Mechanical power press
September 1, 2016
Syracuse auto parts manufacturer fails to correct electrical,
crushing and respiratory hazards
York Metal Toll Processing Inc. faces $218K in additional OSHA fines
crushing and respiratory hazards
York Metal Toll Processing Inc. faces $218K in additional OSHA fines
An auto parts manufacturer where a worker's hand was amputated by a power press two years ago is facing $218,000 in fines for allegedly failing to correct multiple safety violations.
Federal workplace safety and health inspectors have cited York Metal Toll Processing Inc. for exposing employees to uncorrected electrical, crushing and respiratory hazards, as well as recurring amputation hazards.
The Syracuse Area Office of the U.S. Department of Labor's Occupational Safety and Health Administration opened two follow-up inspections at the company's Syracuse manufacturing facility on March 14, 2016, after the employer failed to provide evidence that they corrected violations cited during previous OSHA inspections. One of the previous inspections occurred as a result of an employee's hand being amputated by a power press.
Agency inspectors found that York Metal Toll Processing failed to:
- Ensure electrical equipment used in a powder coat booth conformed with electrical standards.
- Properly guard live electrical parts to prevent contact with energized circuits.
- Safely remove powder coat via exhaust ducts to a powder recovery system.
- Adequately train workers performing inspections and maintenance on power presses.
- Inspect mechanical power presses.
- Ensure lockout/ tag out procedures were specific to equipment in the facility.
- Perform annual lockout/ tag out procedure inspections.
- Train employees who wear respiratory equipment, and provide medical evaluations to ensure that they can wear a respirator safely.
- Provide proper ventilation for welders working in spaces less than 10,000 cubic feet.
- Inspect steel slings used for hoisting.
- Maintain passageways and aisles in passable condition.
As a result of the follow-up inspections, OSHA has issued York Metal Toll Processing citations for failure to abate fourteen previously cited violations, four repeat violations, and three serious violations. The company faces proposed penalties totaling $218,502 for these violations. The company manufactures parts primarily used in the automotive industry.
The citations can be viewed here, here, and here.
York Metal Toll Processing has 15 business days from receipt of its citations and proposed penalties to comply, request a conference with OSHA's area director or contest the findings before the independent Occupational Safety and Health Review Commission.
To ask questions, obtain compliance assistance, file a complaint, or report amputations, eye loss, workplace hospitalizations, fatalities or situations posing imminent danger to workers, the public should call OSHA's toll-free hotline at 800-321-OSHA (6742) or the agency's Syracuse office at (315) 451-0808.
Under the Occupational Safety and Health Act of 1970, employers are responsible for providing safe and healthful workplaces for their employees. OSHA's role is to ensure these conditions for America's working men and women by setting and enforcing standards, and providing training, education and assistance. For more information, visit https://www.osha.gov.
A mechanical power press shears, punches, forms, or assembles metal or other materials by means of tools or dies attached to slides or rams. Metalworking occurs by placing stock on a bottom die and striking it with a top die. The top die is attached to a crankshaft with connecting rods and rotation of the crankshaft is accomplished from a motor, flywheel, and gear power transmission.
Typical mechanical power presses fall under two primary categories with respect to their specific clutch system:
Mechanical Full Revolution Clutch
Mechanical Part Revolution Clutch
Under these two categories are lists of the specific barriers, guards and hazards for each type of power press.
For additional information on electrical requirements, covers and auxiliary safeguarding for mechanical power presses, please refer to the Press Safety Considerations page.
Online Mechanical Power Presses Injury Form
Power presses, because of their use in high-production manufacturing and integral operator involvement, result in maximum hazards. Careful operation and safety precautions are extremely necessary.
Full Revolution Clutch as defined
by OSHA, [29 CFR 1910.211(d)(5)], is a type of clutch that, when tripped, cannot be
disengaged until the crankshaft has almost completed a full revolution and
the press slide a full stroke.
This type of press was designed to make one full machine stroke or crankshaft revolution after each engagement of the mechanical pin, collar, or rolling key. Operator Involvement The worker will activate the machine through a foot switch or palm buttons. Once this is done the press will perform a full stroke, barring any mechanical failures, before stopping at top dead center (TDC). This inability to stop the machine stroke poses a hazard to the operator and other workers. Hazards:
Solutions:
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A Part
Revolution Clutch, as defined by OSHA, [29
CFR 1910.211(d)(6)], is a
type of clutch that can be disengaged at any point before the
crankshaft has completed a full revolution and the press slide has
completed a
full stroke.
The majority of part revolution presses are air clutch and brake. They are designed to trap air in a chamber or tube. When compressed air is put into these chambers, the clutch is engaged and the brake is disengaged. The press then makes a single stroke. To stop the press, the reverse takes place.
Operator Involvement
This type of press is not as dangerous as the full
revolution clutch press. However, hazards still exist. Here, the operator must keep the operating controls depressed
throughout the machine stroke. A release of either
control will stop the press action.
 Note:
Many older models of part
revolution clutch presses use a mechanical-friction clutch. These types of presses are generally not as safe but can be updated by adding a properly sized air
cylinder to the part revolution control.
For a printable sample form of a periodic inspection record for partial revolution power presses, please see Appendix E.
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