OSHA Inspection: PACKAGING CORPORATION OF AMERICA

Issued

Jun 11, 2024

Abate by

Jul 26, 2024

Penalty

Initial $12,676 · Current $0 Reduced

General-duty citation text

29 CFR  1910.146(c)(2):The employer did not inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces:  a. Packaging Corporation of America - Ashland, Ohio: On or about January 17, 2024, the employer did not post danger signs, or any other equally effective means to inform exposed employees of the existence and location of and the danger posed by a permit-required confined space.  Employees who accessed the space within the Modul Facer, located at the corrugator line, for cleaning and preventive maintenance tasks were exposed to caught-in, crushing, and burn injuries.   In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence, or written records.

Issued

Jun 11, 2024

Abate by

Jul 26, 2024

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.146(c)(4):When the employer decided that its employees would enter permit spaces, the employer did not develop and implement a written permit space entry program that complied with 29 CFR 1910.146:  a. Packaging Corporation of America - Ashland, Ohio:  On or about January 17, 2024, the employer did not develop and implement a written permit space program that addressed the required standard elements for full body entry in the corrugator line Modul Facer when performing cleaning and preventative maintenance tasks within the space, thereby exposing employees to caught-in, crushing, and burn hazards.  With respect to the Modul Facer, the company's written procedures lacked the development of items such as, but not limited to the following:  i. Specific measures necessary to prevent unauthorized entry into the Modul Facer space as required by 1910.146(d)(1);  ii. Specific means, procedures, and practices necessary for specifying acceptable conditions for entry of the Modul Facer as required by 1910.146(d)(3)(i);  iii. Specific means, procedures, and practices necessary for isolating the space's gravitational, heat, and hydraulic source as required by 1910.146(d)(3)(iii); iv. Specific means, procedures, and practices necessary for verifying that conditions in the Modul Facer are acceptable for entry throughout the duration of an authorized entry as required by 1910.146(d)(3)(vi);  v. Specific designation of the persons who are to have active roles in operations for entering the Modul Facer space as required by 1910.146(d)(8);  vi. Specific procedures for summoning rescue and emergency services to the space in the Modul Facer, for rescuing entrants from the space, for providing necessary emergency services to employees rescued from the space, and for preventing unauthorized personnel from attempting a rescue into the space as required by 1910.146(d)(9);  vi. Specific procedures for reviewing entry operations into the Modul Facer space when the employer has reason to believe that the measures taken under the permit space program may not protect employees and revising the program to correct deficiencies found to exit before subsequent entries are authorized as required by 1910.146(d)(13);  vii. Specific procedures for reviewing the permit space program's effectiveness for the Modul Facer space using cancelled permits and revising the program as necessary as required by 1910.146(d)(14).  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence, or written records.

Issued

Jun 11, 2024

Abate by

Jul 26, 2024

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.146(c)(7)(iii):The employer did not document the basis for determining that all hazards in a permit space had been eliminated, through a written certification that contained the date, the location of the space, and the signature of the person making the determination.   a. Packaging Corporation of America - Ashland, Ohio: On or about January 17, 2024, employees entered inside the space of the Modul Facer where rotating parts, pinch points, and heat hazards would classify the space as a permit-required confined space.  The employer did not document and certify the reason in which the space was reclassified to a non-permit required confined space.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence, or written records.

Issued

Jun 11, 2024

Abate by

Jul 26, 2024

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.146(g)(1):The employer did not provide training so that all employees whose work was regulated by 29 CFR 1910.146 (permit required confined spaces) acquired the understanding, knowledge, and skills necessary for the safe performance of the duties assigned under 29 CFR 1910.146:  a. Packaging Corporation of America - Ashland, Ohio: On or about January 17, 2024, the employer did not provide operators and maintenance employees with the necessary permit-required confined space training prior to allowing an employee to fully enter the space inside the corrugator line Modul Facer machine to perform cleaning and preventive maintenance tasks.  Employees were exposed to rotating parts, pinch points, and heat hazards.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence, or written records.

Issued

Jun 11, 2024

Abate by

Jul 26, 2024

Penalty

Initial $16,131 · Current $8,065 Reduced

General-duty citation text

29 CFR  1910.147(c)(7)(i):The employer did not provide adequate training to ensure that employees acquired the knowledge and skills required for the safe application, usage and removal of energy control devices:  a. Packaging Corporation of America - Ashland, Ohio: On or about January 7, 2024, the employer did not ensure that employees who setup the corrugator line were adequately trained in the skills required for the safe application, usage, and removal of energy controls.  Employees who thread the wet-end of the corrugator line were not trained to isolate energy sources in a safe condition.   In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence, or written records.

Issued

Jun 11, 2024

Abate by

Jul 26, 2024

Penalty

Initial $16,131 · Current $0 Reduced

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):   a. Packaging Corporation of America - Ashland, Ohio: On or about January 7, 2024, employees were exposed to injury from rotating parts and pinch points created by moving components of equipment such as, but not limited to, the splicers, external and internal pre-heaters, modular facer, and corrugator rolls, at the wet-end of the corrugator line, in that the equipment was not locked out prior to threading the line for production.  The employer did not ensure that energy control applications steps were implemented to control the equipment's hydraulic and electrical energy sources prior to the setup tasks - the employer did not: - Ensure that equipment was turned off or shut down. - Physically operate energy isolating devices to control energy sources and affix lockout device(s). - Ensure that all potentially hazardous stored or residual energy was relieved, disconnected, and rendered safe. - Verify that isolation and deenergization of the machine or equipment had been accomplished.

Issued

Jun 11, 2024

Abate by

Jul 26, 2024

Penalty

Initial $16,131 · Current $8,066 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:  Packaging Corporation of America - Ashland, Ohio: On or about January 12, 2024, employees who worked at the corrugator's preconditioner (machine #010, section 66) were exposed to being caught in an ingoing nip point created by the machine's heat roll and wrap arm.  An employee performing splicing tasks sustained fracture, burn, and degloving injuries after being caught in the unguarded nip point.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence, or written records.