OSHA Inspection: HUSSMANN CORPORATION

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(5)(i): Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware were not provided by the employer for isolating, securing or blocking of machines or equipment from energy sources:    a. Blocking devices specifically designed for isolation of gravity, such as, but not limited to, the scrap tables at cells 5, 8, 9, 13, were not provided.    b. Lockout devices specifically designed for isolation of pneumatic energy sources were not provided.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(5)(ii): Lockout devices and tagout devices were not singularly identified:    a. There were no blocking devices specifically identified for the purpose of isolation of gravity, such as for the scrap tables at cells 5, 8, 9, 13.    b. There were no lockout devices specifically identified for the purpose of isolation of pneumatic energy, such as for covering air hose ends, removed from quick disconnects.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(B): Lockout and tagout devices were not standardized within the facility in at least one of the following criteria: color; shape; or size:    a. Any blocking devices that might have been used for isolation of energy as a result of gravity, such as wood 2x4's or jack stands, for working under equipment such as the scrap tables or elevators at cells 5, 8, 9, 13, were not standardized as required by the OSHA requirement.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(C)(1): Lockout devices were not substantial enough to prevent removal without the use of excessive force or unusual techniques, such as with the use of bolt cutters or other metal cutting tools:    a. A wood 2x4 blocking device that was used for energy isolation of scrap tables, such as at cells 5, 8, 9, 13, was not specifically designed for that purpose and could become displaced because of improper application or inadvertently by contact with another object or by a worker.    b. Lockout devices not specifically designed for isolation of pneumatic energy sources such as for covering the end of air hoses could be removed by hand without excessive force.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $4,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(d)(4)(i): Lockout or tagout devices were not affixed to each energy isolating device by authorized employees:    a. During work on shears in order to adjust the ram at top dead center (TDC), employees raise the guard to the flywheel and belt/pulley, and make adjustment without shutting off the machine and locking out.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(d)(6): Prior to starting work on machines or equipment that had been locked out or tagged out, the authorized employee did not verify that isolation and de-energization of the machine or equipment had been accomplished:    a. Equipment was not verified for de-energization after placing a lock on the energy isolating device, including for electrical and pneumatic energy sources.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Penalty

Initial $3,000 · Current $7,000

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There were damaged parts that may adversely affect safe operation or mechanical strength of electric equipment, such as parts that were broken, bent, cut or deteriorated by corrosion, chemical action, or overheating:    a. The end table emergency stop at cell 12 was not functioning, exposing the operator to potential injury, such as being caught by the final belt.

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $5,000 · Current $7,000

General-duty citation text

29 CFR 1910.303(g)(2)(i): Except as elsewhere required or permitted by Subpart S of Part 1910, live parts of electric equipment operating  at 50 volts or more were not guarded against accidental contact by use of approved cabinets or other forms of approved enclosures or by any of the means identified in paragraphs (A), (B), (C), and (D) of 29 CFR 1910.303(g)(2)(i):    a. Electrical panels were not secured closed at the sheet metal cell electrical control panels, such as, but not limited to, at the cell 8, E4 electrical panel.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Penalty

Initial $4,250 · Current $7,000

General-duty citation text

29 CFR 1910.333(c)(10): An interlock system was not returned to its operable condition when the work was completed:  a. At cell 3, a key controlled interlock switch on the electrical control panel to the turret was frozen in the "off" (non-safe) position.  Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).  29 CFR 1910.305(g)(2)(iii): Flexible cords and cables were not connected to devices and fittings so that strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws:    a. In shipping area, the electrical plugs (connectors) to Hobart EZ Charge forklift chargers  (Unit 10 & 12) were used and were not connected to devices and fittings so that strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws.

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $5,000 · Current $7,000

General-duty citation text

29 CFR 1910.335(a)(1)(i): Employees working in areas where there were potential electrical hazards were not provided with electrical protective equipment that was appropriate for the specific parts of the body that needed to be protected and for the work being performed:    a. Electrically insulated gloves (and that were tested according to the requirements of the standard), were not consistently used when entering and performing work in electrical cabinets with components up to 460 V.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $70,000 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(B): The energy control procedures did not clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.    a. Energy control procedures did not document specific steps for shutting down machines such as, but not limited to, in cells 3, 5, 7, 8, 9, 12, 13, 16, and 30, where machines included turret punches, shears, conveyor tables with electrical, pneumatic, and gravity as energy sources.  The procedures only stated, "Shut off electric supply," and "shut off pneumatic supply," with no specific steps on how to accomplish shutting down.    b. Energy control procedures did not document what machines were energized by the energy isolating device listed in the procedures, such as, but not limited to, for cells 3, 5, 7, 8, 9, 12, 13, 16, 30.  The procedures listed energy sources such as "Electric" at "Location E1 through E5," and "Pneumatic" at "Location P1 through P4" for cell 8, but  specific machines isolated by the energy sources were not specified.    c. Blocking to control gravity was not documented on the procedures, such as, but not limited to, for the scrap tables on cells 5, 8, 9, 13.    d. Each energy control procedure, such as, but not limited to, for cells 5, 7, 8, 9, 12, 13, 16, 30, labeled one electrical energy source as "Main Source", but the electrical energy did not isolate energy to the remainder of the electrical disconnects and cabinets in those cells.  Electrical energy to the machines was only isolated electronically, which was not an acceptable means for energy isolation.    e. Energy control procedures, such as, but not limited to, for cells 5, 7, 8, 9, 12, 13, 16, 30, labeled one pneumatic energy source as "Main Source," but each pneumatic source was individually isolated; there was no main source.    f. Electrical and pneumatic energy sources were mislabeled on energy control procedures, such as, but not limited to, electrical source E6 was labeled as E5 (cell 5), pneumatic sources P1-P3 were not labeled at the cell (cell 5), electrical sources E1-E6 were labeled as "turn knobs" but all switches were operated by a handle (cell 5), electrical sources E1-E3 were labeled as "turn knobs" but all switches were operated by a handle (cell 7), electrical sources E1-E5 were labeled as "turn knobs" but  switches E1, E3-E5 were operated by a handle (cells 8, 9, 12), a pneumatic valve near E1 was not labeled on the procedure for cell 9, electrical sources E1-E5 were labeled as "turn knobs" but  switches E1-E3, E5 were operated by a handle (cell 13), electrical sources E1-E3 were labeled as "turn knobs" but were operated by a handle (cells 16, 30), a pneumatic valve next to electrical source E1 was not listed on the procedure (cell 30), pneumatic source P2 was mislabeled on the procedure as P1 (cell 30), other examples existed of the sources not labeled at the cell, such as the P4 valve at cell 8 which was the energy source to the scrap table where a fatal injury occurred.      (Note: there was no mention on the employer's energy control procedures for locking out at the cell perimeter gate interlock switches, even though there were instances of the gate switches being used for energy isolation during maintenance, such as at cells 5, 8, 9, 13.)    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(C): The energy control procedure did not clearly and specifically outline the steps for placement, removal and transfer of lockout devices or tagout devices and the responsibility for them:    a. Pneumatic energy sources listed on energy control procedures, such as, but not limited to, for cells 3, 5, 7, 8, 9, 16, and 30 had listed "Remove hose and make sure air pressure is isolated," but there was no description on how to isolate the energy source, such as by applying a cover to the hose or to the disconnect.    b. Pneumatic energy source P1 did not have a lockable valve as described on the procedure (cell 7), pneumatic sources P2-P4 valves were not lockable as listed on the procedure (cell 8), pneumatic source P1 valve was not lockable as listed on the procedure (cell 9), pneumatic source P2 valve was not lockable as listed on the procedure (cell 12), cell 12 pneumatic source P4 was actually two valves, one with a handle that could not be locked and the other that could be locked; pneumatic sources P1-P4 valves were not lockable as listed on the procedure (cell 13), pneumatic sources P1 and P3 valves were not lockable as listed on the procedure (cell 16), pneumatic sources P1 and P2 valves were not lockable as listed on the procedure (cell 30).    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(D): The energy control procedures did not clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control:    a. Energy control procedures did not document specific methods for energy isolation testing of machines such as, but not limited to, for cells 3, 5, 6, 7, 8, 9, 12, 13, 16, and 30, where machines included turret punches, shears, conveyor tables with electrical, pneumatic, and gravity as energy sources.  The procedures only stated, "Verify total de-energization of all sources," with no specific steps on how to accomplish de-energization.    (Note: there was no mention in the employer's energy control procedures for energy isolation for gravity.  In addition there was no mention on the employer's energy control procedures for locking out at the cell perimeter gate interlock switches or for testing de-energization of the machines after placing a lock on the gate switches, even though there were instances of the gate switches being used for energy isolation during maintenance work, such as at cells 5, 8, 9, 13.)    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $70,000 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirement of this standard were being followed:    a. Each energy control procedure was not inspected during the annual review as required by the standard.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(6)(i)(B): The periodic inspection of the energy control procedure was not conducted to correct any deviations or inadequacies:    a. The annual inspection did not correct numerous deficiencies with the written lockout procedures, such as not including all energy sources on the procedures such as gravity, energy sources not identified with the machines de-energized, incorrect information about "main" energy sources, no specificity for how to test for energy isolation, not identifying all energy sources on the written procedures, incorrect energy isolation equipment listed (such as handles existing instead of knobs, or quick disconnects instead of handles), not identifying equipment as missing devices so that lockout could be made, such as pneumatic handles that could not accept a lock to prevent re-energization, and mislabeling of energy sources.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(6)(i)(C): Where lockout was used for energy control, the periodic inspection did not include a review, between the inspector and each authorized employee, of that employee's responsibilities under the energy control procedure being inspected:     a. During the annual lockout/tagout inspection, a review was not made with each authorized employee of his or her responsibilities.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $70,000 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.147(d)(3): All energy isolating devices that were needed to control the energy to the machine or equipment were not physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s):    a. Electronic interlock gate switches, such as, but not limited to, on cells 8 and 9, were used as a substitute for an energy isolating device during servicing and/or maintenance of machines.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).

Issued

Mar 4, 2015

Abate by

Jul 19, 2015

Penalty

Initial $0 · Current $7,000

General-duty citation text

29 CFR 1910.147(d)(4)(i): Lockout or tagout devices were not affixed to each energy isolating device by authorized employees:    a. During work on 9-6-14, on the scrap table at cell 8, sheet metal department, the equipment was not de-energized and tagged such as by blocking the equipment to prevent it from dropping onto the employee.  There were previous instances of not blocking a scrap table during maintenance work and during clean-up.    b. Examples existed of equipment maintained but not locked out, such as but not limited to work on the turret punch at cell 9, on 9-24-14.      c. Examples existed of work performed without locking out both electrical and/or pneumatic energy sources, such as opening the cover of the chain and sprocket at the cell 6 elevator, in order to work on the suction device.    Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citation(s).