Two Fatalities in Last Month for Tyson Factories

Eufaula, AL- Within the last month, there have been two fatalities in Tyson factories within the United States. A worker died on March 2nd at a Keystone Foods chicken processing plant in Eufaula, AL while cleaning a piece of equipment.

Barbour County Coroner Chip Chapman said in the report that 39-year-old contractor Carlos Lynn became “caught in a pinch-point of the equipment,” and that the cause of death was a decapitation. The official told the broadcaster that the equipment involved in the incident was a chiller.

Tyson Foods, the owner of the plant, told WRBL that operations halted at the facility the day following the industrial accident.

“We’re investigating an accident at our Eufaula, AL facility yesterday that involved a worker employed by an outside contractor and will provide more information when we can,” Tyson Foods said in a statement printed by the station. “We’re grateful for the swift response and assistance of local emergency personnel.”

Another worker died in a Tyson plant March 23rd in Garden City, Kansas.

Deputies responded to the plant for a man not breathing. EMS transported the man, identified as 30-year-old Kendrick Gregory of Garden City, to the hospital where he died.

The Finney County Sheriff’s Office said their initial investigation showed that Gregory was doing maintenance on the harvest assembly line when he was pulled up by harness against a takeaway belt. Another co-worker was able to cut him free.

These two fatalities in Tyson factories could have potentially been prevented with proper and secure Lockout Tagout procedures. Lockout Tagout isolates and locks each energy source for a given piece of equipment, helping to prevent the startup of machinery or equipment that may result in injuring a worker.

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Worker Seriously Injured in Industrial Accident in Steel Mill

Gary, IN- A worker was seriously injured in an industrial accident at Gary Works Wednesday.

The steelworker suffered multiple injuries and was taken to Methodist Hospitals Northlake Campus in downtown Gary. Information on his condition was not immediately available but he is expected to survive.

“We had a worker that got seriously hurt with several injuries but none life-threatening,” United Steelworkers District 7 Director Mike Millsap said. “All I know is he is a maintenance technician and was working on (a blast furnace) and he got hit by something.”

U.S. Steel’s OSHA Recordable Incident Rate has been 0.14 per 200,000 hours so far this year, down from 0.17 in 2017.

steel mill industrial accident Though the United Steelworkers union and steelmakers have worked for years to prioritize workplace safety at the industrial mills, the hulking factories where metal is forged post many inherent hazards that include hot temperatures, catwalks over great heights, and moving equipment that weighs tons. Steelworker ranks as the sixth most deadly job nationally, according to the Bureau of Labor Statistics.

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Family Sues GE Appliances after Worker’s Death

Kentucky, USA- The family of a Kentucky man killed in a workplace incident has filed a lawsuit against his employer, GE Appliances, as well as other parties.

Steve Herring, who has worked for GE Appliances for more than two decades, died in February after being pinned by machinery while working on a refrigerator-building assembly line. News sources are reporting that the state OSHA’s investigation into the workplace incident found that it could have been caused by an inadvertent activation of an improperly positioned gate interlock control.worker killed in machine incident

The lawsuit filed in Jefferson Circuit Court last week names General Electric Company, Design Safety Engineering Inc., Doerfer Corperation, Doerfer Acquisition Company, JR Automation Technologies LLC, Haier US Appliance Solutions Inc. and Kentucky resident Mark Miller as defendants.

The lawsuit claims that the assembly line Herring was working on was “unreasonably dangerous” and in “defective condition.” It alleges that there were no instructions or warnings about the hazards on the line — and that the companies being sued were aware of the defects. The suit requests punitive and compensatory damages.

According to Kentucky OSHA, GE made changes to the safety programming on an assembly line that was identical to the one at which Herring was pinned following a 2014 incident. However, the company didn’t fix the line where Herring worked until after Herring died.

An inspection conducted by the agency after the fatality resulted in GE being cited for seven safety violations and fined $98,000, which the company is appealing.

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Worker Deaths Spur MSHA Safety Alert on Electrical Hazards

Arlington, VA- Prompted by reports of three recent fatalities involving electricity, the Mine Safety and Health Administration has issued a safety alert.

Electricity has killed three people in the mining industry since August 7, 2019.

An electrician contacted an energized component of a 4,160 VAC electrical circuit while adjusting the linkage between the disconnect lever and the internal components of the panel that supplied power to the plant feed belt motors. A contract electrician contacted an energized 120 VAC conductor while working inside a fire suppression system’s electrical
panel. An electrician contacted an exposed energized connector while troubleshooting a 995 VAC flooded bed scrubber motor circuit on-board a continuous mining machine.Electrical Safety Alert

MSHA offers numerous best practices for electrical incident prevention. Among them:

-Perform lockout/tagout procedures on circuits before working on electrical equipment.

-Don’t rush, and never work alone. Talk with co-workers and confirm your plan is safe.

-Identify and control all hazardous energy sources before conducting tasks, and follow safe work procedures.

-Train miners on equipment they may use.

-Always perform troubleshooting without power. If you must troubleshoot an energized circuit, use properly rated personal protective equipment to prevent hazards.

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Contractor fined $662K after Electrical Shock Injury

Fort St. John, British Colombia – Peace River Hydro Partners has been fined $662,102.48 by WorkSafeBC. The fine was imposed on August 21, 2019, after a worker sustained an electrical shock injury. A worker was able to access the main circuit breaker in a high-voltage electrical cabinet for tunneling equipment.

According to WorkSafeBC, the main electrical breaker extensions on the exterior cabinet door were not functioning, the de-energization switches had been circumvented and the main breaker switch-box isolation covers were in disrepair.Electrical worker operates on wires

WorkSafeBC staff also determined that it was a standard work practice at this site to access the main circuit breaker without following lockout procedures.

A stop-use order was issued for the tunneling equipment because Peace River Hydro Partners failed to ensure its equipment was capable of safely performing its functions, and was unable to provide its workers with the information, instruction, training, and supervision necessary to ensure their health and safety.

WorkSafeBC says these were both repeated violations.

This is the largest fine WorkSafeBC can issue under B.C. legislation.  The report from WorkSafeBC did not disclose the condition of the worker or the exact date of the incident.

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Heavy Fines for Machine Safety Hazards at WI Facility

machine safety hazardsEau Claire, WI – A cookie dough manufacturing facility in Eau Claire, Wisconsin faces $782,526 in penalties for “continually exposing employees to machine safety hazards.” Choice Products USA LLC was cited for similar machine safety violations following an OSHA inspection in 2016, and as a consequence has now been placed in OSHA’s severe violator enforcement program.

Choice Products was cited for five egregious willful violations for their failures to implement an effective lockout/tagout (LOTO) program. OSHA also found that employee training on lockout/tagout was inadequate to prevent worker’s from unintentional contact with machinery during service and maintenance activities. Federal workplace safety inspectors also determined that Choice Products failed to install proper machine guarding.

Choice Products had been cited in a 2016 inspection for exposing employees to similar lockout/tagout and machine safety hazards.OSHA’s severe violator enforcement program  targets employers who have demonstrated what they term an “indifference” workplace safety obligations by committing “willful, repeated, or failure-to-abate violations.”

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$132K in OSHA Fines for GA Countertop Manufacturer

osha fines manufacturerDecatur, GA – Last week OSHA announced $132,604 in penalties for safety violations documented at Atlanta Kitchen LLC. According to their press release, Atlanta Kitchen employees were exposed to health hazards from silica used in the facility and safety hazards from amputation risks and electrical dangers found at the Decatur kitchen countertop manufacturer.

Federal workplace safety investigators claim that Atlanta Kitchen exposed workers to unsafe levels of silica. Silica is a mineral used in construction materials which, according to OSHA, can be dangerous if inhaled. OSHA found the manufacturer failed to conduct monitoring to determine employees’ exposure to silica.

OSHA also found that employees were at risk of electrical shocks, and that Atlanta Kitchen did not put safeguards on dangerous equipment. Lapses in machine safety and/or machine guarding create amputation hazards around machinery in workplaces.

In addition, Atlanta Kitchen was cited for Lockout/Tagout failures. OSHA documented failures to develop written procedures for a hazardous energy control and failures in implementing the facility’s lockout/tagout program.

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Lockout Accident Kills Contractor at IN Ethanol Plant

Bluffton, IN – Valero Renewable Fuels was the site of a workplace death this month caused by a lockout accident. A 42-year-old contractor was found dead at the plant, his body trapped in a piece of machinery.

Ryan West became trapped in machinery while working as a contractor at the Valero Renewable Fuels ethanol plant in Bluffton, IN. Local police have stated that Valero employees called 911 saying they couldn’t find West and feared he had been in an accident. When emergency responders arrived, they found his body caught in a piece of equipment. West was employed by Diversified Industrial Services, a grain equipment supplier, and was performing maintenance work on a large auger.

Lockout procedures provide detailed instruction on how to isolate and lock each energy source for a given piece of equipment, helping to prevent the startup of machinerylockout accident or equipment that may result in worker injury. Lockout/Tagout is also known as LOTO or Control of Hazardous Energy. These terms refers to the same safety standard and procedures and practices designed to prevent the unexpected start up or movement of equipment, especially crucial during maintenance or service work.

A study conducted by the United Auto Workers revealed that 20% of fatalities among their membership were attributed to inadequate hazardous energy control or lockout/tagout (LOTO) procedures. An estimated 3 million workers service equipment as a part of their work duties. These employees face the greatest risk of injury if lockout/tagout is not properly implemented. Compliance with the lockout/tagout standard is said to prevent approximately 120 fatalities and 50,000 injuries each year at facilities across the US.

Indiana’s arm of OSHA is investigating this latest incident, while local news media are reporting a history of safety violations at the ethanol plant. Earlier this year, Valero’s Bluffton plant was fined for “serious safety violations” involving machinery safety and lockout/tagout.

Tragedies such as this lockout accident in Indiana are preventable. Please contact a Lockout Specialist at Martin Technical today to discuss how we can help to make your plant or facility better, safer, and more efficient with the support of our suite of Lockout Tagout, Arc Flash, Electrical Safety, Risk Assessment, Training, Machine Safety, and Safety Consulting services.

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Failure to Lockout Machine Breaks Worker’s Arm and Prompts $100+ in Fines

Napoleon, OH – Failure to lockout a machine at Silgan Containers Manufacturing Corp. was found to have been the cause of a worker’s broken arm. Federal workplace safety agents inspected the aluminum can manufacturing facility following a lockout/tagout accident, and Silgan Containers now faces proposed penalties of $106,080 for one repeat and three serious safety violations of lockout/tagout standards.

The fines were the result of an OSHA investigation triggered by an employee who suffered a broken arm while servicing a machine at Silgan Containers’ Ohio facility. An estimated 3 million workers service equipment at their jobs. These employees face the greatest risk of injury if lockout/tagout (LOTO) is not properly implemented. Compliance with the federal lockout/tagout standard prevents approximately 120 fatalities and 50,000 injuries annually in this country alone, and saves an average of 24 workdays that would be needefailure lockout machined for recuperation in the case of a lockout accident.

The single repeat and three serious safety violations were issued for failure to train employees on energy control procedures, perform periodic inspections of energy control procedures, and failure to provide adequate machine guarding at a pinch point. Lockout/Tagout (also known as LOTO) refers to a system of controlling hazardous energy in an effort to prevent the unexpected start up or movement of equipment, which especially necessary to reduce worker exposure to injury during service and maintenance activities.

According to OSHA’s Area Director, “Employers are required to train their employees on proper lockout/tag out procedures to prevent the release of stored energy or unexpected startup of equipment.”

It has been reported that OSHA cited Silgan Containers for similar violations at its Wisconsin plant in 2015.

Contact a Lockout/Tagout Specialist at Martin Technical today to discuss how we can provide practical safety and efficiency services to make your plant or facility a better, safer, and more efficient place to work.

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Machine Guarding Failures Lead to $687,650 in Penalties

Strattanville, PA – A 2018 amputation due to machine guarding failures at a PA modular home manufacturing facility lead to an OSHA investigation which revealed numerous workplace safety violation and resulted in a staggering $687,650 in penalties.

Last month, OSHA issued willful and serious citations to Champion Modular Inc. for failures in the areas of machine guarding, fall protection, electrical safety, hazard communication, lockout/tagout (LOTO), combustible dust, and training.

On the topic of machine guarding failures, OSHA’s local Area Office Director stated that “moving machine parts have the potential to cause severe workplace injuries if they are not safeguarded…Employers’ use of machine guards and devices is not optional. Employers are legally responsible for ensuring that machine operators are protected.”

In the investigation triggered by the November 2018 amputation, OSHA documented Champion Modular employees’ exposure to numerous workplace safety hazards. Some of the machine guarding failures included damaged plastic guards on a table saw which exposed employees to the saw blade, work rests on grinding machinery not adjusted properly, a grinder was being used without the proper guard, and a hand-fed circular ripsaw found without a spreader and missing a kickback device.

Hazards caused by combustible dust were also evident at the Champion Modular machine guarding failuresfacility. Combustible dust was found to have accumulated in the higher areas of the facility, which posed an increased risk of fire. Additionally, a dust collector that was not equipped with devices and systems to prevent fire was noted as having the potential to expose employees to fire, burn, and deflagration hazards.

Violations of federal Lockout/Tagout (LOTO) machine safety standards was another a part of the citations and penalties OSHA issued. OSHA inspectors found equipment and machinery at the manufacturing facility that was missing lockout/tagout procedures altogether. Additionally, Champion Modular allegedly failed to perform periodic inspections of machine servicing and equipment maintenance procedures.

OSHA investigators also noted electrical safety violations and hazards at the PA manufacturing facility. Electrical equipment was found installed and/or in use outside of the intended purpose, not in compliance with instructions. Inspectors noted duct tape and electrical tape being used to cover up and hold together a damaged control pendant.

Violations and fines of this magnitude are avoidable through conscientious workplace safety programs – 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 simplify complex workplace safety practices by applying real-world solutions for Lockout Tagout, Arc Flash, Electrical Safety, Risk Assessments, Training, Machine Safety & Safety Consulting Services.

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