OSHA Inspection: SIGMA ENGINEERED SOLUTIONS

Issued

2024-07-12 00:00:00

Abate by

2024-08-16 00:00:00

Penalty

Initial $11524.00 · Current $6914.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.134(c): This paragraph requires the employer to develop and implement a written respiratory protection program with required worksite-specific procedures and elements for required respirator use. The program must be administered by a suitably trained program administrator. In addition, certain program elements may be required for voluntary use to prevent potential hazards associated with the use of the respirator.  a) At the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; in Knockout, the employer did not implement a written respiratory protection program where respirators were necessary to protect an employee from the hazards of respirable crystalline silica while performing tasks, such as but not limited to manual knockout, sweeping, and running knockout, and when an employee voluntarily wore a half-face tight-fitting elastomeric respirator while performing tasks, such as but not limited to cleaning the Knockout Booth, exposing employees to the hazards associated with respirable crystalline silica and inadequate physical/physiological capability. One employee working  in Knockout performing tasks, such as but not limited to manual knockout, was overexposed to respirable crystalline silica, which exceeded the 8-hour time-weighted average (TWA) permissible exposure limit (PEL) of 50 micrograms per cubic meter (�g/m3), and was not required to wear a respirator.  All provisions of 29 CFR 1910.134 (c)(1)(i) through (m) must be contained in a written respiratory protection program and implemented, as applicable. Key elements include, but are not limited to the following: 1) Medical evaluations of employees required to use respirators 2) Fit testing of employees required to use respirators 3) Training on maintenance, use and care of respirators 4) Program evaluation

Issued

2024-07-12 00:00:00

Abate by

2024-08-09 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR  1910.134(e)(1): The employer shall provide a medical evaluation to determine the employee's ability to use a respirator, before the employee is fit tested or required to use the respirator in the workplace. The employer may discontinue an employee's medical evaluations when the employee is no longer required to use a respirator.  a) On or about and at times prior to May 9, 2024, at the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; at Knockout, the employer did not provide a medical evaluation to determine an employee's ability to use a half-face tight-fitting elastomeric respirator (Safety Works 9200) that was worn while performing tasks, such as but not limited to cleaning the Knockout Booth, exposing an employee to the hazards associated with inadequate physical/physiological capability.

Issued

2024-07-12 00:00:00

Abate by

2024-08-16 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(g)(2): Respiratory protection program. Where respirator use is required by this section, the employer shall institute a respiratory protection program in accordance with 29 CFR 1910.134.   a) At the facility located at 1149 North Margaret Street, Markesan, Wisconsin; in Knockout, the employer did not institute a respiratory protection program in accordance with 29 CFR 1910.134, where respirator use was required, exposing an employee to the hazards associated with respirable crystalline silica. The employer did not fully institute medical evaluations, fit testing, training, program evaluations, and include all provisions in the written respiratory protection program as required by 29 CFR 1910.134. One employee working in Knockout was overexposed to respirable crystalline silica, which exceeded the 8-hour time-weighted average (TWA) permissible exposure limit (PEL) of 50 micrograms per cubic meter (�g/m3) and was not required to wear a respirator.

Issued

2024-07-12 00:00:00

Abate by

2024-08-30 00:00:00

Penalty

Initial $11524.00 · Current $6914.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(c): The employer shall ensure that no employee is exposed to an airborne concentration of respirable crystalline silica in excess of 50 g/m3, calculated as an 8-hour TWA.  a) On or about February 22, 2024, at the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; in Knockout, an employee performing tasks, such as but not limited to manual knockout, sweeping, and running knockout, was exposed to an 8-hour time-weighted average (TWA) of 60.3 micrograms per cubic meter (�g/m3) for respirable crystalline silica, approximately 1.2 times the permissible exposure limit (PEL) of 50 �g/m3. The exposure level was derived from a sample collected over a 226-minute sampling period, with zero exposure assumed for the unsampled period of 254 minutes.

Issued

2024-07-12 00:00:00

Abate by

2024-08-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(d)(3)(iii): Where the most recent exposure monitoring indicates that employee exposures are at or above the action level (AL) but at or below the permissible exposure limit (PEL), the employer shall repeat such monitoring within six months of the most recent monitoring.  a) On or about February 22, 2024, at the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; at Knockout, the employer had not repeated exposure monitoring within six months of the most recent monitoring that was conducted on November 15, 2022, that indicated that an employee exposure was above the action level but below the PEL for respirable crystalline silica, exposing an employee to the hazards associated with respirable crystalline silica.

Issued

2024-07-12 00:00:00

Abate by

2024-10-17 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(f)(1): The employer shall use engineering and work practice controls to reduce and maintain employee exposure to respirable crystalline silica to or below the PEL, unless the employer can demonstrate that such controls are not feasible. Wherever such feasible engineering and work practice controls are not sufficient to reduce employee exposure to or below the PEL, the employer shall nonetheless use them to reduce employee exposure to the lowest feasible level and shall supplement them with the use of respiratory protection that complies with the requirements of paragraph (g) of this section.  a) On or about February 22, 2024, at the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; in Knockout, the employer did not determine and implement feasible administrative or engineering controls to achieve compliance with paragraph (c) of 29 CFR  1910.1053. On this date, an employee was exposed to respirable crystalline silica that exceeded the permissible exposure limit (PEL) while performing tasks, such as but not limited to manual knockout, sweeping, and running knockout. The employee was exposed to an 8-hour time-weighted average (TWA) of 60.3 micrograms per cubic meter (�g/m3) of respirable crystalline silica, approximately 1.2 times the permissible exposure limit (PEL) of 50 �g/m3. Zero exposure assumed for the unsampled period of 254 minutes.  Applicable engineering or administrative controls may include but are not limited to the following:  Step 1: Effective respiratory protection shall be provided and used by exposed employees as an interim protective measure until feasible engineering and/or administrative dust controls can be implemented or whenever such controls fail to reduce employee exposure to within permissible exposure limits. For selection of appropriate respiratory protection equipment, actual time weighted averages for employee exposure must be used to determine maximum use concentrations.   Step 1 abatement is due August 11, 2024.  Step 2: Submit to the Area Director a written, detailed plan of abatement outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposure to hazardous substances as referenced in this citation. This plan shall include, at the minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation:  1. Evaluation and listing of engineering/administrative dust control options. Ensure the following are considered in your control options evaluation: Analysis of existing emission sources, the worker proximity to the dust emission source(s), and the job task or tasks being performed;  2. Selection criteria for control method(s), selection of the optimum control methods and completion of design; 3. Procurement, installation and operation of selected control measures; 4. Testing and acceptance or modification/redesign of controls.  All proposed control measures shall be approved for each particular use by a competent industrial hygienist, certified industrial ventilation specialist experienced in complex processes, or other technically qualified person. Identify the person and qualifications in the report of plan to the Area Director.  Step 2 abatement is due September 10, 2024.  Step 3: Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance. Submission to the Area Director of personal employee exposure air monitoring is required for documenting engineering control effectiveness.  Feasible administrative and/or engineering controls could include, but is not limited to, the following: 1. Equip processes with local exhaust ventilation such as, but not limited to, hooded work positions for anticipated job functions.  2. Consider utilization of tool integrated dust capture at the point of dust generation as part of a coordinated solution with local exhaust ventilation to increase ventilation system effectiveness.  3. Place emphasis on the design phase in attempting to create a solution that is fixed in place in lieu of portable in nature. The use of fixed placement versus portable systems is one method to assure the capture ventilation is positioned in the designed placement for maximum effectiveness.  4. Consider the use of increased general dilution air (otherwise known as make-up air), during capture ventilation system design, to increase exhaust ventilation system dust capture. Introduction of targeted make-up air systems such as air islands, increasing flow into existing ventilation systems providing air into the work area and relocation of existing general dilution air ductwork are examples of dilution ventilation system improvements to increase dust capture system efficiency.  5. Consider and develop work practices for reducing emissions of particulate matter into the breathing zone through body and tool positioning.  Step 3 abatement is due October 10, 2024.

Issued

2024-07-12 00:00:00

Abate by

2024-08-30 00:00:00

Penalty

Initial $11524.00 · Current $6914.00 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(e)(1): The employer shall establish a regulated area wherever an employee's exposure to airborne concentrations of respirable crystalline silica is, or can reasonably be expected to be, in excess of the permissible exposure limit (PEL).  a) On or about and at times prior to February 22, 2024, at the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; in Knockout, the employer did not ensure that a regulated area was established, where an employee's exposure to respirable crystalline silica exceeded the PEL, exposing an employee to the hazards associated with respirable crystalline silica.

Issued

2024-07-12 00:00:00

Abate by

2024-08-16 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(f)(2)(ii):The employer shall review and evaluate the effectiveness of the written exposure control plan at least annually and update it as necessary.  a) At the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; the employer did not evaluate the effectiveness of the written exposure control plan at least annually and update it as necessary, exposing employees to the hazards associated with respirable crystalline silica. Multiple deficiencies were found during the inspection, such as but not limited to not establishing a regulated area, not documenting housekeeping measures, such as but not limited to the use of sweeping compound and an industrial floor sweeper, employees using compressed air to blow off clothing, and lack of implementation of the written respiratory protection, which indicate inadequate evaluation or updating.

Issued

2024-07-12 00:00:00

Abate by

2024-08-09 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(h)(2)(i): The employer shall not allow compressed air to be used to clean clothing or surfaces where such activity could contribute to employee exposure to respirable crystalline silica unless compressed air is used in conjunction with a ventilation system that effectively captures the dust cloud created by the compressed air.  a) On or about and at times prior to February 22, 2024, at the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; the employer allowed the employees to use compressed air to clean clothing without the use of a ventilation system, exposing employees to the hazards associated with respirable crystalline silica.

Issued

2024-07-12 00:00:00

Abate by

2024-08-09 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9000

General-duty citation text

29 CFR  1910.1053(j)(1): The employer shall include respirable crystalline silica in the program established to comply with the hazard communication standard (HCS) (29 CFR 1910.1200). The employer shall ensure that each employee has access to labels on containers of crystalline silica and safety data sheets, and is trained in accordance with the provisions of HCS and paragraph (j)(3) of this section. The employer shall ensure that at least the following hazards are addressed: Cancer, lung effects, immune system effects, and kidney effects.  a) On or about and at times prior to February 22, 2024, at the establishment located at 1149 North Margaret Street, Markesan, Wisconsin; the employer did not ensure that each employee exposed to respirable crystalline silica while performing tasks, such as but not limited to manual knockout, was provided training on the hazards of respirable crystalline silica.