Willful Violations Lead to Preventable Amputation

Pennsauken, NJ – Failure to implement OSHA recommendations has led to an amputation and over $200,000 in fines for willful violations documented at an NJ snack food manufacturing facility.

A worker at J&J Snack Foods Corporation suffered a partial finger amputation in a lockout accident that could have been prevented by rectifying prior violations identified by OSHA. Following an investigation, J&J faces $206,019 in fines for federal workplace safety violations, including willful violations.

OSHA’s investigation found that failures to correct previously issued workplace safety violations led to the amputation accident at J&J’s Pennsauken manufacturing facility. The snack-food maker failed to correct prior violations of safety procedures known as lockout/tagout procedures which are written instructions for de-energizing each piece of equipment.

OSHA inspectors determined that the worker was cleaning a machine when it activated. This is typical of accidents whose cause can be traced back to lockout/tagout failures or energy control hazards.

Million of American workers service equipment as a part of their job, and these people face the greatest risk of injury if lockout/tagout is not properly implemented. It is estimated that compliance with the federal lockout/tagout standard prevents 120 fatalities and 50,000 injuries each year. Workers injured on the job from exposure to hazardous energy lose an average of 24 workdays for recuperation. OSHA’s area director stated that “the employer’s failure to correct previously identified violations and follow basic safety standards resulted in this preventable incident.”

J&J was cited for willfully failing to conduct periodic inspections of energy control procedures used to de-energize equipment when cleaning; failing to implement lockout procedures to prevent unintentional machine start-up; and failing to train employees on lockout/tagout procedures and energy hazards.

OSHA requires that employees be trained on lockout policies and procedures. Training is done to ensure that the purpose and function of the energy control program are understood by employees, and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees.

J&J Snack Foods Corp manufactures popular snack foods like soft pretzels, churros, water ice, and frozen lemonade for popular brands sold throughout the United States.

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AL Auto Workers Exposed to Electrical and Amputation Hazards

electrical amputation hazardsAuburn, AL – Arkal Automotive USA Inc. faces $47,857 in proposed federal workplace safety penalties after an investigation of its Auburn (AL) plant revealed that workers were exposed to electrical and amputation hazards.

According to OSHA, Arkal Automotive was cited for inadequate machine guarding, failure to implement lockout/tagout (LOTO) procedures to keep workers safe during machine maintenance and servicing, failing to implement safety procedures for entering a robotic cage, and for exposing employees to hazardous energy.

OSHA’s fines and citations were issued following a complaint that employees were not properly protected while entering injection molding machines. Joseph Roesler, OSHA’s area office director, stated that “Arkal Automotive USA Inc. failed to identify and correct hazards to ensure the safety and health of their employees.”

Multiple lockout/tagout failures were revealed in the course of the OSHA investigation. Arkal Automotive was found lacking proper lockout procedures for working with robots or molds, including when removing parts or cleaning molds. Additionally, safety inspectors found an insufficient amount of the required lockout equipment for employees to use for hazardous energy control. The OSHA complaint said the company failed to ensure that if more than one employee was working in a robotic area, each employee had individual lockout devices.

It was also reported that Arkal Automotive failed to ensure continuity of lockout procedures on shift change and did not have adequate machine guarding when employees reached under a portion of a robot cage to retrieve parts and pass to the operator while the machine was running.

According to OSHA records, the same facility was issued four serious violations in 2017 for lockout hazards and other violations.

Arkal Automotive is a company based in Israel, with production plants worldwide. The Auburn (AL) injection molding plant opened in 2011, and is their only production plant in the US. The Auburn facility produces door carriers, wheel liners and other functional auto parts.

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Worker Hospitalized After Becoming Stuck in Conveyor Belt Housing

Baiting Hollow, NY – A worker is in critical condition after he became stuck inside a conveyor belt housing. Once in the confined space, the man lost consciousness and went into cardiac arrest at the sand and gravel pit where he was working.

According to local police reports,conveyor belt the 40-year-old man “became lodged inside the conveyor belt housing of a plant screener that is used for sifting soil on the property.”

The worker, currently in critical condition, is an employee of BGLJ Servicing Corporation. He was working at a property used for excavating material.

The employee shut the conveyor off and crawled into a small opening to free a jam. While in the space, he got stuck and lost consciousness. His co-worker pulled him out and emergency responders were called to the scene.

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Top 10 Most Cited OSHA Violations for 2016

Making sure your industrial property is OSHA compliant is vital to your business. If you’re found to have any violations, you will have to pay a hefty fine. OSHA pretty much covers every part of your business from walkways to employee training. They even have regulations on industrial doors so you better make sure you’ve gone to a reliable INDUSTRIAL DOOR COMPANY! Every year, OSHA shares the most commonly cited violations to try to name and shame the worse areas of safety. This way, businesses will hopefully pay more attention to them in the future.

Lockout/Tagout violations were the #5 most commonly issued OSHA violation in 2016, the #2 most common willful violation, and the #4 most commonly cited serious violation in the safety trainingpast year as presented by Patrick Kapust (deputy director of OSHA’s Directorate of Enforcement Programs) at the 2016 National Safety Council Congress & Expo in Anaheim, CA.

In sharing OSHA’s Top 10 list of most frequently cited violations for 2016, Kapust recommends that each safety manager looks at the list and compare it to their own workplace. Since these are the most common violations OSHA is finding in the US, Kapust suggests that EHS managers ask themselves: “Would they find these at my workplace?”

Fall Protection was the most cited OSHA violation for the sixth year in a row. Hazard Communication and Scaffolding were second and third most common, which is unchanged from 2015’s top 10 most cited. Respiratory Protection and Lockout/Tagout were the next most common, in fourth and fifth position.

OSHA’s standards for Lockout/Tagout (or LOTO) outline the minimum performance requirements for the control of hazardous energy during servicing and maintenance of machines and equipment.

While Lockout violations are the fifth most common overall, LOTO was the #2 most common willful violation in 2016. Willful violations are defined as those “committed with an live training, electrical training, arc flash trainingintentional disregard of or plain indifference to the requirements of the Occupational Safety and Health Act and requirements.”

Additionally, Lockout/Tagout represented the #4 most common serious violation issued in 2016. Serous violations are those which pose a “substantial probability that death or serious physical harm could result, and the employer knew or should have known of the hazard.”


OSHA’s Top 10 Most Cited Violations for 2016:
  • Fall Protection – General Requirements
  • Hazard Communication
  • Scaffolding
  • Respiratory Protection
  • Lockout/Tagout
  • Powered Industrial Trucks
  • Ladders
  • Machine Guarding
  • Electrical – Wiring Methods
  • Electrical – General Requirements

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$76K in OSHA Fines for AL Meat Processor

Bakerhill, AL – OSHA has issued 12 citations for serious safety violations to a meat processing plant located in southeast Alabama. An investigation was triggered after an employee’s fingertip was amputated in an accident at the Keystone Foods processing plant in Bakerhill (AL). OSHA is proposing $76,734 in fines.

In March of this year, a 65-year-old employee lost the tip of his index finger while cleaning an overhead saw blade at the plant. OSHA’s subsequent investigation uncovered numerous serious safety violations including amputation hazards due to ungosha fines meat-processing-plantuarded machinery and failure to follow safety procedures to prevent machinery from starting while cleaning, among others. Such procedures are known as Lockout/Tagout.

OSHA laws require each piece of equipment to have lockout procedures written specifically for it. These lockout procedures provide detailed instructions on how to isolate and lock each energy source for a given piece of equipment. Lockout/Tagout (or LOTO) helps to prevent the unexpected energization or startup of machinery and equipment, and/or prevents the release of hazardous energy during service and maintenance activities. Writing equipment-specific procedures for each piece of equipment can seem like the most difficult part of implementing a lock out tag out program in any kind of manufacturing facility – Martin Technical’s Rapid LOTO lockout procedure development program is designed to provide high quality procedures that are easy to follow.

Approximately 3 million workers service equipment and these people face the greatest risk of injury if lockout/tagout (LOTO) is not properly implemented. Compliance with federal lockout/tagout standards prevents an estimated 120 fatalities and 50,000 injuries each year. Contact a Martin Technical Safety and Compliance Expert today to discuss how we can help your company implement an effective lockout/tagout (LOTO) program and policy for your facility.

The Keystone plant in Bakerhill (AL) is operated by Keystone Foods of West Chester (PA). Keystone is a supplier of fresh and frozen food products including poultry, beef, fish and pork.

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