Page 2 Fri Jan 27. 2U12 11:39am BLUE BELL CIWANIERIES, LP Inspection 315631919 I '37: I'llifiif?firg: 1.33: fi: if? idem?; as: 1.35;; as; g; 55.1.55; 5; if a; -. SAFETY NARRATIVE t.zisfz-iasaecgisaatlases; 315626929 COVERAGE INFORMATION: Gram Fruit Feeder manufactured in Tampa. Florida. NATURE ano scoPE' Check Applicable Boxes and Explain Findings: Complaint Items Referral Items Accident Investigation Summary Findings I: Planned Inspection AND SCOPE -- UNUSUAL CIRCIMSTANCES (Mark and explain all that apply:) None [1 Denial of entry? (see denial memo) Delays in conducting the inspection l: Strikes Jurisdictional lssues Trade Secrets Other Comments: 08! ?8,110] was sent to the plant by supervisor to investigate a complaint that was called into the AAO regarding an elltpioyce that had amputated three fingers on an industrial machine. CSHO arrived on site and presented credentials and explained the scope of the inspection to the Risk Manager for the company Mr. Howard Zuch. C3110 met with Mr. "Koch and discussed his knowledge of the woditions of the accident. Shortly later. Mr. Koch contacted the plant engineer hX- 7C and production manager Mr. Erich Glenwinltle to join CSHO and Mr. Zuch discussing the incident. CSHO conducted hriet? walk around to look at the machine and exited the site. [J8t33r'20] l? CSHD arrived on site and met with Mr. Zuch. and plant operations manager Mr. Paul Frank. CSHO obtained information and requested LOTO documents. CSIIO conducted a walk around for other issues with machines with multiple energy sources and machine guarding issues. CSIIO conducted interviews, took photos and notes. CSHO observed a new fruit feeder throat assembly that was equipped with a guard that had 1?inch spaced horizontal bars so hands could not go into the throat. 1 AtRev. tits-?3} Page 3 Mon Jan 30, 2012 11:37am BLUE BELL CREAMERIES, LP lnspecdon Nr. 31. .6929 Citation Nr. 01 lteranroup 001 08.318301] 20. Instance Description Describe the following: a) CAUGHT IN- Employees are required to perform service and maintenance related activities on machines with multiple energy sources without the employer developing specific LOTO procedures to control hazardous stored energy, exposing the employees to the hazard of being caught-in machines. The plant has numerous machines with multiple energy sources including the approximate 35 freezers and 35 filling machines in the production areas. Employees operating and working _with these machines are required to break them down and clean them. In doing so, employees are not following a specific procedure to control the stored energy. The cleaning process falls under service and maintenance in the Directive CPL 02-00-147. The freezers have electrical, pneumatic and pressurized anunonia. The filling machines have electrical and pneumatic sources of energy. Employees are also cleaning the 20 fruit feeders that are not being locked out to isolate the hazardous electrical energy and to prevent unintentional startup. Most of the employees that are cleaning machines are not provided locks by the employer and when they are. they do not have a specific procedure to lock out the equipment. The employer provided a short. 5- page LOTO program that has general procedures for locking out equipment for electrical safety, but the program did not address the need for procedures with multiple sources of energy. The company has trained approximately 54 employees on a LOTO powerpoint. The powerpoint does not include the requirements for developing procedures on machines with multiple energy sources. b) Equipment: Freezers, filling machines, fruit feeders; e) Location: Production areas of the plant; d) Injuryr'Illness: Broken bones, lacerations, amputations; e) Measurements: Visual observation: Elie 2'3. Employer Knowledge The production department manager Mr. Erich Glenewinltel stated to CSHO during an interview that he knew that the freezers and filling machines had multiple energy sources. Mr. Glenewinkel stated that he thought that some of the machines had written LOT 0 procedures, but he?d have to go back and look. He stated that they employees locked out the freezers, though. Mr. Glenewinkel stated that he Wasn?t aware of the OSHA requirement to have written procedures for the machines with multiple energy sources and that he wasn?t aware if the company's LOTO program had written procedures. Mr. Glenewinkel stated that some of the employees working with the machines perform cleaning operations on thorn. The corporate risk manager Mr. Howard Zuch stated to CSHO during the inspection that the department managers are responsible for taking LOTO procedures in the program to the employees on the floor. He stated that he couldn?t say if he had heard of multiple energy sources needing procedures. Mr. Zuch stated that there are LOTO procedures fro cleaning the fruit feeder machine. NOTE: The company could not produce procedures to support this., He also stated that the employee was cleaning the machine with it plugged in. Paul Prazak, plant operations manager, stated to CSHO during walk around that since the inspection began, the new procedure is to turn off discotmect to the machines and put a lock on it. The Gram fruit feeder manual provided by the company states on page #4 under tab general operating safety, to make certain proper service and maintenance procedures have been performed. On page #5 under tab cleaning safety, the manual states on item #2 that when the cleaning cycle is controlled from a remote or automated control centre, establish fail-safe procedures to avoid automatic start-up while servicing equipment in the circuit. 24. Conunents (Employer, Employee, Closing Conference) The company?s LOTU program, toolbox talks and training pewerpeint did not address the requirements for developing procedures on machines with multiple energy sources. page 7 Mon Jan Sill, 2012 11:37am BLUE BELL CREAMERTES. LP Inspection Nr. 31. 6929 Citation Nr. 01 ltemlGroup 002 Although the machine has a sensor to ensure the machine is inoperable when the cover is removed from the rotor assembly, it was found in the investigation that the sensor was by passed. The employees operating are not trained on LOTD requirements in the OSHA standard and the company does not have an adequate LDTO program. The companyI does have a LOTO powerpoint to train employees on the importance of utilizing a loci-rout system when working on machines. but these employees have not been through the training. Approximately 54 of approximately 200 employees in the production area have been trained on LOTO. NOTE: CSHO evaluated the training and the training does not cover multiple power sources and speci?c machines that the employees work on daily. Some employees working with the freezers are issued locks and personnel are issuer! locks. The employees working with the freezers loci: out the power, however, they do not bleed out the pressure of the stored ammonia or pneumatic energy. b) Equipment: Fruit feeders. freezers, filling machines; e) Location; Throughout the production area of the facility; d} Broken bones, lacerations, amputations; e) observation, steel tape measure; 1 ,5 23. Employer Knowledge; The production department manager Mr. Erich Glenewinkel stated to CSHO in an interview that not all of the employees cleaning, maintaining and servicing machines were isstted locks. He stated that not all of the employees were issued locks because they did n't thin}: that everyone needed them. Mr. Glenewinltel stator] that locks work on the some of the feeders and some of the supervisors had their own locks. Mr. Glenewinltet stated to CSHO tha1 currently the plant' engineer issues locks to authorised and affected employees, but prior to the inspection, he was not sure who issued locks for the company. He stated that for the narrator crew working on the freezers, their department ordered them, themselves. The corporate rislt manager for the company Mr. .l-loward Fletcher stated to that there are LO?l'tl procedures for cleaning the machine. He stated that the employee that was injurred was cleaning the machine with it plugged in. The pram mgm?ur EX. stated to CSHO during the inspection that they turn. the power off at the machine when cleaning it and he thought that you could look that switch. He stated that during cleaning,I the machines are probably not locked out. Paul Prazak. plant operations manager. stated to CSHO during walk around that since the insnrection began, the new procedure is to turn off to the machines and put a lock on it. The Grant fruit feeder manual states on page #3 under tab installation, to make sure a punter disconnect orn?oll? for the power sources is installed on the machine. The discormect must be of a type that can he looked in the power off position and the key must he removed. On page #4 under tab Service and maintenance safety, the manual notes on item #8 that for maithnum protection, the power source should he locked out using a lock for which only you have the key. This prevents anyone from accidentally turning on the power while you are servicing the machine. 114. Comments (Employer, Employee, Closing Conference) The employee that had his finger tips amputated Ex. stated to C3110 in an interview that before the accident he had never heard the term lockontltagout. He stated that since the accident he has received some intermalion about it from other people. EX. 7"(1 stated to C5110 that he was trained to turnoff the power on the machine?s touch screen and it displays everything that is off. 25. Other hmployer information as";finiteness" EE: Rail-3T Ir?tl- 9393i U. S. Department of Lab" Occupational Safety and Health Worksheet Mon Jan 30, 2012 11:37am 5 ?itirmhcij 315626.929 Opp-3.: ,Iitspli, 23!! BLUE BELL CREAMERIES, LP Serious 'tilumherfihip'd?sed 4U 1910.0212t 2) 01 has 20 REG-tit. -.- i. .. - That; assists-an '3 - .. giants-:23? maestro . .. Ii 1 . 1t) 02115.!12 .Jl it 29 CPR Guardts) on ntaohineis) were not affixed to the machine or secured elsewhere when auaclnnout to the machine was not possible: On or about August 18. 2011, and in times prior thereto, employees are required to add inclusions, clear jammed inclusions and monitor the hielusions being mixed into the ice cream by removing, the lid of the throat assembly attached to tho fruit feeders whore tin-guarded rotatth shafts and rotor assemblies are present, exposing the employees to the hazard of being caught in the rotating parts. Pursuant to 29 Chit. 19(13.19. within ten (IO) caiendat days of the date of this citation, the employer must submit documentation showing that it is in compliance with the standard, including describing the steps that it is taking to eustlro thal all m.chines, including, but not limited to fruit feeders, are equipped 1with guards to prevent hazards such as those created by point of operation, ingong nip points, rotating parts, flying chips sud sparks. . E31: 3' 15ft? 35-? ?mutation; "ct eta-assistsa 'f-Filfii?o?ti [fl] High Lehm- 05 5000.00 0 dam I, 0 ITi'i-li 75571.- Nf'lrifii?t?staissii EX. 37C O?il?ri W1