OSHA Inspection: DK MANUFACTURING FRAZEYSBURG, INC

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $12,768 · Current $12,768

General-duty citation text

29 CFR 1910.28(b)(1)(i): (1) Unprotected sides and edges. (i) Except as provided elsewhere in this section, the employer must ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2 m) or more above a lower level is protected from falling by one or more of the following:  a) On or about March 11, 2025, located at Press #29, employees were required to climb onto injection molding presses to perform hopper cleaning activities without any means of fall protection, which exposed the employees to a fall hazard of approximately six feet.

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $14,895 · Current $14,895

General-duty citation text

29 CFR 1910.146(c)(2): If the workplace contains permit spaces, the employer shall 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) On or about March 12, 2025, located in the Production Department, the employer did not inform exposed employees of the existence and location of, and the danger posed by, injection molding machines, a permit-required confined space, by posting danger signs or any equally effective means. As a result, employees were exposed to struck-by and caught-between hazards. On March 12, 2025, and March 18, 2025, employees performed full-body entry into Press #21, which did not have any posting of a danger sign or an equally effective means to inform the employees of the hazardous space, which exposed the employees to a caught-between hazard.   Note: A sign reading "DANGER - PERMIT-REQUIRED CONFINED SPACE, DO NOT ENTER" or using other similar language would satisfy the requirement for a sign.

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $14,895 · Current $14,895

General-duty citation text

29 CFR 1910.146(c)(4): If the employer decides that its employees will enter permit spaces, the employer shall develop and implement a written permit space program that complies with this section. The written program shall be available for inspection by employees and their authorized representatives.  a) On or about March 12, 2025, located in the Production Department, the employer had not developed and implemented a written permit space program that addressed the required standard elements for full body entry into injection molding machines by employees for cleaning ejectors, troubleshooting and performing mold changes, which exposed the employees to struck-by and caught-between hazards. With respect to the injection molding machines, the company's confined space 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 injection molding machines as required by 1910.146(d)(1); ii. Specific means, procedures, and practices necessary for specifying acceptable condition for entry into the injection molding machines as required by 1910.146(d)(3)(i); iii. Specific means, procedures, and practices necessary for verifying that conditions in the injection molding machines are acceptable for entry throughout the duration of an authorized entry as required by 1910.146(d)(3)(vi);  iv. Specific designation of the persons who are to have active roles in injection molding machine entry operations as required by 1910.146(d)(8);  v. Specific procedures for summoning rescue and emergency services to the injection molding machines, for rescuing entrants from the injection molding machines, for providing necessary emergency services to employees rescued from the injection molding machines, and for preventing unauthorized personnel from attempting a rescue into the injection molding machine as required by 1910.146(d)(9); vi. Specific procedures for reviewing entry operations into injection molding machines 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 exist 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 injection molding machine using cancelled permits and revising the program as necessary as required by 1910.146(d)(14).

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $14,895 · Current $14,895

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:  (c)(4)(ii)(A) A specific statement of the intended use of the procedure; (c)(4)(ii)(B) Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy; (c)(4)(ii)(C) Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them; and (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 March 11, 2025, located in the Production Department, employees performed service and maintenance on 22 different injection molding machines without having procedures that provided the necessary specific information as required for the control of hazardous energy. The employer relied on a deficient energy control procedure, Procedure #17, for 22 injection molding machines, which exposed the employees to the hazards associated with performing service and maintenance; such as, struck-by, caught-between, and thermal burn hazards. The procedure did not include the following:  (1) Specific scope and purpose statement to include, but not limited to, mold changes, cleaning of molds, making adjustments, testing/positioning and troubleshooting the press -1910.147(c)(4)(ii)[A]. (2) Clear and specific steps for shutdown, isolating, and securing the press to control the electrical, hydraulic, gravitational, thermal and pneumatic energy - 1910.147(c)(4)(ii)[B]. (3) Specific steps for placement, removal and transfer of lockout devices and the responsibilities of performing them on the press - 1910.147(c)(4)(ii)[C].  (4) Specific requirements for testing the machine to verify the effectiveness of the lockout and energy control measures of the press - 1910.147(c)(4)(ii)[D].  b) On or about March 11, 2025, located in the Production Department, employees performed service and maintenance on Press #28, an injection molding machine, without having a procedure that provided the necessary specific information as required for the control of hazardous energy. The employer relied on a deficient energy control procedure, Procedure #18, for the injection molding machine, which exposed the employees to the hazards associated with performing service and maintenance; such as, struck-by, caught-between, electrical shock up to 480 VAC and thermal burn hazards. The procedure did not include the following:  (1) Specific scope and purpose statement to include, but not limited to, mold changes, cleaning/spraying molds, making adjustments, testing/positioning and troubleshooting the press -1910.147(c)(4)(ii)[A]. (2) Clear and specific steps for shutdown, isolating, and securing the press to control the electrical, hydraulic, gravitational, thermal and pneumatic energy - 1910.147(c)(4)(ii)[B]. (3) Specific steps for placement, removal and transfer of lockout devices and the responsibilities of performing them on the press - 1910.147(c)(4)(ii)[C].  (4) Specific requirements for testing the machine to verify the effectiveness of the lockout and energy control measures of the press - 1910.147(c)(4)(ii)[D].  c. On or about March 11, 2025, located in the Production Department, employees performed service and maintenance on 23 robots that were each interconnected with its own injection molding machine without having procedures that provided the necessary specific information as required for the control of hazardous energy. The employer relied a on deficient energy control procedure, Procedure #19, for 23 injection molding machines, which exposed the employees to struck-by and/or caught-between hazards. The procedure did not include the following:  (1) Specific scope and purpose statement to include, but not limited to, mold changes on presses, cleaning/spraying molds, making adjustments to robot and/or press, testing/positioning and troubleshooting the robot/press or anytime there is service and maintenance of equipment while an employee is within the robot's restricted space-1910.147(c)(4)(ii)[A].  (2) Clear and specific steps for shutdown, isolating, and securing the press to control the electrical, and pneumatic energy - 1910.147(c)(4)(ii)[B]. (3) Specific steps for placement, removal and transfer of lockout devices and the responsibilities of performing them on the robots- 1910.147(c)(4)(ii)[C].  (4) Specific requirements for testing the machine to verify the effectiveness of the lockout and energy control measures of the robots - 1910.147(c)(4)(ii)[D].

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $14,895 · Current $14,895

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 March 18, 2025, the employer did not conduct a periodic inspection of the energy control procedure at least annually for the 23 injection molding machines located at the facility, which exposed the employees to the hazards associated with performing servicing and maintenance tasks on the machines; such as but not limited to, struck-by, caught-between, thermal burn and fall from/into press hazards.

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $14,895 · Current $14,895

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 March 18, 2025, and days prior, the employer did not train employees to ensure they had the knowledge and skills necessary prior to performing service and maintenance tasks on horizontal injection molding machines, which exposed employees to struck-by and caught-between hazards.

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $10,641 · Current $10,641

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 or about March 11, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and troubleshooting of Press #29, a 400-ton injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  b) On or about March 12, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and cleaning of a mold on Press #29, a 750-ton Ferromatik Milacron injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  c) On or about March 11, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and cleaning while standing on Press #29, a 400-ton Ferromatik Milacron injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  d) On or about March 11, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and changing the mold on Press #36, a 309-ton BOLE injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  e) On or about March 14, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and spraying of molds with rust preventative for all 23 injection molding machines at the end of 2nd shift. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $14,895 · Current $14,895

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. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.  a. On or about March 3, 2025, located at Press #29, the employer did not ensure that a Ranger robot was adequately guarded to prevent employee exposure during the robot's movement when lowering parts onto a conveyor, which exposed employees reaching beyond the guarding to struck-by hazards.  b. On or about March 12, 2025, located at Press #21, the employer did not ensure that a Ranger robot was adequately guarded to prevent employee exposure during the robot's movement when lowering parts onto a conveyor, which exposed employees reaching beyond the guarding to struck-by hazards.   c. On or about March 18, 2025, located at Press #21, the employer did not ensure that a Ranger robot was adequately guarded to prevent employee exposure during the robot's movement when lowering parts onto a conveyor, which exposed employees reaching beyond the guarding to struck-by hazards.

Issued

Aug 22, 2025

Abate by

Sep 11, 2025

Penalty

Initial $148,963 · Current $148,963

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 or about March 18, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and cleaning of a mold on Press #21, a 750-ton Ferromatik Milacron injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  b. On or about March 12, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and cleaning of a mold on Press #21, a 750-ton Ferromatik Milacron injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  c. On or about March 18, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and troubleshooting of Press #34, a 500-ton BOLE injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  d. On or about March 18, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during the servicing and troubleshooting of Press #24, a 500-ton Toyo injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  e. On or about March 23, 2025, located in the Production Department, an employee was exposed to machine hazards associated with moving parts during a mold change on Press #12, a 500-ton Ferromatik Milacron injection molding machine. The employer did not implement energy control application steps as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements]. As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.