OSHA Inspection: WAUPACA FOUNDRY, INC.

Issued

Nov 2, 2021

Abate by

Dec 13, 2021

Penalty

Initial $117,024 · Current $14,502 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:  At a workplace located at 805 Ogden Street in Marinette, Wisconsin:  On or about May 18, 2021, employees operating the CB #1 Machine No. 44174-000 located in the Core Room were exposed to laceration, amputation, and crushing hazards associated with the horizontal and vertical movements of the traveling pick-off arm assembly/carriage used to remove cores from the core box.  The machine was not effectively guarded to prevent exposure to these hazards.

Issued

Nov 2, 2021

Abate by

Dec 30, 2022

Penalty

Initial $14,502 · Current $14,502

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. Examples of guarding methods are-barrier guards, two-hand tripping devices,electronic safety devices, etc.  On or about May 18, 2021, and July 9, 2021, employess operating the CB #4 Machine No. 44125-00 located in the Core Room were exposed to laceration, amputation, and crushing hazards associated with the horizontal and vertical movements of the traveling pick-off arm assembly/carriage used to remove cores from the core box.  The machine was not effectively guarded to prevent exposure to these hazards.

Issued

Nov 2, 2021

Abate by

Dec 30, 2022

Penalty

Initial $14,502 · Current $14,502

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. Examples of guarding methods are-barrier guards, two-hand tripping devices,electronic safety devices, etc.  On or about May 18, 2021, employees operating the CB #5 Machine No. 44153-000 located in the Core Room were exposed to lacaration, amputation, and crushing hazards associated with the horizontal and vertical movements of the traveling pick-off arm assembly/carriage used to remove cores from the core box.  The machine was not effectively guarded to prevent exposure to these hazards.

Issued

Nov 2, 2021

Abate by

Dec 30, 2022

Penalty

Initial $14,502 · Current $14,502

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. Examples of guarding methods are-barrier guards, two-hand tripping devices,electronic safety devices, etc.  On or about May 18, 2021, and September 28, 2021, employees operating the CBG #8 Machine No. 2428 located in the Core Room were exposed to laceration, amputation, and crushing hazards associated with the horizontal and vertical movements of the traveling pick-off arm assembly/carriage used to remove cores from the core box.  The machine was not effectively guarded to prevent exposure to these hazards.

Issued

Nov 2, 2021

Abate by

Dec 2, 2021

Penalty

Initial $11,703 · Current $14,502

General-duty citation text

29 CFR 1910.28(b)(1)(i): Except as provided elsewhere in this section 29 CFR 1910.28, the employer did not ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2 m) or more above a lower level is protected from falling by one or more of the systems described in 29 CFR 1910.28(b)(1)(i):  At a workplace located at 805 Ogden Street in Marinette, Wisconsin:  (a) On or about July 22, 2021, the employer did not ensure an employee servicing the receiver on Autopour #2 was protected from falling through the gap in the guardrails between the autopour deck to the mobile service platform, exposing employees to a fall hazard of approximately 5 feet, 5 inches from the mobile service platform.   (b) On or about August 24, 2021, the employer did not ensure an employee engaged in scraping the rails under Autopour #3 was protected from falling off the ledge leading into the area, exposing the employee to a fall height of approximately 4 feet, 5 inches.  (c) The employer did not ensure employees cleaning near the slag pot on the southeast side of Autopour #1 were protected from falling into the pit immediately adjacent to the slag pot, exposing employees to a fall hazard of approximately 5 feet.  (d) The employer did not ensure employees cleaning near the slag pot on the southeast side of Autopour #2 were protected from falling into the pit immediately adjacent to the slag pot, exposing employees to a fall hazard of approximately 5 feet.  (e) The employer did not ensure employees cleaning near the slag pot on the southeast side of Autopour #3 were protected from falling into the pit immediately adjacent to the slag pot, exposing employees to a fall hazard of approximately 5 feet.  (f) The employer did not ensure employees cleaning near the slag pot on the southeast side of Autopour #4 were protected from falling into the pit immediately adjacent to the slag pot, exposing employees to a fall hazard of approximately 5 feet.  (g) The employer did not ensure employees cleaning near the slag pot on the southeast side of Autopour #5 were protected from falling into the pit immediately adjacent to the slag pot, exposing employees to a fall hazard of approximately five feet.  (h) The employer did not ensure employees cleaning near the slag pot on the southeast side of Autopour #6 were protected from falling into the pit immediately adjacent to the slag pot, exposing employees to a fall hazard of approximately five feet.

Issued

Nov 2, 2021

Abate by

Dec 2, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.28(b)(3)(i): The employer must ensure each employee is protected from falling through any hole (including skylights) that is 4 feet (1.2 m) or more above a lower level:   At a workplace located at 805 Ogden Street in Marinette, Wisconsin:  (a) Employees working near Autopour deck #1 were exposed to fall hazards created by a pit opening that was approximately 10 x 3 feet, approximately 5 feet deep, and was located adjacent to Autopour deck #1. The opening was partially covered with a grate made of welded rebar with holes approximately 4 x 4 inches, which exposed employees to trip hazards.   (b) Employees working near Autopour deck #2 were exposed to fall hazards created by a pit opening that was approximately 10 feet 3 inches by 3 feet, approximately 5 feet deep, and was located adjacent to Autopour deck #2. The opening was partially covered with a grate made of welded rebar with holes approximately 4 x 4 inches, which exposed employees to trip hazards.   (c) Employees working near Autopour deck #3 were exposed to fall hazards created by a pit opening that was approximately 10 x 3 feet, approximately 5 feet deep, and was located adjacent to Autopour deck #3. The opening was partially covered with a grate made of welded rebar with holes approximately 4 x 4 inches, which exposed employees to trip hazards.   (d) Employees working near Autopour deck #4 were exposed to fall hazards created by a pit opening that was approximately 10 x 3 feet, approximately 5 feet deep, and was located adjacent to Autopour deck #4. The opening was partially covered with a grate made of welded rebar with holes approximately 4 x 4 inches, which exposed employees to trip hazards.   (e) Employees working near Autopour deck #5 were exposed to fall hazards created by a pit opening that was approximately 10 x 3 feet, approximately 5 feet deep, and was located adjacent to Autopour deck #5. The opening was partially covered with a grate made of welded rebar with holes approximately 4 x 4 inches, which exposed employees to trip hazards.   (f) Employees working near Autopour deck #6 were exposed to fall hazards created by a pit opening that was approximately 10 x 3 feet, approximately 5 feet deep, and was located adjacent to Autopour deck #6. The opening was partially covered with a grate made of welded rebar with holes approximately 4 x 4 inches, which exposed employees to trip hazards.

Issued

Nov 2, 2021

Abate by

Dec 2, 2021

Penalty

Initial $11,703 · Current $0 Reduced

General-duty citation text

29 CFR 1910.23(b)(9): Ladders are inspected before initial use in each work shift, and more frequently as necessary, to identify any visible defects that could cause employee injury:  At a workplace located at 805 Ogden Street in Marinette, Wisconsin:  (a) The fixed ladder on Autopour #2 in the melt department was not inspected before the work shift. The ladder was bent and damaged in several places, exposing employees to a fall hazard.  (b) The fixed ladder on Autopour #3 in the melt department was not inspected before the work shift. The ladder was bent and damaged in several places, exposing employees to a fall hazard.

Issued

Nov 2, 2021

Abate by

Dec 2, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.23(b)(10): Any ladder with structural or other defects is immediately tagged "Dangerous: Do Not Use" or with similar language in accordance with �1910.145 and removed from service until repaired in accordance with �1910.22(d), or replaced;  a) In the Melt Department, a fixed ladder on Autopour #2 was bent and damaged in several places, exposing employees to a fall hazard.  b) In the Melt Department, a fixed ladder on Autopour #3 was bent and damaged in several places, exposing employees to a fall hazard.

Issued

Nov 2, 2021

Abate by

Dec 2, 2021

Penalty

Initial $13,653 · Current $14,502

General-duty citation text

29 CFR 1910.147(d):The established procedure for the application of energy control (the lockout or tagout procedures) did not cover the actions listed in and was not done in sequence as required by 29 CFR 1910.147(d)(1)-(6):  At a workplace located at 805 Ogden Street in Marinette, Wisconsin:  (a) On or about May 4, 2021, an employee in the Mill Department was exposed to machine hazards associated with moving parts when they were engaged in cleaning activities on broaching machine #15. The employer did not ensure that employees implemented energy control application steps prior cleaning the broaching machines.  The two operating controls were inadvertently depressed and caused the machine to actuate, resulting in an amputation.  The machine was not deenergized prior to the employee engaging in a servicing and/or maintenance activity.  As a result, the remaining applicable energy control elements, involving machine isolation [1910.147(d)(3)], lockout/tagout device application [1910.147(d)(4)], dissipation of residual energy [1910.147(d)(5)(i)], and verification of isolation [1910.147(d)(6)] were not implemented to protect employees from machine servicing hazards.

Issued

Nov 2, 2021

Abate by

Dec 2, 2021

Penalty

Initial $9,753 · Current $14,502

General-duty citation text

29 CFR 1910.305(g)(1)(iv): Unless specifically permitted otherwise in paragraph (g)(1)(ii) of this section, flexible cords and cables may not be used for purposes prohibited by paragraphs (A) through (F) of 29 CFR 1910.305(g)(1)(iv):  At a workplace located at 805 Ogden Street in Marinette, Wisconsin:  (a) On or about June 30, 2021, an extension cord near Shakeout Line #5 was used as permanent power from a junction box to a sensor in the gating system. The extension cord was zip-tied to a handrail and went through an opening in a welded steel bracket on the adjoining building structure.