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

Issued

Feb 3, 2025

Abate by

Jun 30, 2025

Penalty

Initial $0 · Current $10,000

General-duty citation text

29 CFR 1910.132(a): Application. Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment, chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact.   At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 22, 2024, to August 29, 2024, Die Cast Machine (DCM) Operators were not provided and required to use protective equipment and/or protective clothing for the torso and extremities to prevent physical contact with hot surfaces and splashing molten aluminum. Employees were exposed to permanent skin damage from contact burns and splashing molten aluminum during activities such as, but not limited to, removing die cast aluminum parts from DCMs, manipulating metal die heater shutoff valves, handling DCM rams and shot sleeves during ram changes, and skimming dross off the molten aluminum pot on the DCM holding furnaces inside of the refractory cement.  b) On or about August 22, 2024, to August 29, 2024, Furnace Tenders were not provided and required to use protective equipment and/or protective clothing for the torso and extremities to prevent physical contact with hot surfaces and splashing molten aluminum. Employees were exposed to permanent skin damage from contact burns and splashing molten aluminum during activities such as, but not limited to, changing the dies in the DCMs, skimming dross off the ladle, and feeding scrap into the central melt furnace.

Issued

Feb 3, 2025

Abate by

Jun 30, 2025

Penalty

Initial $16,550 · Current $0 Reduced

General-duty citation text

29 CFR 1910.132(d)(1): The employer shall assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of personal protective equipment (PPE). If such hazards are present, or likely to be present, the employer shall: (i) Select, and have each affected employee use, the types of PPE that will protect the affected employee from the hazards identified in the hazard assessment; (ii) Communicate selection decisions to each affected employee; and, (iii) Select PPE that properly fits each affected employee.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 22, 2024, to August 29, 2024, the employer did not assess the workplace to determine if contact burn hazards were present, or likely to be present, which necessitated the use of personal protective equipment (PPE) in an aluminum foundry and die casting environment. Employees were exposed to contact burn hazards during activities such as, but not limited to, handling die cast aluminum parts with their hands and arms, manipulating metal die heater shutoff valves with their hands, handling DCM rams and shot sleeves during ram changes with their hands, arms, and torsos, and performing die changes with their hands and torsos on or near the hot dies.  b) On or about August 22, 2024, to August 29, 2024, the employer did not assess the workplace to determine if molten aluminum splash hazards were present, or likely to be present, which necessitated the use of personal protective equipment in an aluminum foundry and die casting environment. Employees were exposed to molten aluminum splash hazards to the hands, arms, heads, and torsos, while performing activities such as, but not limited to, operating the DCMs at the operator's control panel adjacent to the holding furnace, knocking solidified aluminum off of the Advance robot ladles, skimming dross off the holding furnace pots, skimming dross off the ladle attachment, and charging the central melt furnace with scrap.

Issued

Feb 3, 2025

Abate by

Jun 30, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.138(a): General requirements. Employers shall select and require employees to use appropriate hand protection when employees' hands are exposed to hazards such as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasions; punctures; chemical burns; thermal burns; and harmful temperature extremes.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 22, 2024, to August 29, 2024, the employer did not select and require Die Cast Machine (DCM) operators to use appropriate hand protection during activities such as, but not limited to, removing hot parts from DCMs while operating in single-cycle mode, handling DCM rams and shot sleeves during ram changes, changing DCM dies, and skimming dross off the pots of the DCM holding furnaces, exposing their hands to severe burns and permanent skin damage.   b) On or about August 22, 2024, to August 28, 2024, the employer did not select and require Furnace Tenders to use appropriate hand protection during activities such as, but not limited to, skimming molten aluminum metal in the ladle attachment, changing DCM dies, and loading scrap aluminum into the central melt furnace exposing their hands to severe burns and permanent skin damage.  c) On or about August 29, 2024, the employer did not select and require forklift operators changing propane tanks on LP forklifts to use hand protection while removing the liquid propane connection, exposing their hands to frostbite and permanent skin damage.

Issued

Feb 3, 2025

Abate by

Apr 17, 2026

Penalty

Initial $13,005 · Current $16,500

General-duty citation text

29 CFR 1910.178(a)(4): General requirements. Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 22, 2024, to August 28, 2024, the "ladle truck", a UniCarriers 35 LP forklift (Model: MCP1F1A18LV; Serial: CP1F1-9N23539) was equipped with a ladle attachment used daily to transfer molten metal from the central furnace to the holding furnaces of each of the die cast machines (DCMs). The ladle attachment was not approved by the manufacturer, and which affected the capacity and safe operation of the vehicle. The capacity and operation plate was not updated to adjust the lifting capacity, exposing employees to tip over hazards.

Issued

Feb 3, 2025

Abate by

Apr 17, 2026

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(a)(5): General requirements. If the truck is equipped with front-end attachments other than factory installed attachments, the user shall request that the truck be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 22, 2024, to August 28, 2024, the employer did not ensure that the ladle attachment equipped on the "ladle truck", a UniCarriers 35 LP forklift (Model: MCP1F1A18LV; Serial: CP1F1-9N23539), was identified as an attachment, and the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered.

Issued

Feb 3, 2025

Abate by

Sep 2, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(l)(3)(i)(G): Training program content. Powered industrial truck operators shall receive initial training in the following topics as required by 29 CFR 1910.178(l)(3)(i)(A) - (M), except in topics which the employer can demonstrate are not applicable to safe operation of the truck in the employer's workplace. Truck-related topics shall include: Fork and attachment adaptation, operation, and use limitations.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 22, 2024, to November 21, 2024, Furnace Tender employees operating the "ladle truck", a UniCarriers 35 LP forklift (Model: MCP1F1A18LV; Serial: CP1F1-9N23539), equipped with a ladle attachment to transport molten aluminum, were not trained in the fork and attachment adaptation, safe operation of the attachment, and use limitations.  b) On or about August 29, 2024, north of the central melt furnace, Furnace Tender employees operating a Nissan 30 LP forklift (Model: MCPL01A15LV; Serial: CPL01-9N0509), equipped with a Morse Heavy-Duty Forklift-Karrier barrel dumper to empty 55-gallon steel drums of scrap aluminum, were not trained in the fork and attachment adaptation, safe operation of the barrel dumper, and use limitations.

Issued

Feb 3, 2025

Penalty

Initial $13,005 · Current $0 Reduced

General-duty citation text

29 CFR 1910.178(m)(5)(i): Truck operations. When a powered industrial truck is left unattended, load engaging means shall be fully lowered, controls shall be neutralized, power shall be shut off, and brakes set. Wheels shall be blocked if the truck is parked on an incline.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the shipping and blasting area:  a) On or about August 28, 2024, a Nissan 30 (Model: MCPL01A15LV) LP forklift was left unattended with the load engaging means elevated approximately 12 inches above the walking/working surface and the key in the "on" position.

Issued

Feb 3, 2025

Abate by

Sep 2, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(m)(5)(iii): Truck operations. When the operator of an industrial truck is dismounted and within 25 ft. of the truck still in his view, the load engaging means shall be fully lowered, controls neutralized, and the brakes set to prevent movement.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 29, 2024, north of the central melt furnace, employees were exposed to struck-by and crushed-by hazards when forklift operators dismount the Nissan 30 LP forklift (Model: MCPL01A15LV; Serial: CPL01-9N0509) and do not fully lower the load engaging means to empty 55-gallon steel drums of scrap aluminum in the Morse Heavy-Duty Forklift-Karrier barrel dumper. The operators dismount the forklift with the forks and load in the elevated position to rotate and tilt the barrel dumper to empty the scrap metal into a bin.  b) On or about August 28, 2024, at the pouring area of the central melt furnace, employees were exposed to struck-by and crushed-by hazards when forklift operators dismounted the "ladle truck", a UniCarriers 35 LP forklift (Model: MCP1F1A18LV; Serial: CP1F1-9N23539), to load molten aluminum in the ladle attachment. The operators dismount the forklift with the ladle attachment elevated to operate the furnace controls and then stand in front of the ladle and use a spoon to skim the dross off the top of the molten aluminum in the ladle.

Issued

Feb 3, 2025

Abate by

Sep 2, 2025

Penalty

Initial $13,005 · Current $16,500

General-duty citation text

29 CFR 1910.178(o)(5): Loading. A load engaging means shall be placed under the load as far as possible; the mast shall be carefully tilted backward to stabilize the load.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 29, 2024, north of the central melt furnace, employees were exposed to struck-by and crushed-by hazards while operating a Nissan 30 LP forklift (Model: MCPL01A15LV; Serial: CPL01-9N0509) and a Morse Heavy-Duty Forklift-Karrier to empty 55-gallon steel drums of scrap aluminum into a bin. The load engaging means was not placed under the load as far as possible when the operator dismounted the forklift to utilize the pour chain to rotate the barrel forward and away from the forklift to dump the scrap in the barrel.

Issued

Feb 3, 2025

Abate by

May 30, 2025

Penalty

Initial $13,005 · Current $0 Reduced

General-duty citation text

29 CFR 1910.178(p)(1): Operation of the truck. If at any time a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, the truck shall be taken out of service until it has been restored to safe operating condition.  At an establishment located at 1419 Illinois Avenue in Sheboygan, Wisconsin, in the Die Cast Department:  a) On or about August 8, 2024, to August 28, 2024, the employer did not remove a Nissan 50 LP forklift (Model: MCPL02A25LV; Serial: CPL02-9P1853) with a deficient parking brake and stretched lift chains from service after the deficiencies were identified by a third-party inspection service.  b) On or about August 8, 2024, to August 28, 2024, the employer did not remove the "ladle truck", a UniCarriers 35 LP forklift (Model: MCP1F1A18LV, Serial: CP1F1-9N23539) with deficient and/or delaminated tires that were in need of replacement after the deficiencies were identified by a third-party inspection service.

Issued

Feb 3, 2025

Abate by

May 30, 2025

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(q)(7): Maintenance of industrial trucks. Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected.   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 each powered industrial truck used on a round-the-clock basis was examined after each shift to identify any condition that could adversely affect the safety of the vehicles such as, but not limited to, severed parking brakes, malfunctioning driving brakes, broken seats, and delaminated and/or unserviceable tires.