OSHA Inspection: KI, INC.

Issued

Dec 16, 2021

Abate by

Feb 1, 2022

Penalty

Initial $11,605 · Current $5,803 Reduced

General-duty citation text

29 CFR  1910.147(c)(7)(i)(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.  On or about June 21, 2021, an employee engaged in the service and maintenance activity of changing out dies on the Versa Leg Kick Back Bender was not trained 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.

Issued

Dec 16, 2021

Abate by

Feb 1, 2022

Penalty

Initial $0 · Current $0

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).  On or about June 21, 2021, an employee was exposed to machine hazards associated with moving parts when they engaged in a servicing activity of setting up the Versa Leg Kick Back Bender was exposed to potential hazards associated with moving parts when the machine was not locked out prior to the employee changing out parts of the machine. The employer did not ensure that employees implemented energy control application steps prior to conducting machine change over and changing out parts.   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

Dec 16, 2021

Abate by

Mar 1, 2022

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.147(f)(1):Testing or positioning of machines, equipment or components thereof. In situations in which lockout or tagout devices must be temporarily removed from the energy isolating device and the machine or equipment energized to test or position the machine, equipment or component thereof, the following sequence of actions shall be followed: Clear the machine or equipment of tools and materials, remove employees from the machine or equipment area, remove the lockout or tagout devices, energize and proceed with testing or positioning and deenergize all systems and reapply energy control measures.  On or about June 21, 2021, an employee was testing the Versa Leg Kick Back Bender following a die change but had not removed himself from the hazard area prior to operating the machine. Because the machine was energized with the guard removed, the employee had several fingers pinched between the part and the die resulting in a partial amputation to three fingers on the right hand.

Issued

Dec 16, 2021

Abate by

Aug 31, 2022

Penalty

Initial $11,605 · Current $5,803 Reduced

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.  Employees working at KI, Inc. were exposed to hazards associated with moving machine parts:  a) in the Tool & Die Shop when the chuck for K.O. Lee Grinder was not guarded to prevent possible entanglement by the operator.   b) in the Tool & Die Shop when employees using the Supermax Vertical Mill were exposed to flying chips and sparks because the mill was not equipped with a chip guard.   c) in the Tool & Die Shop when employees using the Acer Vertical Mill were exposed to flying chips and sparks because the mill was not equipped with a chip guard.   d)  in the Tool & Die Shop when employees were using the W. F. Mills Model W-9-1 Horizontal Band Saw and the unused portion of the blade was not effectively guarded to prevent contact with the blade.  e) in the Tool & Die Shop when employees were using the W. F. Mills Model W Horizontal Band Saw and the unused portion of the blade was not effectively guarded to prevent contact with the blade.  f) in the Press Department when employees using the W. F. Mills Horizontal Band Saw and the unused portion of the blade was not effectively guarded to prevent contact with the blade.

Issued

Dec 16, 2021

Abate by

Aug 31, 2022

Penalty

Initial $11,605 · Current $0 Reduced

General-duty citation text

29 CFR  1910.212(a)(3)(ii):The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefor, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.  Employees working at KI, Inc. were exposed to machine hazards associated with the point of operation on:  a) the foot actuated Upholstery Presses in the Opt 4 and Versa Assembly Departments which is used  to press down and hold material in place and poses a caught in hazard to employees.   b) the foot actuated C-Gex Machines in Opt 4, Versa and Matrix Perry Assembly Departments which is used  to  press down and hold material in place while also pulling outward on strings to attach seat covers presenting a caught in hazard to operators.  c) the Cardboard Bender in Uniframe Assembly which is used to pinch and bend cardboard for packing product and presents a caught in hazard to employees.   d) the Hydraulic Press in Uniframe Fabrication that had seen damage to the barrier guard which allowed employees to access the point of operation and presented a caught in hazard.

Issued

Dec 16, 2021

Penalty

Initial $11,605 · Current $5,803 Reduced

General-duty citation text

29 CFR  1910.217(c)(3)(i)(e): Point of operation devices shall protect the operator by requiring application of both of the operator's hands to machine operating controls and locating such controls at such a safety distance from the point of operation that the slide completes the downward travel or stops before the operator can reach into the point of operation with his hands.   Employees of KI, Inc were exposed to potential caught-in and crushing hazards when the two handed control used as a point of operation guard on the was USI 110 Full Revolution Mechanical Power Press was not located a safe distance from the point operation and would allow the operator to reach the point of operation before downward travel of the slide stopped.

Issued

Dec 16, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.217(c)(2)(i)(a): Every point of operation guard shall prevent entry of hands or fingers into the point of operation by reaching through, over, under or around the guard.  Employees of KI, Inc were exposed to potential caught-in and crushing hazards when the presence sensing devices used as a point of operation guard on the Komatsu 80 Part Revolution Mechanical Power Press did not protect all sides of the point of operation from access and would have allowed an operator to operate around the side of the guard.