OSHA Inspection: INGERSOLL-RAND INDUSTRIAL U.S., INC.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $16,550 · Current $8,500 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:  (A) A specific statement of the intended use of the procedure;  (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.   At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  On or about August 7, 2024, through September 11, 2024, the employer did not ensure that compliant hazardous energy control lockout/tagout procedures for Die Cast Machines (DCMs) such as, but not limited to, DCM #6 (procedure #9481), DCM #8 (procedure #9475), DCM #10 (procedure #9479), and DCM #11 (procedure #9467), were developed and utilized by employees tasked with performing servicing and maintenance tasks on DCMs. Employees were exposed to caught-in and struck-by hazards created by the energized machines likely to result in serious injury while performing servicing and maintenance tasks such as, but not limited to, changing dies, changing and inspecting the ram, cleaning the shot end, and repairing hydraulic piping. The procedures listed above did not specify their intended use for these activities and did not contain shut down, isolation, and verification steps for all energy sources present such as, but not limited to, hydraulic, thermal, steam, gravitational, and pneumatic.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $0 · Current $0

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.   At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  On or about August 22, 2024, the employer did not conduct periodic inspections of their energy control procedures to ensure that the procedures were compliant and that lockout was used by employees performing servicing and maintenance tasks on equipment including but not limited to, the die cast machines (DCMs), extraction robots, sprayer robots, and ladle robots.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $16,550 · Current $8,500 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.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 7, 2024, to September 11, 2024, the employer did not ensure that each die cast machine (DCM) operator was adequately trained on the methods and means necessary for the isolation and control of all hazardous energy sources prior to starting work. DCM Operators were performing maintenance and/or servicing tasks on energized machines such as, but not limited to the following: 1.  Inspecting the ram tip for water leaks and tightening the tip on DCM #6;  2.  Replacing the ram on the shot end of DCM #10,  3.  Cleaning and scraping flash off the cold chamber inside of the shot end guarding on DCM #11, and; 4.  Cleaning beneath the Advance SL-1200 robotic metal ladle on DCM #11.  Employees had their hands, fingers, and upper bodies exposed to caught-in and struck-by hazards of unexpectedly moving machines likely to result in serious injury because they did not know when lockout was required, what energy sources needed to be isolated, and how to control and verify isolation of those energies.     b) On or about August 28, 2024, the employer did not ensure that each maintenance employee was adequately trained on the methods and means necessary for the isolation and control of all hazardous energy sources prior to starting work. Maintenance employees were performing hydraulic pipe repairs and cleaning inside of die cast machine (DCM) #6 within the work envelopes of the extractor and sprayer robots. Employees entered into the danger zones of the machines and were exposed to caught-in and struck-by hazards of the unexpectedly moving machines likely to result in serious injury because they did not know when lockout was required and what energy sources needed to be isolated.  c) On or about August 29, 2024, the employer did not ensure that each furnace tender employee was adequately trained on the methods and means necessary for the isolation and control of all hazardous energy sources prior to starting work. Furnace tenders were performing die changes and cleaning inside of the die cast machines (DCMs) while within the work envelopes of the extractor and sprayer robots. Furnace tenders bodily entered into the danger zones and were exposed to burn hazards created by the hot dies and hydraulic fluid, and caught-in and struck-by hazards of the unexpectedly moving machines likely to result in serious injury because they did not know when lockout was required, what energy sources needed to be isolated, and how to control and verify isolation of those energies.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $16,550 · Current $16,550

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): (d)(1) Preparation for shutdown; (d)(2) Machine or equipment shutdown; (d)(3) Machine or equipment isolation; (d)(4) Lockout or tagout device application; (d)(5) Stored energy release; and, (d)(6) Verification of isolation.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 28, 2024, the employer did not ensure that all the steps outlined in 29 CFR 1910.147(d), required for the control of hazardous energy sources, were performed prior to employees conducting servicing and maintenance tasks on die cast machine (DCM) #6 in the work envelope of the sprayer and extractor robots. Maintenance employees were exposed to struck-by and caught in-between hazards associated with moving machines when they engaged in hydraulic pipe repairs and cleaning activities on the DCM. The employer did not ensure that employees shut down the equipment and followed a de-energization sequence prior to allowing them to work inside of the DCM that was adjacent to the robots.   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(d)(5)(i)], and verification of isolation [1910.147(d)(6)] were not implemented to protect employees from machine hazards.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $16,550 · 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): (d)(1) Preparation for shutdown; (d)(2) Machine or equipment shutdown; (d)(3) Machine or equipment isolation; (d)(4) Lockout or tagout device application; (d)(5) Stored energy release; and, (d)(6) Verification of isolation.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  On or about August 29, 2024, the employer did not ensure that all the steps outlined in 29 CFR 1910.147(d), required for the control of hazardous energy sources, were performed prior to employees conducting servicing and maintenance tasks on die cast machine (DCM) #8 in the work envelope of the sprayer robot. Furnace Tenders were exposed to struck-by, caught in-between, and burn hazards associated with moving machines and hot parts/fluids when they engaged in die changes inside of the DCM. The employer did not ensure that employees shut down the equipment and followed a de-energization sequence prior to allowing them to work inside of the DCM that was adjacent to the robot.   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(d)(5)(i)], and verification of isolation [1910.147(d)(6)] were not implemented to protect employees from machine hazards.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $16,550 · Current $16,550

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): (d)(1) Preparation for shutdown; (d)(2) Machine or equipment shutdown; (d)(3) Machine or equipment isolation; (d)(4) Lockout or tagout device application; (d)(5) Stored energy release; and, (d)(6) Verification of isolation.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about September 11, 2024, the employer did not ensure that all the steps outlined in 29 CFR 1910.147(d), required for the control of hazardous energy sources, were performed prior to employees conducting servicing and maintenance tasks on die cast machine (DCM) #10. Employees were exposed to struck-by and caught in-between hazards associated with moving and hot parts/fluids when they engaged in ram changes and cleaning inside the shot end of the DCM. The employer did not ensure that employees shut down the equipment and followed a de-energization sequence prior to allowing them to work inside of the shot end of the DCM.  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(d)(5)(i)], and verification of isolation [1910.147(d)(6)] were not implemented to protect employees from machine hazards.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $16,550 · 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): (d)(1) Preparation for shutdown; (d)(2) Machine or equipment shutdown; (d)(3) Machine or equipment isolation; (d)(4) Lockout or tagout device application; (d)(5) Stored energy release; and, (d)(6) Verification of isolation.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 27, 2024, to August 28, 2024, the employer did not ensure that all the steps outlined in 29 CFR 1910.147(d), required for the control of hazardous energy sources, were performed prior to employees conducting servicing and maintenance tasks beneath and in the work envelope of the Advance robotic ladle (Model: SL-1200) feeding die cast machine (DCM) #11. DCM Operators were exposed to struck-by and burn hazards associated with moving and hot parts/fluids when they engaged in cleaning beneath the robotic ladle. The employer did not ensure that employees shut down the equipment and followed a de-energization sequence prior to allowing them to work inside of the work envelope of the robot.   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(d)(5)(i)], and verification of isolation [1910.147(d)(6)] were not implemented to protect employees from machine hazards.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $16,550 · Current $8,500 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): Types of guarding. One or more methods of machine guarding shall be 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.   At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 7, 2024, the employer did not ensure that adequate guarding was provided on Die Cast Machines (DCMs) such as, but not limited to, #6, #8, #9, #10, and #11, to prevent exposure to the nip-point and caught-between hazards created by the injection ram and/or shot sleeve, and the die when the ram automatically retracted after its time-delay expired. The machines were not effectively guarded to prevent exposure to these hazards.  b) On or about August 22, 2024, to August 29, 2024, the employer did not ensure that adequate guarding was provided on Die Casting Machines (DCMs) such as, but not limited to, DCM #2, #6, #8, #10, and #11, to prevent exposure to the struck-by and molten aluminum splash hazards created by the moving Advanced robotic servo ladler (Model: SL-1200) and furnace pots while employees were operating the DCMs, knocking solidified aluminum off the ladle, and skimming dross off the top of the molten metal ladle furnace. The machines were not effectively guarded to prevent exposure to these hazards.  c) On or about August 27, 2024, to August 28, 2024, the employer did not ensure that adequate guarding was provided on Die Cast Machines (DCMs) such as, but not limited to, DCM #6, #8, #9, #10, and #11, to prevent exposure to the struck-by, crushed-by, and flying particle hazards created by the Sprayer robot when DCM Operators observed the robot's spraying cycle with the door open to the DCM. The machines were not effectively guarded to prevent exposure to these hazards.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(c)(2)(i): All exposed parts of horizontal shafting seven (7) feet or less from floor or working platform, excepting runways used exclusively for oiling, or running adjustments, shall be protected by a stationary casing enclosing shafting completely or by a trough enclosing sides and top or sides and bottom of shafting as location requires.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 29, 2024, an employee cleaning up a hydraulic fluid leak from the motor and hydraulic lines on die casting machine (DCM) #2 was exposed to caught-in hazards created by the unguarded, rotating drive shaft.

Issued

Feb 3, 2025

Abate by

Dec 31, 2025

Penalty

Initial $91,025 · Current $66,400 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): (d)(1) Application of Control; (d)(2) Preparation for shutdown; (d)(3) Machine or equipment shutdown; (d)(4) Lockout or tagout device application; (d)(5) Stored energy; and, (d)(6) Verification of isolation.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 7, 2024, the employer did not ensure that all the steps outlined in 29 CFR 1910.147(d), required for the control of hazardous energy sources, were performed prior to employees conducting servicing and maintenance tasks on die cast machine (DCM) #6. DCM Operators were exposed to caught in-between hazards associated with the moving ram when they conducted inspections of the ram's tip to identify water leaks, and tightened the tip of the ram. The employer did not ensure that employees shut down the equipment and followed a de-energization sequence prior to allowing them to work inside of the DCM.  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(d)(5)(i)], and verification of isolation [1910.147(d)(6)] were not implemented to protect employees from machine hazards.  Ingersoll Rand, Inc. dba Gardner Denver Thomas, Inc., was previously cited for a violation of this Occupational Safety and Health Standard 29 CFR 1910.147(d), which was contained in OSHA inspection number 1534848, citation number 1, item 1b, and was affirmed as final order on December 27, 2021, with respect to a workplace located at 1419 Illinois Avenue in Sheboygan, Wisconsin.