OSHA Inspection: SMITHFIELD FOODS

Issued

Jun 30, 2023

Abate by

Aug 17, 2023

Penalty

Initial $15,625 · Current $9,375 Reduced

General-duty citation text

29 CFR  1910.147(c)(4): General - Energy control procedure. (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:   (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 before March 14, 2023, the energy control procedures provided by Smithfield Foods for the Rapid Pak/Loader Flex Line 1 located in the Packaging Department the procedures identified the need for 2 lockout devices in the Lockout Equipment Needed section, the machine specific procedures, photographs shows 3 different lockout points.   b) On or before March 14, 2023, the energy control procedures provided by Smithfield Foods for the Rapid Pak/Loader Flex Line 1 located in the Packaging Department for step #3, step #4, and step #5 did not contain verification of the effectiveness of the lockout devices for the Rapid Pak/Loader Flex Line 1, nor did the procedures for the loader under step #7 contain verification of effectiveness of the lockout devices for the loader.  c) On or before April 12, 2023, the energy control procedures provided by Smithfield Foods for the Flex Line 2 Rapid Pak located in the Packaging Department had an incorrect picture for step #2 and step #4 in that the picture shows a 4 button panel instead of a 5 button panel. For step #3, the picture shows a yellow air valve instead of a blue valve.  d) On or before April 12, 2023, the energy control procedures provided by Smithfield Foods for the KSI Blender located in the Manufacturing Department had the incorrect picture for step #3 in that the picture shows the panel for the F blender and not the KSI blender (Serial No. 7293 Model No. DM 4096-R).  e) On or before April 12, 2023, the energy control procedures provided by Smithfield Foods for the Flex 1 located in the Packaging/Metal Detector Department was missing procedures for another piece of equipment located on this line in that there was no photograph of the electrical disconnect for that piece of equipment.  f) On or before April 12, 2023, the energy control procedures provided by Smithfield Foods for the Rapid Pak Line 2 in the Packaging Department had not been updated in that the picture for step #3 did not show the most recent update such as a different electrical disconnect than the electrical disconnect in the picture.  g) On or before April 12, 2023, the energy control procedures provided by Smithfield Foods for the Rapid Pak/Loader flex line 1 in the Packaging Department had not been updated in that the picture for step #3 and step #4 did not show the most recent update such as a different electrical disconnects than the electrical disconnect in the picture.

Issued

Jun 30, 2023

Abate by

Aug 17, 2023

Penalty

Initial $15,625 · Current $0 Reduced

General-duty citation text

29 CFR  1910.147(c)(6)(i): General - Periodic inspection. 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) The periodic inspection shall be performed by an authorized employee other than the ones(s) utilizing the energy control procedure being inspected.  (B) The periodic inspection shall be conducted to correct any deviations or inadequacies identified.  a) On or before March 14, 2023, the employer had not conducted adequate periodic inspections of the energy control procedures for the Packaging, Manufacturing, and the Packaging/Metal Detector Department.

Issued

Jun 30, 2023

Abate by

Aug 17, 2023

Penalty

Initial $15,625 · Current $9,375 Reduced

General-duty citation text

29 CFR  1910.147(c)(7): Training and communication. (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 before March 14, 2023, the employer did not ensure that production and sanitation employees performing lockout on machines in the packaging, production, and packaging/metal detector departments were adequately trained as authorized employees for the application, usage, and the removal of lockout devices nor were they trained on the recognition of hazardous energy sources such as, but not limited to: pneumatic and electrical.

Issued

Jun 30, 2023

Abate by

Jul 27, 2023

Penalty

Initial $15,625 · 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:   (d)(1) Preparation for shutdown. Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy.  (d)(2) Machine or equipment shutdown. The machine or equipment shall be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage.  (d)(3) Machine or equipment isolation. All energy isolating devices that are needed to control the energy to the machine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s).  (d)(4) Lockout or tagout device application.  (d)(4)(i) Lockout or tagout devices shall be affixed to each energy isolating device by authorized employees.  (d)(5) Stored energy.  (d)(5)(i) Following the application of lockout or tagout devices to energy isolating devices, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise rendered safe.  (d)(5)(ii) If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists.  (d)(6) Verification of isolation. Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee shall verify that isolation and deenergization of the machine or equipment have been accomplished.  a) On March 11, 2023, the employer did not ensure that employees unjamming the plastic film from the chain and sprocket for the conveyer on the Rapid Pak/Loader Flex Line 1 were required to follow the requirements of (d1-d6) prior to removing plastic film from the chain and sprocket.  b) On or before March 14, 2023, the employer did not ensure that sanitation employees performing sanitation on the KSI Blender located in the Manufacturing Department were required to follow the requirements of (d1-d6) prior to performing sanitation.   c) On or before March 14, 2023, the employer did not ensure that sanitation employees performing sanitation on the Flex 1 located in the Packaging/Metal Detector Department were required to follow the requirements of (d1-d6) prior to performing sanitation.   d) On or before March 14, 2023, the employer did not ensure that sanitation employees performing sanitation on the Rapid Pak Line 2 located in the Packaging Department were required to follow the requirements of (d6) prior to performing sanitation.