OSHA Inspection: MAHLE ENGINE COMPONENTS USA, INC.

Issued

Sep 12, 2023

Abate by

Sep 22, 2023

Penalty

Initial $15,625 · Current $11,719 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section.   a. On the East Rough Slitter, or on about June 13, 2023, and at times prior, employees did not utilize the documented energy control procedure in place while performing maintenance and servicing covered activities such as, but not limited to, inspection/ troubleshooting of the scrap chopper, knives changes, machine adjustments and machine setup. As a result, employees were exposed to caught-in/between and struck-against/struck-by hazards.  b. On the North Line East PG, on or about March 15, 2023, employees did not utilize the documented energy control procedure in place while performing maintenance and servicing covered activities such as, but not limited to, performing repairs to the actuator of the PG East vertical hydraulic cylinder. As a result, employees were exposed to caught-in/between and struck-by hazards.

Issued

Sep 12, 2023

Abate by

Sep 22, 2023

Penalty

Initial $0 · Current $0

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 the East Rough Slitter, on or about June 13, 2023, employees were exposed to machine hazards associated with pinch points, rotating parts, and shear points, during maintenance and servicing covered activities such as, but not limited to, inspection and troubleshooting the scrap chopper of the East Rough Slitter. The employer did not implement energy control application steps as the East Rough Slitter and its scrap chopper, was not shutdown prior to performing the inspection and troubleshooting work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, including machine and equipment isolation from hazardous energy sources [(d)(3)], lockout/tagout device application [(d)(4)], dissipation of residual and/or stored energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards. As a result, the chopper knives unexpectedly energized and rotated, amputating an employee's hand.  b. On the East Rough Slitter, on or about June 13, 2023, and at times prior, employees were exposed to machine hazards associated with pinch points and rotating parts, during maintenance and servicing covered activities such as, but not limited to, performing setup, knive changes, and machine adjustments. The employer did not implement energy control application steps as the East Rough Slitter was not isolated from the hazardous energy sources prior to performing the servicing covered activities [per the 1910.147(d)(3) requirements]. As a result, the remaining applicable energy control elements, involving lockout/tagout device application [(d)(4)], dissipation of residual and/or stored energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  c. On the North Line East PG, on or about March 15, 2023, employees were exposed to machine hazards associated with pinch points and shear points during activities such as, but not limited to, repairs to the actuator of the PG vertical hydraulic cylinder. The employer did not implement energy control application steps as the hazardous energy sources, including, but not limited to, gravitational energy, were not isolated prior performing the servicing work [per the 1910.147(d)(3) requirements]. As a result, the remaining applicable energy control elements, involving lockout/tagout device application [(d)(4)], dissipation of residual and/or stored energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards. As a result, the PG vertical hydraulic cylinder unexpectedly moved, pinching an employee's hand between the cylinder and the machine frame, resulting in serious injuries to the employee's hand requiring hospitalization.

Issued

Sep 12, 2023

Abate by

Sep 22, 2023

Penalty

Initial $15,625 · Current $11,719 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:   29 CFR 1910.147(c)(4)(ii)(B): Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy;  a. On or about June 13, 2023, and at times prior, the energy control procedures in use for maintenance and servicing activities performed on the East Rough Slitter such as, but not limited to, setup, repairs, replacements, and preventative maintenance, did not include specific procedural steps for shutting down the machinery such as, but not limited to, the specific control locations and stop buttons to select. The procedure also did not include adequate specific procedural steps for isolating the electrical and pneumatic energy such as, but not limited to, the specific locations of controls and energy sources for isolation.  b. On or about March 15, 2023, and at times prior, the energy control procedures in use for maintenance and servicing activities performed on the North Line East PG actuators and PG vertical hydraulic cylinders such as, but not limited to, repairs and replacements and preventative maintenance, did not include the specific procedural steps for shutting down the machinery such as, but not limited to, the specific control locations and stop buttons to select. The procedure also did not include the specific procedural steps for or isolating, blocking, and securing the gravitational energy of the machinery.

Issued

Sep 12, 2023

Abate by

Sep 22, 2023

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(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 June 13, 2023, and at times prior, the energy control procedures in use for maintenance and servicing covered activities performed on the East Rough Slitter such as, but not limited to, setup, repairs, replacements, and preventative maintenance, did not include adequate specific procedural steps for testing the machinery and equipment to verify effectiveness of the energy control measures such as, but not limited to, the specific control panels and buttons and selector switches to operate. As a result, employees were exposed to caught-in/between and struck-by hazards associated with moving parts and pinch points on the machinery.  b. On or about March 15, 2023, and at times prior, the energy control procedures in use for maintenance and servicing covered activities performed on the North Line East such as, but not limited to, setup, repairs, replacements, and preventative maintenance, did not include adequate specific procedural steps for testing the machinery and equipment to verify effectiveness of the energy control measures such as, but not limited to, the specific control panels and buttons and selector switches to operate. As a result, employees were exposed to caught-in/between and struck-by hazards associated with moving parts and pinch points on the machinery.

Issued

Sep 12, 2023

Abate by

Oct 2, 2023

Penalty

Initial $15,625 · Current $11,719 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.  a. On or about June 13, 2023, and at times prior, the employer did not conduct periodic inspections of the East Rough Slitter energy control procedure to ensure that the procedure contained all of the necessary information, that any deviations or inadequacies were identified and corrected, that authorized employees understood their responsibilities under the procedure, and that the requirements of the standard were being followed. As a result, employees were exposed to hazards such as, but not limited to, struck-by and caught-in/between hazards associated with the points of operation and moving components associated with the machinery and equipment during the covered maintenance and servicing tasks.  b. On or about March 15, 2023, and at times prior, the employer did not conduct periodic inspections of the North Line East PG energy control procedure to ensure that the procedure contained all of the necessary information, that any deviations or inadequacies were identified and corrected, that authorized employees understood their responsibilities under the procedure, and that the requirements of the standard were being followed. As a result, employees were exposed to hazards such as, but not limited to, struck-by and caught-in/between hazards associated with the machinery and equipment during the covered maintenance and servicing tasks.

Issued

Sep 12, 2023

Abate by

Oct 2, 2023

Penalty

Initial $15,625 · Current $11,719 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.  a. On or about June 13, 2023, and at times prior, and at times prior, authorized employees did not receive training on the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation associated with the machinery such as, but not limited to, East Rough Slitter. As a result, employees were exposed to hazards such as, but not limited to, struck-by and caught-in/between hazards associated with the point of operations, pinch points, and moving components associated with the equipment during maintenance and servicing covered tasks.  b. On or about March 15, 2023, and at times prior, authorized employees did not receive training on the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation associated with the machinery such as, but not limited to, North Line East PG Actuators and Vertical Hydraulic Cylinders. As a result, employees were exposed to hazards such as, but not limited to, struck-by and caught-in/between hazards associated with the pinch points and moving components associated with the equipment during maintenance and servicing covered tasks.

Issued

Sep 12, 2023

Abate by

Oct 2, 2023

Penalty

Initial $15,625 · Current $11,719 Reduced

General-duty citation text

29 CFR 1910.147(f)(3)(i): When servicing and/or maintenance is performed by a crew, craft, department or other group, they shall utilize a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device.  a. On or about June 13, 2023, and at times prior, a crew of authorized employees that performed maintenance and servicing covered tasks on the East Rough Slitter, including, but not limited to, inspection, repairs, and troubleshooting, did not utilize a procedure that protected all employees during the maintenance and servicing covered tasks. As a result, employees were exposed to struck-by and caught-in/between hazards associated with the machinery, resulting in a hand amputation after unexpected reenergization of the scrap chopper knives.