OSHA Inspection: PROPHET GEAR CO.

Issued

Jan 24, 2023

Abate by

Feb 22, 2023

Penalty

Initial $4,465 · Current $2,300 Reduced

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.   On or about October 14, 2022, the employer did not ensure that periodic inspections of energy control procedures were conducted at least annually to identify and correct any deviations or inadequacies. Employees who engaged in servicing and maintenance activities on the gear hobbing machine were not familiar with the energy isolation steps needed to control hazardous energy sources, nor of any requirement to use them. If the periodic inspections had been performed as required, these knowledge deficiencies could have been identified and corrected.  Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jan 24, 2023

Abate by

Feb 22, 2023

Penalty

Initial $6,250 · Current $0 Reduced

General-duty citation text

29 CFR  1910.147(d): Application of control. The established procedures for the application of energy control (the lockout or tagout procedures) shall cover the following elements and actions and shall be done in the following sequence:  a) On or about October 24, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #4 Barber Colman manufactured gear hobbing machine Model NO. 6-10 6-16 6-20. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    b) On or about October 24, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #64 Barber Colman manufactured gear hobbing machine Model NO. 6-10 6-16 6-20. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    c) On or about October 24, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #22 Barber Colman manufactured gear hobbing machine Model NO. 3. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    d) On or about October 24, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #55 Barber Colman manufactured gear hobbing machine Model NO. 3. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    e) On or about October 25, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #10 Barber Colman manufactured gear hobbing machine Model NO. 6-10 6-16 6-20. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    f) On or about October 25, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #69 Barber Colman manufactured gear hobbing machine Model NO. 6-10 6-16 6-20. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    g) On or about October 25, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #30 Barber Colman manufactured gear hobbing machine Model NO. 3. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    h) On or about October 26, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #41 Barber Colman manufactured gear hobbing machine Model NO. 2 1/2 - 4. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating parts.    i) On or about October 26, 2022 the employer did not ensure that employees implemented energy control application steps prior to allowing them to perform service and maintenance activities on the #14 Barber Colman manufactured gear hobbing machine Model NO. 2 1/2 - 4. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing activities, including, but not limited to, machine set-up, removing and installing feed and index gears, removing and installing cutting tools (hobbs), shifting hobbs, and lubricating 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, likely to result in serious injury.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jan 24, 2023

Abate by

Feb 22, 2023

Penalty

Initial $4,465 · Current $2,300 Reduced

General-duty citation text

29 CFR  1910.219(d)(1):Guarding. Pulleys, any parts of which are seven (7) feet or less from the floor or working platform, shall be guarded in accordance with the standards specified in paragraphs (m) and (o) of this section. Pulleys serving as balance wheels (e.g., punch presses) on which the point of contact between belt and pulley is more than six feet six inches (6 ft. 6 in.) from the floor or platform may be guarded with a disk covering the spokes.  On or about October 26, 2022, employees working near the Pratt and Whitney manufactured 4 1/2 thread miller Model C were exposed to caught-in and amputation hazards from the rotating power transmission belt and pully hazards on the machine. The guard for the belt and pulley was neither affixed to the machine, nor did it adequately cover the belt and pulley to prevent employees' hands from entering the danger zone.  Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

Jan 24, 2023

Abate by

Jun 1, 2023

Penalty

Initial $78,130 · Current $42,400 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.  a) On or about October 14, 2022 the employer did not ensure that the Barber Colman manufactured gear hobbing machine Model NO. 3 point of operation were properly guarded during operating cycles to protect employees from caught-in and amputation hazards associated with ingoing nip points and rotating parts.   b) On or about October 14, 2022 the employer did not ensure that the Barber Colman manufactured gear hobbing machines Model NO. 6-10 6-16 6-20 point of operation were properly guarded during operating cycles to protect employees from caught-in and amputation hazards associated with ingoing nip points and rotating parts.  c) On or about October 26, 2022 the employer did not ensure that the Barber Colman manufactured gear hobbing machines Model NO. 2 1/2 - 4 point of operation were properly guarded during operating cycles to protect employees from caught-in and amputation hazards associated with ingoing nip points and rotating parts.  Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jan 24, 2023

Abate by

Feb 22, 2023

Penalty

Initial $12,500 · Current $8,000 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 October 26, 2022, the employer did not ensure that employees who performed service and maintenance tasks on the gear hobbing machines were adequately trained on the means and methods needed to effectively isolate and control hazardous energy sources. Employees were exposed to caught-in and amputation hazards associated with ingoing nip points and rotating parts while performing service and maintenance activities, including, but not limited to, set-up, removing and installing feed and index gears, removing and installing hobbs, shifting hobbs, and lubricating parts.    The employer was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(c)(1), which was contained in OSHA inspection number 1340573, citation number 1, item number 1 and was affirmed as a final order on September 28, 2018, with respect to a workplace located at 65 Grove St. Prophetstown, IL 61277.  Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Jan 24, 2023

Abate by

Feb 22, 2023

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii): The energy control procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, including, but not limited to items of this section 29 CFR 1910.147(c)(4)(ii)(A) - (D):  a) On or about October 26, 2022, the employer did not ensure that its machine specific energy control procedures for the gear hobbing machines included set-up activities within the scope and purpose of the procedure.  Employees were exposed to caught-in and amputation hazards when performing these service and maintenance activities without first lockout out the equipment.  Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).