20 frequently missed hazards in manufacturing from 2016

20 Frequently Missed Hazards in

Manufacturing from 2016John Newquist813-354-6853

johnanewquist@gmail.com

.151(c)

.178(l)(1)(i)

.23(c)(1)

.303(b)(2)

.147(c)(4)(i)

.212(a)(3)(ii)

.134(e)(1)

.1200(h)(1)

.212(a)(1)

.1200(e)(1)

KN

DS

JO

IZ

OZ

540

544

603

603

618

626

688

1339

1563

1743

Most Frequently Cited Serious Violations in General Industry 2015

2

Overall 1910 M

FCHAZARD COMMUNICATION – WRITTEN PROGRAM

MACHINE GUARDS – GENERAL

HAZARD COMMUNICATION – INFORMATION AND TRAINING

EYE & BODY FLUSHING FACILITIES

ELECTRICAL – PROPER INSTALLATION & USE OF EQUIPMENT

WALKING/WORKING SURFACES – OPEN-SIDES FLOORS

RESPIRATORS – MEDICAL EVALUATIONS

LOCKOUT/TAGOUT – DEVELOPED PROCEDURES

POWERED INDUSTRIAL TRUCKS – COMPETENCY TRAINING

MACHINE GUARDS - POINT OF OPERATION

29 C

FR 1

910

SUBP

ARTS

1 - Lockout Cleaners• Probable OSHA Penalty: $6,200• Regulations: 1910.147(c)(4)(i) - Procedures

shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section

Lockout Cleaners• Probable OSHA Penalty: $6,200• Regulations: 1910.147(c)(7)(i) - 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 employees.

2 - Lockout Periodic Audits• Probable OSHA Penalty: $124,000• Regulations: 1910.147(c)(6)(i) - The employer

shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements of this standard are being followed.

Sep 2016• Amputation• Hit Off Switch

Sep 2016• Went to lock out.• 480 panel • Lockout up in air• Audit would have caught the issues

3 – Conveyor Guarding• Probable OSHA Penalty: $7000• Regulations: 1910.212(a)(1) - Types of

guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.

4 – Vertical Mill Guarding• Probable OSHA Penalty: $7000• Regulations: 1910.212(a)(1) - Types of

guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.

5 – Lathe Guarding• Probable OSHA Penalty: $12.400• Regulations: 1910.212(a)(1) - Types of

guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.

6 – Table Saw Guarding• Probable OSHA Penalty: $12,400• Regulations: 1910.213(d)(1) - Each circular

crosscut table saw shall be guarded by a hood which shall meet all the requirements of paragraph (c)(1) of this section for hoods for circular ripsaws.

7 – Hydraulic Press Guarding • Probable OSHA Penalty: $12,400• Regulations: 1910.212(a)(3)(ii) - The point of

operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefor, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.

8 – Dock Fall• Probable OSHA Penalty: $5500• Regulations: 1910.28(b)(1) - the employer

must ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2 m) or more above a lower level is protected from falling.

9 – Stairs with no Midrails • Probable OSHA Penalty: $5500• Regulations: 1910.28(b)(11)(ii) - Each flight

of stairs having at least 3 treads and at least 4 risers is equipped with stair rail systems and handrails.

10 – Roof is Weak• Probable OSHA Penalty: $4000• Regulations: 1910.22(b) - Loads. The

employer must ensure that each walking-working surface can support the maximum intended load for that surface.

11 – Live Parts• Probable OSHA Penalty: $5500• Regulations: 1910.303(g)(2)(i) - Except as

elsewhere required or permitted by this standard, live parts of electric equipment operating at 50 volts or more shall be guarded against accidental contact by use of approved cabinets or other forms of approved enclosures

12 – Panel Blocked• Probable OSHA Penalty: $5500• Regulations: 1910.303(g)(1) - Space about

electric equipment. Sufficient access and working space shall be provided and maintained about all electric equipment to permit ready and safe operation and maintenance of such equipment. Table S-1 requires 3 feet of clear space.

13 – Compactor Confined Space Sign • Probable OSHA Penalty: $7000• Regulations: 1910.146(c)(2) - If the workplace

contains permit spaces, the employer shall inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces.

14 – No Certifications for Non-permits Pits• Probable OSHA Penalty: $7000• 1910.146(c)(5)(ii)(H) - The employer shall verify

that the space is safe for entry and that the pre-entry measures required by paragraph (c)(5)(ii) of this section have been taken, through a written certification that contains the date, the location of the space, and the signature of the person providing the certification. The certification shall be made before entry and shall be made available to each employee entering the space or to that employee's authorized representative.

15 – No Annual Fit Test Respirators• Probable OSHA Penalty: $3500• Regulations: 1910.134(f)(2) - The employer

shall ensure that an employee using a tight-fitting facepiece respirator is fit tested prior to initial use of the respirator, whenever a different respirator facepiece (size, style, model or make) is used, and at least annually thereafter.

16 – No Seat Belts Forklifts• Probable OSHA Penalty: $6000• Regulations: This is cited under the general duty clause.

Typical citation would be like this. • On or about April 19, 2016, the employer failed to

ensure employees were protected from hazards associated with falls while driving forklifts without wearing an operator restraint system. Abatement method: Instruct the Forklift drivers about the safety instructions included in the Diesel Doosan Forklift model # D25S-5 Operators Manual page 2, which states "The DOOSAN operator restraint system can minimize injuries. The DOOSAN operator restraint system keeps the operator substantially within the confines of the operator's compartment and overhead guard

17 – Using Basket to Lift when Prohibited• Probable OSHA Penalty: $4000• Regulations: 1910.178(a)(4) -

Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval.

18 - Ergonomics• Probable OSHA Penalty: $7000• Section 5(a)(1) - employees were required to perform

material handling tasks involving ergonomic risk factors including, but not limited to, forceful exertions, repetitive motions, and awkward postures occurring for prolonged durations which had caused, are causing or are likely to cause injuries,

• These actions required employees to handle such items as bag-in-boxes of syrup and beverage cases, to remove plastic shrink wrap from pallets of product, and to frequently manually transport loads weighing up to 1000 pounds on a cart or dolly, on all manner of surfaces including stairs, exposing employees to hazards which had caused, are causing, or are likely to cause serious injuries involving the back, shoulder, arm, wrist, hand and leg

19 – Combustible Dust Training• Probable OSHA Penalty: $2200• Regulations: 1910.1200(h)(1) - Employers shall

provide employees with effective information and training on hazardous chemicals in their work area at the time of their initial assignment, and whenever a new chemical hazard the employees have not previously been trained about is introduced into their work area. Information and training may be designed to cover categories of hazards (e.g., flammability, carcinogenicity) or specific chemicals. Chemical-specific information must always be available through labels and safety data sheets.

20 – Racks Not Labels with Capacity • Probable OSHA Penalty: $3500• Regulations Section 5(a)(1) for no rack labeling. • The Rack Manufacturers Institute has several safety

guidelines for the use of metal rack systems. MH16.2 - Specification for the Use of Industrial and Commercial Steel Storage Racks-Manual of Safety Practices/A Code of Safety Practices outlines characteristics for the safe installation, use and maintenance of various storage racks. It includes sections on safety elements drawn from RMI standards and common rack problems with their solutions

Summary• Use top cited and this ppt to find hazards. • Thank you for coming!