Surgoinsville, TN – Five serious workplace safety violations have been documented at MIS Industries in an investigation following a February 12 lockout/tagout accident that killed 34-year-old Arthur James Hendrickson. Hendrickson was crushed while retrieving a part that had jammed a hangar blaster machine at the Tennessee metal finishing facility.
Local officials say that Hendrickson climbed into the hangar blaster to remove a part that had gotten lodged in the equipment. Once he removed the piece, the door closed and Hendrickson was trapped. He was pronounced dead at the scene.
In the course of the investigation, TOSHA (Tennessee Occupational Safety and Health Administration) discovered that neither of the MIS team leaders could recall receiving training on Lockout/Tagout (LOTO) and were ignorant of any of the energy control procedures.
The TOSHA investigator concluded that team leaders on duty initiated maintenance activities on the Hangar Blaster without ensuring that the machine was de-energized to prevent unexpected startup. Lockout/Tagout is sometimes referred to as Hazardous Energy Control (or the Control of Hazardous Energy) – these terms refer to the same standard of preventing unexpected start up or movement of equipment.
It is estimated that 3 million workers service equipment and these employees face the greatest risk of injury if Lockout/Tagout is not properly implemented. Compliance with the lockout/tagout standard prevents an estimated 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. In a study conducted by the United Auto Workers (UAW), 20% of the fatalities that occurred among their members were attributed to inadequate lockout/tagout and hazardous energy control procedures.
TOSHA concluded that MIS did not make use of its energy control program, did not effectively train employees on their role in Lockout/Tagout, and also neglected to conduct periodic evaluations of their LOTO program.
The five serious violations were: employees were exposed to a caught-in hazard as they failed to apply energy control measures to the Hangar Blaster machine; written lockout procedures failed to clearly and specifically outline the steps for safely shutting down, isolating and securing machinery and equipment to control hazardous energy; MIS failed to conduct annual inspection of their lockout procedures; employees were not instructed in the purpose and use of lockout procedures; and machine guarding were found to be insufficient to protect the operator and other employees in the machine area from hazards.
Mount Laurel, NJ – Lockout/tagout training and machine guards could have saved the life of 23-year-old Dakota LaBrecque. That’s the finding of federal workplace safety inspectors following a 2017 worker fatality at Springfield Power LLC’s Springfield (NH) biomass plant.
EWP Renewable (doing business as Springfield Power LLC) faces $125,460 in fines following the employee fatality. OSHA has cited EWP Renewable Corp. for 25 safety violations after 23-year-old employee Dakota LaBrecque was pulled into a conveyor and died from his injuries.
In investigating the facility after the worker’s death, federal workplace safety inspectors found that the conveyor and other machinery lacked required safety guarding, and employees were not trained in lockout/tagout procedures to prevent equipment from unintentionally starting.
Springfield Power was also cited for fall hazards; electric shock and arc flash hazards; and a lack of adequate emergency evacuation, fire prevention, and hazardous energy control programs.
Rosemarie Cole, OSHA’s New Hampshire area director, stated that EWP Renewable’s “failure to protect employees resulted in a tragedy that could have been prevented if training was provided and machinery was appropriately guarded.”
OSHA requires equipment specific lockout procedures for each piece of equipment. These lockout/tagout procedures provide detailed instruction on how to isolate and lock each energy source for a given piece of equipment, helping to prevent the unexpected energization or startup of machinery and equipment. Martin Technical’s Rapid LOTO lockout procedure development program is designed to provide high quality procedures that are easy to follow.
Additionally, OSHA requires that employees be trained on lockout policies and procedures. Proper training ensures that the purpose and function of the lockout/tagout or 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 the workforce.
Martin Technical is a leading provider of practical safety and efficiency services that make industrial plants and facilities better, safer and more efficient. Our experts can help simplify the complex by applying real-world solutions for Lockout Tagout, Arc Flash, Electrical Safety, Risk Assessments, Training, Machine Safety & Safety Consulting Services. Contact a member of our professional safety services team today.
PETERS TOWNSHIP, PA – Cameron Allen Funk, 19, Greencastle, was found dead at Mellott Manufacturing, according to a release from Pennsylvania State Police, Chambersburg. Funk’s death was caused by a heavy piece of machinery falling on him.
Dispatchers identified the incident as an industrial accident with entrapment when first calling emergency personnel to the scene. An update soon after indicated there was no entrapment, but that a person was dead. State police arrived on scene around 3:00 PM on Wednesday, February 28.
State Police, the Franklin County Coroner’s Office and OSHA are investigating the incident. As of right now the death ruled an accident.
“The employer has no prior OSHA inspection history,” said Joanna P. Hawkins, deputy regional director for the U.S. Department of Labor, Philadelphia. “OSHA has up to six months to complete its investigation.”
Mellott Manufacturing makes conveyors and machines for the sawmill, pallet and woodworking industry. Sixty employees work there, per the company’s website.
This is the fourth death in Franklin County, PA in the last month from heavy machinery. Three people died earlier this month as a result of a crane accident at Manitowoc Crane in Shady Grove, just east of Greencastle.
Helena, AL – OSHA has proposed fines of $195,144 against ABC Polymer Industries LLC after an employee suffered fatal injuries when she was pulled into a plastics recycling machine at the Alabama facility in 2017. OSHA has determined that ABC Polymer’s machine guarding failure was “willful” and resulted in what they’ve called a “preventable tragedy.”
Following their investigation, OSHA levied one willful citation against ABC Polymers for failing to provide machine guards which protect employees from hazards like getting caught in machinery and amputation dangers. Of the 16 violations found at the AL facility, the willful machine guarding failure amounts to the largest portion of the proposed fine total. OSHA’s Birmingham Area Office issued a statement: “This company’s failure to install machine guarding equipment has resulted in a preventable tragedy.”
ABC Polymer Industries was also cited for repeat, serious, and other-than-serious violations, including failing to evaluate all powered industrial trucks every three years, not having machine specific lockout tagout procedures, and failing to install a rail system on both sides of an open platform.
According to the local Coroner’s office, the employee, Eva Saenz (age 45), was working next to rollers and bent over to cut a piece of plastic when she got pulled up into the rollers and equipment. She was pronounced dead at the scene by emergency responders.
ABC Polymer Industries makes polypropylene bulk storage bags and flexible containers for industrial markets. They are one of the largest suppliers of flexible intermediate bulk containers in North America as well as a manufacturer of polypropylene concrete fibers, and extruded PP products, including microsynthetic and macrosynthetic concrete fibers.
Canton, OH – A Fresh Mark employee died recently after his leg was caught in a waste grinder. Ohio’s Stark County Coroner’s Office stated that 62-year-old Samuel Martinez stepped into a chute and was caught in a waste grinder at the meat processing plant outside of Cleveland. Authorities say he died at the scene.
Fresh Mark Inc. supplies grocery stores, restaurants, and food service companies with bacon, ham, hot dogs and deli meats.
Fresh Mark officials are working with authorities to determine the cause of the accident.
Machine safety is crucial to workplace safety. Machine Safety and Lockout Tagout procedures, training, and awareness save lives, maintain production schedules, and keep machinery operational on a daily basis and are the foundation of a safe and efficient workplace.
Auburn, New South Wales – Craig Tanner (42), father of three, was killed in a tragic lockout accident at an industrial ink manufacturer in West Sydney, Australia. Two other workers were hospitalized after also being trapped in the vat of ink. The three workers were cleaning the ink vat as part of a routine maintenance check when they became stuck at the DIC Australia Ink factory.
The men became trapped when a mixing blade unexpectedly started up while the tank was being cleaned at the factory. Tanner was working at DIC as a contractor. He was inside and cleaning the tank when the blade started moving and cut into his legs.
The vat was a cylinder shape, about 26 feet high with a mixing blade inside. Rescuers used manhole access at the bottom of the of the confined space to reach the workers. “Ink slush” at the bottom of the vat plus the confined nature of the space made the rescue extremely difficult. It took four hours to free the men who were covered in black ink, which further complicated their rescue and treatment.
A thorough investigation will be made to identify cause(s) of the accident, with special attention paid to how the mixing arm of the large vat accidentally switched on when the men were inside it at the time.
Benson, MN – Minnesota safety regulators are investigating the death of a worker who fell into a hopper last week at the Benson Power plant in central Minnesota. The Benson biomass plant supplies power to Xcel Energy and has previously been fined by OSHA for hazardous energy concerns.
Rescue personnel arrived and administered lifesaving measures on the scene, and the victim was later transported to a local hospital where he died. Authorities have yet to release the man’s name.
The Benson (MN) facility (previously known as FibroMinn) was fined several times in the past for OSHA violations, including a $1,050 fee in 2012 for inadequate hazardous energy control and another $11,000 fine in 2012 for not providing employee right-to know information and poorly storing flammable liquids and exposed wiring.
Lockout/Tagout (LOTO) and Hazardous Energy Control or Control of Hazardous Energy all refer to the same standard of preventing unexpected start up or movement of equipment. The terms are used interchangably, although “Lockout” is more universally used in the United States as it is the term OSHA uses, while ANSI uses “Control of Hazardous Energy ” in their standard, which is used more often by non-US entities.
Benson Power burns turkey manure and wood chips to generate power for Xcel Energy, but is expected to shut down soon as a cost saving measure. MN state utility regulators approved Xcel’s plan to close the 55-megawatt Benson plant and two other biomass electricity generators. Xcel anticipates that the buyout will lead to long-term savings of $345 million.
Jeffersonville, IN – Lockout procedures and lockout training could have saved the life of former Autoneum employee Melissa Stephens. That’s the finding of the Indiana arm of OSHA which found five safety violations following the employee death in October at Autoneum’s Jeffersonville (IN) facility. The automotive manufacturer has been fined $224,000 for violations which IOSHA believes were entirely preventable: “had the appropriate safety precautions been in place, the fatality would not have occurred.”
Additional violations were classified as those with a “high probability of death or serious harm,” and totaled $14,000: failure to establish and maintain safe work conditions through employees’ exposure to being caught in rotating machine parts due to loose clothing; and lack of effective training on hazardous power sources, such as power from moving belts, that could cause employees to become caught or pinched by machinery.
Melissa Stephens (age 44) died after an incident with a machine at the Jeffersonville plant on Oct. 21, 2017. Preliminary cause of her death was ruled multiple blunt force trauma.
Autoneum is a Swiss-based company that manufactures GM and Ford parts and specializes in vehicle acoustic and thermal management systems. They have 50 locations in more than 20 countries and employ over 11,000 people.
Salinas, CA – Growers Street Cooling has agreed to pay $310,000 in costs and civil penalties as a result of legal action brought by the Monterey County District Attorney following a 2013 worker fatality at the Salinas-based produce-cooling company.
The death of Jose Juan Serrano (30) prompted the Monterey County District Attorney to file a worker fatality action against Growers Street Cooling. Serrano was working on a large piece of machinery at the Salinas facility in 2013 when a piece of equipment fell on him.
On the day of his death, Serrano was applying plastic covering to pallets of strawberries. Prosecutors said a portion of a pallet broke off and became lodged, causing the machine to stop automatically. However, Serrano failed to press the emergency-shutoff switch before dislodging the wood, which caused a large counterweight to fall and kill him instantly.
Serrano had been working for Growers Street Cooling as a machine operator for only 16 days prior to the accident. According to the DA, Serrano was assigned to operate a TransFresh Tectrol – a piece of heavy machine which wraps pallets of strawberries in plastic wrap and uses hydraulics to squeeze the strawberry containers in on the pallet for easier shipping and handling. As the compression occurs, a large counterweight on the opposite end balances the machine.
The day Serrano was killed, he was operating the Tectrol machine alone. When a wooden pallet became lodged inside the machine and caused it to jam, Serrano climbed behind the machine and used a crowbar to release the wood. Unfortunately, he did not de-energize, turn off the machine, or perform any lock-out/tag-out procedures. As soon as the jam was cleared, the machine reactivated and a large counterweight crushed him against the wall.
California state law and federal safety standards require businesses using any kind of heavy machinery to train workers in proper lockout/tagout procedures to minimize accidental injury and death. Lockout procedures provide detailed instruction on how to isolate and lock each energy source for a given piece of equipment, thereby helping to prevent the unexpected energization or startup of machinery and equipment, or the release of hazardous energy during service or maintenance activities. The Monterey DA found that Growers Street Cooling never trained Serrano on lockout procedures before assigning him to operate the machine which killed him.
Additionally, the DA said that Growers Street Cooling did not maintain a written lockout/tagout policy or training program, and charged that they systematically violated worker safety laws. OSHA CFR 29 1910.147 provides regulations on LOTO (LockOut/TagOut) and 25 states have their own approved lockout tagout and worker safety standards. Often times, the most overlooked aspect of a lockout tagout program is failure to provide equipment specific lockout procedures. A general corporate written policy does not meet the requirements of OSHA.
The Monterey County court-ordered injunction requires Growers Street Cooling to maintain and implement written hazardous energy control procedures for all heavy machinery and maintain and implement written training programs for lockout/tagout procedures. Additionally, the Monterey DA ordered the company to conduct annual inspections of its lockout/tagout procedures and not assign employees to operate any machinery unless they are trained about the machine’s hazards. According to the DA, Growers Street Cooling has recently provided proof that compliance is underway.
Watkins, MN – A maintenance worker was killed last week when he became pinned in the industrial machinery he was working on at International Barrier Technology. Rescue workers freed the man from the equipment and began life saving efforts, but sadly, he died at the scene.
The worker was identified as Todd Shoutz, 51, of Litchfield (MN). Shoutz, a maintenance worker at Barrier Technology, was reportedly working on a machine and became pinned in a piece of equipment. Despite the efforts of emergency teams on the scene, the employee succumbed to his injuries after being freed from the equipment.
The International Barrier Technology plant in MN processes building materials to make them fire-resistant.