the electrical power box, the location of the pneumatic air, where and how to release the air pressure, and where the lockout points were for this machine for the electrical and pneumatic air, and how to apply the locks for the pneumatic air.   b) On or about May 6, 2021, the Diehl 55 Rip Saw lockout procedure lacked specific information to lockout the machine. There wasn't statement of intended use for the procedure. It did not explain how to disconnect the electrical energy, where and how to apply the lock for the electrical energy, or how to verify that electrical energy was no longer present.   c) On or about May 6, 2021, the Challoner 723 Tenoner Trim Saw lockout procedure lacked specific information to lockout the machine. There was a two part procedure, but only one part was provided, and it did not explain what it was locking out. The Tenoner had multiple electrical boxes with disconnects present, and the procedure did not explain what was to be locked out beyond stating that you were to go to the electrical box in the northeast corner. There were two electrical disconnects in the northeast corner. There was compressed air and pneumatic power, and there was no explanation of where these were located or how to apply the lockout device, or where and how to release the air pressure. The procedures contained two sets of different instructions on how to lockout the Tenoner, which added locking and unlocking a gate, but there was no explanation on where to lock it out, how to unlock it, where it was located, or what the gate was. The pneumatic power was to be verified as locked out by walking around the machine, but did not explain what was to be viewed. Electrical power was to be verified as locked out by turning on and off switches, but there were multiple switches and control panels. It was not explained where or how to verify the electrical lockout.  d) On or about May 6, 2021, the Tyler Power Pod Cold Press #1 lockout procedure lacked specific information to lockout the machine. There wasn't statement of intended use for the procedure. The procedure explained there was electrical at 240 volts and 120 volts, but only one electrical disconnect was identified on the machine. It was not explained how to lockout or release the pneumatic air. There were two plates for the raised load, and there was no address of the stored energy in the raised load of the lower plate under the 32 air pods, or how to release the energy in the 32 air pods. The verification of pushing the power switch will not address the stored energy in the air pods and the lower plate located under the air pods.  e) On or about May 6, 2021, the Panel Saw Across From West Entrance Door lockout procedure lacked specific information to lockout the machine. There wasn't statement of intended use for the procedure. There was electrical and pneumatic energy. There were two disconnects for electrical, and there was no identification of which was to be used. The pneumatic energy in the procedure was explained by the employer to be hydraulic energy. There wasn't a verification procedure present.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

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.  a) On or about May 6, 2021, the employer did not conduct a periodic inspection to address the inadequacies of the lockout procedures for the machines present at the facility. These machines include but were not limited to the Lite Machine, Diehl 55 Rip Saw, Challoner 723 Tenoner Trim Saw, Tyler Power Pod Cold Press #1, and the Panel Saw Across From West Entrance Door.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $9557.00 · Current $0.00 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. The training shall include the following: (A)Each authorized employee shall 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 and control.  a) On or about May 6, 2021, the employed did not provide adequate training  on the lockout program for authorized employees for the safe application, usage, and removal of lockout controls on machines in that employees had not been adequately trained on machines such as but not limited to the Lite Machine,  the Diehl 55 Rip Saw, the Challoner 723 Tenoner Trim Saw,  the Tyler Power Pod Cold Press #1, and the Panel Saw Across From West Entrance Door.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $6827.00 · Current $1000.00 Reduced

General-duty citation text

29 CFR 1910.213(r)(4): The mention of specific machines in paragraphs (a) thru (q) and this paragraph (r) of this section, inclusive, is not intended to exclude other woodworking machines from the requirement that suitable guards and exhaust hoods be provided to reduce to a minimum the hazard due to the point of operation of such machines.  a) On or about May 6, 2021, the employer had not provided point of operation guarding between the pressurized metal plate and the doors of the Tyler Pod Cold Press #1.  b) On or about May 6, 2021, the employer exposed employees to pinch point created where the hinged top comes down on the table of the lite machine.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $9557.00 · Current $2000.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(1): Examination. Electric equipment shall be free from recognized hazards that are likely to cause death or serious physical harm to employees. Safety of equipment shall be determined using the following considerations: (iv) Electrical insulation; (viii) Other factors that contribute to the practical safeguarding of persons using or likely to come in contact with the equipment.   a) On or about May 6, 2021, the employer had not replaced electrical cables with damaged electrical insulation:  1. Under the table at the electric panel saw;  2. For the control pedal for the table lift located at the Costa Sander;  3. And for the orange controller for the table lift located near the Lite Machine.   b) On or about May 6, 2021, the employer did not secured the 240 volt power cable, which ran across the floor from the safety switch located on the wall across the top of the metal arm of the Lite Machine. The cable was on a hinged metal arm that moved and was attached to a moving cutting saw, which would cause wear on the insulation of the cable.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $4096.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There shall be no damaged parts that may adversely affect safe operation or mechanical strength of the equipment, such as parts that are broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating.   a) On or about May 6, 2021 at the Gluer Machine, the employer was not adequately protecting the electrical cables and cords at the scissor lifts and the foot pedals of the scissor lifts in that the machines would stop working due to the line connections being deteriorated by the Doorbond 200 Adhesive used in the Gluer.

Issued

2021-08-17 00:00:00

Penalty

Initial $6827.00 · Current $0.00 Reduced

General-duty citation text

assess the exposure of each employee who is or may reasonably be expected to be exposed to respirable crystalline silica at or above the action level in accordance with either the performance option in paragraph (d)(2) or the scheduled monitoring option in paragraph (d)(3) of this section. (d)(2) Performance option. The employer shall assess the 8-hour TWA exposure for each employee on the basis of any combination of air monitoring data or objective data sufficient to accurately characterize employee exposures to respirable crystalline silica. (d)(3)(i) Scheduled monitoring option. The employer shall perform initial monitoring to assess the 8-hour TWA exposure for each employee on the basis of one or more personal breathing zone air samples that reflect the exposures of employees on each shift, for each job classification, in each work area. Where several employees perform the same tasks on the same shift and in the same work area, the employer may sample a representative fraction of these employees in order to meet this requirement. In representative sampling, the employer shall sample the employee(s) who are expected to have the highest exposure to respirable crystalline silica.   a) On or about July 16, 2021, the employer had not performed an exposure assessment for respirable crystalline silica, which is contained in the Mineral Core (contains 36% to 38% crystalline silica) and Tectonite 900 (contains less than 20% crystalline silica) door cores and are cut to size using an electric panel saw and sanded.

Issued

2021-08-17 00:00:00

Penalty

Initial $6827.00 · Current $3000.00 Reduced

General-duty citation text

29 CFR 1910.1200(e)(1): Employers shall develop, implement, and maintain at each workplace, a written hazard communication program which at least describes how the criteria specified in paragraphs (f), (g), and (h) of this section for labels and other forms of warning, safety data sheets, and employee information and training will be met, and which also includes the following:  a) a) On or about May 6, 2021, the employer did not develop, implement, and maintain a written hazard communication program for chemicals such as but not limited to 3M Hi-Strength Post Forming 94 CA Cylinder Spray Adhesive (respiratory irritation), Doorbond 200 Adhesive (dermatitis), Mineral Core (carcinogen) and Tectonite 900 (respiratory tract irritant).

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.1200(h)(1): Employers shall provide employees with effective information and training on hazardous chemicals in their work area at the time of their initial assignment, and whenever a new chemical hazard the employees have not previously been trained about is introduced into their work area. Information and training may be designed to cover categories of hazards (e.g., flammability, carcinogenicity) or specific chemicals. Chemical-specific information must always be available through labels and safety data sheets.   a) On or about May 6, 2021, the employer did not provide information and training on hazardous chemicals to employees at the time of their initial assignment for chemicals such as but not limited to 3M Hi-Strength Post Forming 94 CA Cylinder Spray Adhesive (respiratory irritation), Doorbond 200 Adhesive (dermatitis), Mineral Core (carcinogen) and Tectonite 900 (respiratory tract irritant).

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.1053(j)(1): Communication of respirable crystalline silica hazards to employees-(1) Hazard communication. The employer shall include respirable crystalline silica in the program established to comply with the hazard communication standard (HCS) (29 CFR 1910.1200). The employer shall ensure that each employee has access to labels on containers of crystalline silica and safety data sheets, and is trained in accordance with the provisions of HCS and paragraph (j)(3) of this section. The employer shall ensure that at least the following hazards are addressed: Cancer, lung effects, immune system effects, and kidney effects.   a) On or about July 16, 2021, the employer did not include respirable crystalline silica in their hazard communication program training in that employees operating the electrical panel saw on Mineral Core (contains 36% to 38% crystalline silica) and Tectonite 900 (contains less than 20% crystalline silica) door cores were exposed to silica without having received training.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.132(d)(2):The employer shall 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) On or about May 6, 2021, the employer did not provided a written certification of the workplace hazard assessment that addressed wearing gloves when working with glues, wearing eye protection to protect eyes from dust, and wearing safety boots to protect feet when lifting and moving wood boards and doors.

Issued

2021-08-17 00:00:00

Abate by

2021-12-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR  1910.147(c)(5)(i): Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be provided by the employer for isolating, securing or blocking of machines or equipment from energy sources.    a) On or about May 6, 2021, the maintenance supervisor did not have a maintenance employee apply a lock while they were both performing maintenance on the same machine in that a second lock was not placed on the on the Ruvo Saw while lubricating the saw and a second lock was not placed on the Tyler Pod Cold Press #1 while replacing a bolt.

Issued

2021-08-17 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.1200(g)(8): The employer shall maintain in the workplace copies of the required safety data sheets for each hazardous chemical, and shall ensure that they are readily accessible during each work shift to employees when they are in their work area(s). (Electronic access and other alternatives to maintaining paper copies of the safety data sheets are permitted as long as no barriers to immediate employee access in each workplace are created by such options.)  a) On or about July 16, 2021, the employer did not maintain in the workplace a copy of a required safety data sheet (SDS) for chemicals such as but not limited to Mineral Core (skin corrosive, eye damage, corrosive respiratory tract, potential carcinogen, contains 36% to 38% crystalline silica).