.5M in Fines for Lockout, Training, and Machine Safety Violations

lockout trainingMacon, GA –  22 citations were announced last week for Lockout, Training, and Machine Safety violations found at a Georgia tire plant. The violations were documented as part of an OSHA follow-up inspection at Kumho Tire Georgia.

Three companies face a collective $523,895 in fines for safety violations allegedly found at the Kumho Tire Georgia plant in Macon: Kumho Tire Georgia Inc., Sae Joong Mold Inc., and J-Brothers Inc. The large fine represents 12 serious, nine repeat, and one other-than-serious workplace safety violations.

The 22 citations announced May 29 are the result of violations documented in a Nov 2018 follow-up inspection conducted at the Kumho Tire facility. OSHA has stated that the follow-up inspection was initiated after the agency failed to receive documents from Kumho indicating that it had abated violations found during a 2017 inspection. As a result of this history of violations, OSHA also announced that Kumho Tire Georgia Inc. has been placed in the Severe Violation Enforcement Program (SVEP).

A portion of the violations documented Kumho were for Lockout/Tagout (LOTO) failures. OSHA cited failures to follow hazardous energy-control procedures (also known as Lockout Procedures or LPs) when Kumho employees performed machine service and maintenance duties. Additionally, OSHA found a failure to train employees on the use and benefits of these energy-control or lockout/tagout procedures.

Additionally, there were failures to provide machine guards on some equipment in use at the Kumho plant. OSHA’s Atlanta-East area director stated the dangers associated with these violations: “This employer exposed workers to multiple safety and health deficiencies that put them at risk for serious or fatal injuries.”

Beyond the Kumho violations, OSHA also issued fines of $9,093 to Sae Joong Mold Inc. for using damaged slings and for electrical hazards at the Macon plant. J-Brothers Inc. was the third company named in these citations. J-Brothers portion of the fine was $7,503 for failure to mount portable fire extinguishers and failure to perform annual maintenance on fire extinguishers.

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Sawmill Fatality Reveals Numerous OSHA Violations

St. Joseph, MO – Following a fatal workplace accident at a Missouri sawmill, OSHA has issued $199,183 in fines for 14 serious and two repeat safety violations at American Walnut Co.

The fatal workplace accident occurred on March 12 of 2018 when American Walnut employee Joshua Hill (38) came into contact with operating equipment. Hill reportedly fell into the chute of a grinder and was killed. OSHA found that Hill was not attached to a tether line when he fell 10 feet into the grinder chute.

Following the sawmill fatality, federal workplace safety investigators identified 14 serious and two repeat safety violations at American Walnut Co. including failure to evaluate job hazards, control hazardous energy, and ensure adequate machine guarding. Additionally, workers were found to have been exposed to hazards associated with falls, ladders, and electrical safety.

Noise hazards observed at American Walnut prompted a separate investigation. OSHA inspectors documented that American Walnut employees were exposed to hazards associated with noise, combustible dust, and chemicals within the St. Joseph (MO) facility.

OSHA’s Kansas City Area Office Director stated tsawmill fatalityhat “Employers must continually evaluate job hazards and ensure safety guards are in use to protect workers from known hazards in their facilities.”

The safety of American workers is always our driving motivation at Martin Technical. Anyone with questions about federal safety standards and/or workplace safety hazards should contact a member of our Industrial Safety Team. Martin Technical is a leading provider of practical safety services that make industrial plants and facilities better, safer, and more efficient. Our experts apply real-world solutions to create effective safety and health programs across this country and beyond.

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Serious Safety Violations Found at IN Bottling Plant

Lapel, IN – Three serious safety violations were found at the Owens-Illinois Bottling facility in Lapel, Indiana. The Indiana Occupational Safety and Health Administration (IOSHA) issued $13,500 in fines for safety violations inspectors which it determined could have led to serious worker injury.

In an investigation last fall, IOSHA found serious safety violations including insufficient employee training and failure to lockout an electrical box while it was in the process of being repaired.serious safety violations

The serious safety violation related to Lockout/Tagout (LOTO) states that lockout “procedures were not developed, documented and utilized for the control of potentially hazardous energy,” during machine maintenance at Owens-Illinois’ Indiana bottling plant.

Additionally, Owens-Illinois was found to have failed to properly train employees on lockout/tagout and machine safety. OSHA requires that employers provide training to ensure that the purpose and function of the energy control or LOTO programs are understood by employees.

The third serious safety violation concerned unused openings in electrical boxes, raceways, and other electrical equipment which were not closed when IOSHA conducted their investigation. Safety inspectors cited Owens-Illinois for failure to protect employees and equipment from exposure to electrical hazards.

Electrical safety, Lockout/Tagout, and training on both of these important components of workplace safety are at the heart of Martin Technical’s suite of safety services. 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, and Safety Consulting Services. Please call a member of our Industrial Safety Team today to discuss how to improve safety and efficiency at your facility.

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Moving Parts Injure 2 at AL Packaging Plant

Mobile, AL – OSHA has issued fines of over $75,000 to an Alabama packaging manufacturer for failing to protect employees from the hazards of moving parts. Ampac Mobile Holdings LLC (operating as ProAmpac) was found to have been exposing employees to caught-in and struck-by hazards at their Mobile (AL) facility. Federal workplace safety investigators are charging $75,156 in penalties for inadequate machine guarding and lockout/tagout procedures violations.

OSHA was alerted to the Ampac/ProAmpac facility after an employee suffered a severe hand injury as a result of getting caught in a piece of equipment. In a moving partsseparate accident, an Ampac employee’s finger was lacerated when struck by moving machine parts.

In the course of their investigation, OSHA determined that Ampac failed to use proper machine guarding measures, and failed to control hazardous energy by implementing effective lockout/tagout procedures.

Unfortunately, these two accidents could have been prevented. As OSHA’s Acting Mobile Area Office Director stated, “A comprehensive safety and health program, includ[ing] an evaluation and correction for amputation hazards, could have identified and prevented these injuries.”

An estimated 3 million American workers service equipment in the course of their jobs. These employees face the greatest risk of injury if lockout/tagout is not effectively implemented. Compliance with the federal lockout/tagout standard prevents approximately 120 fatalities and 50,000 injuries each year. Additionally, it has been estimated that workers injured on the job from exposure to hazardous energy lose an average of 24 workdays for recuperation.

For these reasons and more, please contact a Lockout and Machine Safety Expert at Martin Technical today if you have any concerns about the safety of equipment and employees at your facility.

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Willful Lockout Violations Found at LA Noodle Factory

willful lockout violationsLos Angeles, CA – An amputation at an LA noodle factory prompted a Cal/OSHA investigation resulting in $305,685 in fines for two employers. The amputation occurred in 2018 when a temporary worker was cleaning machinery and lost two fingers at JSL Foods Inc.

The injured man was a temporary worker placed at the JSL food manufacturing facility by Priority Workforce. The worker was cleaning a dough rolling machine when his left hand was pulled partway into the moving rollers, amputating two fingers on Oct. 2, 2018.

Cal/OSHA found JSL liable for one willful repeat serious violation and one willful repeat serious accident-related violation for failing to follow lockout/tagout procedures. JSL Foods has been fined $276,435 in proposed penalties for a total of seven violations. According to Cal/OSHA, JSL Foods was cited twice in 2015 for the same violations.

Three additional serious violations were cited against Priority Workforce, the employer who assigned the temporary worker to JSL Foods. Cal/OSHA found Priority Workforce failed to establish, implement, and maintain an effective Injury and Illness Prevention Program, failed to ensure employees were effectively trained, and failed to ensure machinery was adequately guarded.

According to Cal/OSHA, their investigation found that “the machine had not been adequately guarded to prevent fingers from entering pinch points, [nor had it been] de-energized and locked out to prevent movement while the worker was cleaning it…Neither employer had trained the worker to follow lockout/tagout procedures before cleaning the equipment.”

Lockout/tagout procedures (also known as LOTO) provide detailed instruction on how to isolate and lock each energy source for a given piece of equipment. Workers who are trained in lockout can use these procedures and practices to prevent injuries that might otherwise occur when machinery or equipment starts up unexpectedly during cleaning or maintenance work. Martin Technical’s certified lockout technicians and safety experts work together to provide your safety team with the most effective and accurate lockout program in the industry.

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Amputation Due to Lockout Failures Nets $160K in OSHA Fines

Picayune, MS – OSHA has fined Heritage Plastics $159,118 after finding willful violations of federal workplace safety standards during an investigation triggered by an amputation accident. The Occupational Safety and Health Administration documented failures in lockout/tagout, failures to train employees on LOTO, and failures to install machine guards at the MS PVC conduit, fittings and pipe manufacturer.

A Heritage employee lost four fingers in November of last year when a mixing machine unexpectedly started while the worker was removing material from itamputation due to lockout. OSHA found that the accident was preventable and concluded that it was due to a failure to use a lockout device or properly train its workers on lockout/tagout (LOTO). Heritage was also cited for failing to install adequate machine guarding.

Lockout/tagout is a workplace safety system designed to prevent the startup of machinery or equipment that may result in worker injury. Lockout (or LOTO) procedures provide detailed instruction on how to isolate and lock each energy source for a given piece of equipment. To be compliant with federal energy control standards, employers must establish a lockout program and follow procedures for affixing appropriate lockout or tagout devices to energy isolating devices. Taking steps to prevent the unexpected energization, start up, or release of stored energy prevents employee injury. 
Training employees on the exact protocol to control hazardous energy is a fundamental part of a successful lockout program. Employee must be trained to ensure that the purpose and function of the energy control program is understood, and so that they possess the knowledge and skills required for the safe application, usage, and removal of energy control/lockout devices.
A statement made by OSHA‘s Jackson (MS) Area Office Director emphasized how this accident could have been prevented: “Proper safety procedures, including the effective lockout of all sources of energy, could have prevented this employee’s serious injury…Employers must take proactive steps to develop and implement energy control procedures to minimize risk to their employees.”

Contact a member of our industrial safety team today to discuss how Martin Technical can improve accident prevention measures at your facility.

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Death Due to Willfully Unguarded Machinery Leads to $250K Fine

Santa Ana, CA – Cal/OSHA announced fines of over a quarter of a million dollars against Aardvark Clay & Supplies this week. The fines are the result of Cal/OSHA’s investigation into a 2018 worker death at the facility which has been attributed to willful failure to properly guard equipment and lack of lockout/tagout training.

Enrique Garcia-Vazques (18) died in a workplace accident at the Santa Ana (CA) clay products business on Sept. 20, 2018 when he became fatally entangled in a clay manufacturing machine called a pug mill. According to reports, Garcia-Vazques was packaging clay blocks after they were cut to size when he became caught in the unguarded mixing blades of the machine as he attempted to identify why the clay stopped traveling through the extruder. According to Cal/OSHA’s report, Enrique Vasquez Garcia sustained amputation, puncture and asphyxia-related injuries in the workplace accident.

Cal/OSHA found that machine safety guards had been purposely removed from the industrial mixer and that the worker had not received training on the machine prior to the accident. Local emergency responders tried to free Garcia-Vazques from the equipment, but sadly, in the end he was declared dead at the scene.

According to said Cal/OSHA’s statement, “Pug mills have rotating blades that can cause amputations and fatally injure employees…Employers must ensure all machinery and its parts are properly guarded, and employees are effectively trained to prevent tragic accidents like this.” Aardvark Clay & Supplies uses the industrial pug mills to manufacture and mix clay.

Investigators with California’s Division of Occupational Safety and Health found that all four of the pug mills in Aardvark’s Santa Ana shop had unguarded openings exposing employees to the moving parts. This is in direct violation of safety regulations requiring mixers to have a cover to prevent employees’ hands from entering the machine during operation. This willful failure to guard machinery was cited as one of the willful-serious violations for which Aardvark is being held accountable.

Five violations were levied against Aardvark Clay & Supplies, along with a grand total of $250,160 in proposed penalties. Among the violations, one was categorized as willful-serious accident-related, one was classified as willful-serious, two were deemed serious, and one was general. Accident-related violations are cited when the injury, illness, or fatality is caused by the violation. Serious violations are cited when there is a “realistic possibility” that death or serious harm could result from the hazard created by the violation.

The willful-serious violations were cited for the Aardvark’s failure to guard machine openings and points of operation. The serious violations identified hazards from the unguarded cutting portion of the clay machine and failure of the employer’s safety program to identify unsafe conditions, implement corrective procedures, and effectively train employees on work-related hazards.

The state of California requires employers to conduct and document inspection of safety hazards as a part of their state-mandated Injury and Illness Prevention Program. Employers whose workplaces feature machines with moving parts, such as mixers, are also required to train their employees in Machine Guarding and Lockout/Tagout in an effort to prevent exactly the type of accident that killed Garcia-Vazques.

Aardvark Clay & Supplies was found to have failed to effectively train workers on the hazards involved with operating their machinery, and then found remiss in identifying and correcting their machine safety hazards. Machine safety guards were provided by equipment manufacturer, but Cal/OSHA found that Aardvark had removed the guards. Investigators documented evidence of fabricated guards having been added to the machines at some point in their operation, but these were found to have been later removed when the employer “believed they interfered with the rate of production.”

For this reason, Cal/OSHA categorized Aardvark’s violation as willful. Willful violations are cited when the employer is aware of the law and still violates it or is aware of a hazardous condition and takes no reasonable steps to address it.

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OSHA’s Top 5 Most Cited Violations 2018

For the fifth year running, lockout/tagout is among OSHA’s top five most cited sources of workplace safety violations.

According to statistics for the 2018 fiscal year, Lockout/Tagmost cited violationsout was ranked #5 in most cited OSHA violations, was also the fifth most common source of ‘serious’ violations, and ranked #2 among ‘willful’ violations issued.

The top 5 most cited violations reported for 2018 were: 1) Fall Protection, 2) Hazard Communication, 3) Scaffolding, 4) Respiratory Protection, and 5) Lockout/Tagout.

Within and among the 2,923 total lockout violations cited in 2018, the top five sections cited were:

  1. Procedures shall be developed, documented, and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered in section 1910.147(c)(4)(i). [20% of lockout citations referenced this violation.]
  2. The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements
  3.  of standard 1910.147(c)(6)(i) are being followed. [11.7% of lockout citations referenced this violation.]
  4. The employer shall establish a program consisting of energy control procedures, employee training  and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup, or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative. [11.3% of lockout citations referenced this violation.]
  5. The employer shall provide training 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 the employees. [9% of lockout citations referenced this violation.]
  6. Affected employees shall be notified by the employer or authorized employee of the application and removal of lockout devices or tagout devices. Notification shall be given before the controls are applied, and after they are removed from the machine or equipment. [6% of lockout citations referenced this violation.]

Martin Technical’s team of industrial safety professionals works every day to promote worker safety and facilitate a culture of safety at facilities around the globe. Our RAPID LOTO™ program is a proprietary system developed by Martin Technical that allows faster and more accurate turnaround time for the development of LOTO (lockout/tagout) procedures and placards.

Rapid LOTO is the most advanced and comprehensive program in the industry. Martin Technical leverages our experience in maintenance and safety with innovative technologies to provide a robust yet easily understood system designed for efficient implementation.

Our professional lockout technicians use Rapid LOTO lockout software and an in-field process to label equipment. Placards are developed and reviewed daily, keeping the information at hand relevant and fresh. Martin Technical takes pride in offering a service that can place lockout placards on your equipment as soon as the next day.

Contact a lockout expert today to see how we can help you institute a written lockout program that will benefit the health of your workers, your machinery, and your business.

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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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Employee Loses Arm While Cleaning Machinery

Elysburg, PA – OSHA has proposed $112,523 in penalties after finding that lockout/tagout failures lead to an employee’s arm being amputated while cleaning machinery.

OSHA has cited Toy Factory TX LLC for workplace safety violations after investigating the circumstances that lead to an employee’s arm being amputated while cleaning machinery earlier this year. OSHA has proposed $112,523 in penalties for the company’s failure to develop acceptable procedures to prevent the release of hazardous energy; failure to apply lockout devices; and failure to train employees on lockout/tagout procedures.

OSHA’s local area office director stated that Toy Factory’s “failure to use appropriate machine locking devices resulted in a serious injury that could have been prevented.” Machine locking devices are an important part of an industrial Lockout/Tagout program. Lockout devices are mechanical means of locking a machine in a position that prevents energization of a machine, equipment, or a process. Energy-isolating devices cleaning machineryare applied to machinery during maintenance or while employees are otherwise servicing equipment to prevent unexpected startup and thereby avoid employee injury.

Nearly 3 million workers service equipment and these employees face the greatest risk of injury if lockout/tagout is not properly implemented. Compliance with the federal 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.

Federal workplace safety inspectors determined that Toy Factory TX LLC (doing business as The Toy Factory LLC) failed to develop acceptable written lockout/tagout procedures, failed to apply lockout devices, and failed to train employees on lockout/tagout. OSHA requires that employees be trained on lockout policies and procedures. Appropriate training ensures that the purpose and function of the energy control program are understood by employees and that employees gain the knowledge and skills required for the safe application, usage, and removal of the energy controls.

The Elysburg (PA) facility is one of several owned by Texas-based Toy Factory TX which manufactures stuffed toys intended for use as rewards and prizes at amusement parks, entertainment game centers, and crane machines.

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