Fatal Injury During Machine Cleaning

Gardena, CA – A worker was killed this week in Gardena (CA) when the machine he was cleaning turned back on. The fatal injury occurred at the German Machined Products Inc manufacturing facility. Cal/OSHA is investigating.

fatal injuryOn Monday afternoon, the Los Angeles County Fire Department received a call about a person trapped inside a metal-cutting machine. By the time emergency workers arrived, the man was dead.

The worker’s name has not yet been released, but according to the LA County Coroner’s Office the victim was a Latino man in his 60s.

German Machined Products’ Gardena manufacturing facility specializes in complex machining and assembly for the aerospace industry. There is a history of Cal/OSHA citations and violations at the plant. In 2014, Cal/OSHA issued four general citations and one serious citation against German Machined Products for failing to properly guard hazardous machinery.

In light of this fatal workplace injury, Cal/OSHA will be interviewing co-workers, checking the Gardena facility’s equipment, and thoroughly reviewing safety and training procedures at German Machined Products.

Accidents during machine maintenance and cleaning activities are especially tragic since they are highly preventable. The federal Lockout/Tagout (LOTO) standard is designed to protect the nearly 3 million workers who service equipment and consequently face the greatest risk of injury if lockout/tagout is not properly implemented. Compliance with the lockout/tagout standard is estimated to prevent roughly 120 fatalities and 50,000 injuries annually.

Please contact Martin Technical to learn more about Lockout/Tagout safety procedures.

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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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WI Lumber Operation Fined More Than $250K for Amputations

Marathon, WI – Menzner Lumber & Supply faces a $260,113 fine after an employee’s workplace injury triggered an OSHA investigation. Unfortunately, this was not the first incident of amputation at the Marathon (WI) facility.

In June of this year, a 24-year-old worker at suffered a partial amputation of his right middle finger while servicing a machine. Federal inspectors found that Menzner workers were not properly trained on how to isolate energy sources while setting up, servicing and performing maintenance on machines – processes and procedures known as Lockout/Tagout.

OSHA investigators found 14 safety violations, seven of which it classified as serious. Officials found electrical safety violations, lack of guarding on ladder wellslockout/tagout amputation to prevent falls, inadequate energy control procedures, and several machines lacking the proper safeguards.

Two amputations also occurred at Menzner Lumber & Supply in 2015: a machine severed a 25-year-old employee’s left middle finger in April 2015, and a 34-year-old worker lost the tip of his right thumb in January of 2015. According to OSHA, both accidents happened when the worker came in contact with operating machine parts.

Menzner Lumber & Supply manufactures hardwoods, veneers, moldings and other wood products and operates facilities in Kentucky, Mississippi and South Carolina. The company was founded in 1894 and employs about 300 people.

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Goodyear faces over $1M in Fines after 4 Employee Deaths

Danville, VA – The  Virginia Department of Labor has cited Goodyear’s Danville (VA) facility with nearly $850,000 in fines for workplace safety violations and about $165,000 for health violations. The state issued a grand total of 122 citations including 89 “serious,” four “willful-serious” workplace safety violations, and 26 “serious” and three “other-than-serious” health violations.goodyear employee deaths

In addition, Goodyear was also cited and penalized for the death of Charles “Greg” Cooper at the Danville Goodyear plant on April 12, and for separate non-fatal accidents in which an employee was burned by steam, a machine operator was injured when their arm got caught in a feed conveyor, and another was hurt when their arm got caught in a takeaway belt cement bridge roller.

The largest employer in the Danville area, the Goodyear Tire plant has been the scene of 4 employee deaths within the past year. Billy Scheier died on August 12 from blunt injuries to the chest and medical asphyxia. Greg Cooper died on April 12. Kevin Edmonds died during his work shift on March 31. And in August 2015, Jeanie Lynne Strader also died in an accident at the plant.

The Danville plant was cited for failing to maintain workroom floors in a clean and dry condition and Goodyear was also penalized for not having procedures for controlling “potentially hazardous energy.” These equipment-specific Lockout/Tagout procedures need to be followed before employees troubleshoot problems or perform maintenance on equipment.

VOSH found nearly two dozen instances and locations of inadequate machine guarding within the Danville facility. Their statement says that Goodyear did not provide methods for machine guarding to protect operators and other employees from hazards “such as those created by point of operation, ingoing nip joints, rotating parts, flying chips and sparks.”

Virginia Department of Labor also found untrained machine operators at the Danville Goodyear plant were exposed to 120-to-480-volt circuit conductors when opening cabinet doors to adjust timers and resetting overcurrent devices for machines. Arc Flash accidents generally happen lighting quick and without warning. The result of this violent event is usually destruction of the equipment involved, fire, and severe injury or death to any nearby people. Training is paramount to avoiding any electrical accident. The Martin Technical Arc Flash Risk Assessment, Labeling and Safety Program is one of the most comprehensive in the industry. Read more about our Arc Flash safety and training programs.

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Sunfield Nets a Staggering $3.4M Fine for 100+ OSHA Citations

Hebron, OH – Sunfield, Inc has been issued as many as 118 OSHA citations for machine hazards found at their Hebron (OH) manufacturing plant. These citations total $3.4 million in fines for the Japanese-owned auto manufacturer and constitute one of the largest OSHA penalties ever filed against a company in the automotive parts industry. Many of the violations were deemed to be egregious willful, willful, repeated, and serious.

The $3.4M fine is the result of Sunfield’s failure tocitations osha lockout disconnect machinery from a power supply, failure to prevent sudden movement before maintenance and service, and failure to train workers in operating machine presses safely – all items included in industry-standard lockout-tagout planning, training, and de-energization procedures.

Many accidents have been reported at the Hebron facility as a result of Sunfield’s failure to implement robust lockout-tagout procedures. OSHA investigators inspected the Hebron plant after reports of two injuries earlier this year: In February, an employee’s arm was crushed and amputated; and a temporary employee suffered a fractured elbow in January. OSHA reported that the Hebron facility has an extensive history of federal safety violations, dating back 20 years. For example, a worker’s fingers were severed in 2011, and a employee fractured his leg after being pinned under a coil of rolled steel in 2000.

Sunfield has been placed the company in OSHA’s Severe Violator Enforcement Program for their consistent failure to address safety hazards. Most of the violations involve lack of machine safety procedures which expose workers to amputation, lacerations and other injuries. OSHA found that the company did not take the necessary steps to protect its workers from being injured by moving machine parts. The agency also found multiple electrical safety violations including lack of personal protective equipment, workers exposed to live electrical parts, and use of damaged equipment.

Sunfield supplies parts for several major Japanese and domestic automakers. Sunfield began production in Hebron in June 1994, has a daily workforce of about 175. The Hebron site is the only U.S. plant. The parent company, Ikeda Manufacturing Company LTD. is headquartered in Ota-City, Gunma, Japan.

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Boiler Safety & Maintenance

Boiler Safety & Maintenance


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Class Description

Service your own boiler but make sure to do it safely. This Boiler Safety and Maintenance On-Site training is designed to teach building and facility maintenance personnel how to stay safe while servicing. Reduce the need for outside service contractors, while at the same time increase your confidence and comfort level in operating and maintaining your own boilers.

Purpose of Training

We will take the mystery out of wondering if your boiler is safe and operating efficiently. For the novice technician needing a well-rounded education and the experienced stationary engineer who needs a refresher course for continuing education, this boiler safety training program provides a no-nonsense, practical and real world approach for boiler operation, maintenance and safety. Extend boiler life, improve boiler efficiency, and save energy costs, while establishing a culture of safe work practices among the employees.

Learning Objectives

• How/When to Schedule Preventive Maintenance Procedures
• Differences between High Pressure and Low Pressure boilers
• Differences between Firetube and Watertube boilers
• Primary boiler components
• Operating pressures and temperatures of cast iron boilers
• Differences between steam boilers and hot water boilers
• Applications for Electric Boilers
• Four major perils associated with boilers
• Common boiler accidents to avoid
• All about furnace explosions
• Dangers of low water conditions
• How to inspect your Boiler
• Conducting efficiency tests
• Maintenance troubleshooting tips
• Waterside and Fireside maintenance
• Boiler design and construction codes and standards
• How to safely and efficiently operate your boiler
• Burner operations and combustion control systems

Course Agenda

Day 1

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2 Workers Injured While Cleaning Machinery in MS, OSHA Fines for Violations

Corinth, MS – Mississippi Polymers has been cited for 11 “serious” safety violations, totaling $56,0000, for machine safety and lockout/tagout violations that resulted in severe injury and amputation for two Mississippi Polymers employees in the fall of 2015.

In both accidents OSHA investigated, workers were injured while attempting to clean machinery: On Sept. 28, a 41-year-old print tender suffered severe injury when his hand got entangled in a print roller and was crushed. Six days later on Oct. 4, amachine guard safety violations 59-year-old mill operator caught her hand in a print roller. The machine crushed her pinky finger so badly that a portion of the finger, up to the first joint, had to be amputated.

OSHA cited Mississippi Polymers for exposing workers to unguarded rollers, shafts, and gears; and failing to train workers on the specific procedures to prevent machinery from starting up during maintenance (processes known as lockout/tagout). As noted by OSHA officials, “protective guarding was available and could have prevented such incidents.”

The employer of more than 160 workers in Corinth, Mississippi Polymers manufactures functional and decorative films used in many products such as banners and billboards.

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Ohio Food Manufacturer Fined for Machine Safety Deficiencies

McComb, OH – Hearthside Food Solutions faces OSHA fines for several safety violations related to failure to protect workers from machinery operating parts. $47,000 in OSHA fines have been proposed in connection with an employee suffering severe scalp injuries and multiple cuts in July 2015. The McComb, OH facility produces cookies and crackers for nationally recognized brands.

Hearthside is being accused of several safety violations for failing to protect workers from machinery operating parts. A machine at the factory caught the hairnet of a worker cleaning product waste from the floor last July. She was hospitalized for four days.

OSHA is especially concerned because of similar accidents in the past. Last April, a Hearthside employee lost part of a finger trying to unjam a machine. Hearthside was fined for Lockout/Tagout and machine safety violations for that incident.

Based in Downers Grove, Illinois, Hearthside Food Solutions has 23 facilities in North America and Europe. The company employs about 6,000 workers, nearly 1,800 of them at the McComb plant.

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Wegmans NY Bakery Division Fined $188K for Repeated Violations

Rochester, NY – The NY-based supermarket Wegmans faces fines totaling $188,000 following an investigation of two worker injuries at their bakery facility in Rochester, N.Y. OSHA cited Wegmans on Sept. 1 for three repeated and two serious violations while proposing fines totaling $188,200. After an inspection, the agency accused Wegmans of failing to properly train employees, ensuring that a machine’s moving parts had the proper safeguards, for providing inadequate hand and face protections for workers, and more.

OSHA claims that in March, a sanitation crew member lost a fingertip when it caught in the pinch point of an operating conveyor that he was cleaning. A month later, a mechanic sustained a first degree burn on his wrist when steam released while he attempted to repair a valve. The subsequent inspection by OSHA’s Buffalo (NY) office found hazardous conditions similar to those cited by the agency during a 2011 inspection of the same facility. Wegmans Food Markets faces proposed fines of more than $188,000 for these “recurring hazards.”

In the case of the amputation, OSHA found that Wegmans failed to turn off and lock out the conveyor’s power source, train employees in how to do this, and ensure the conveyor’s moving parts were protected against contact. In the steam burn incident, the company failed to develop a procedure to lockout the valve supplying steam to the pipe. The recurring hazards led the agency to cite Wegmans for three repeated violations with $175,000 in proposed fines. Additionally, OSHA cited the company for inadequate hand and face protection for the employees who worked on the steam valve, with fines amounting to $13,200.

Wegmans disputes the findings: “We work hard to maintain a safe workplace everywhere. Even one injury to an employee is too many for us…The current rate of workplace accidents at Wegmans is the lowest in our history.”

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OSHA Fines WI Furniture Maker $1.76 Million

Arcadia, WI – The U.S. Department of Labor’s Occupational Safety and Health Administration levied a historic $1.766 million dollar fine this week against Ashley Furniture Industries, based in Wisconsin. Investigators documented numerous and repeated serious violations at the facility, landing Ashley Furniture on OSHA’s Severe Violator Enforcement Program list for “employers who have demonstrated indifference to their OSH Act obligations by willful, repeated, or failure-to-abate violations.”

The plant employs 4,500 and in the past 3 years has seen over 1,000 worker injuries. Workers were not adequately protected against moving machinery, most of it woodworking machinery. Lack of training and accidents with tools, blades, and saws have resulted in multiple amputations. The OSHA report and $1.76 million dollar penalty allege that Ashley Furniture “failed to safeguard against woodworking machines unintentionally starting when workers were making tool and blade changes,” which is also known as lockout tagout or control of hazardous energy.

Additional citations were issued for “not training workers on safety procedures and hazards present when servicing machinery; lacking adequate drenching facilities for workers exposed to corrosive materials; electrical safety violations; and not equipping all machines with easily-accessible emergency stop buttons.” OSHA categorizes these violations as serious since physical harm resulted from a hazard they estimate that the “employer knew or should have known [to] exist.”

“We rarely issue a fine that is more than $1 million,” commented U.S. Labor Department Assistant Secretary David Michaels. “Having 1,000 work injuries in three years is proof positive that safety in this plant needs tremendous ­improvement.” U.S. Secretary of Labor Thomas E. Perez stated: “Safety and profits are not an ‘either, or’ proposition. Successful companies across this nation have both.” For its part, Ashley Furniture denies the findings, stressing that they are allegations only.

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