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Speaking of Precision

Speaking of Precision is a knowledge preservation and thought leadership blog covering the precision machining industry, its materials and services. With over 36 years of hands on experience in steelmaking, manufacturing, quality, and management, Miles Free (Milo) Director of Industry Research and Technology at PMPA helps answer "How?" "With what?" and occasionally "Really?"

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Pedestal Grinders, OSHA, And You

Posted August 09, 2011 9:00 AM by Milo

OSHA cited Advantage Powder Coating in Defiance, Ohio, for 15 safety violations and fined the company $159,600 after a pedestal grinder operator was killed when the abrasive wheel on the grinder exploded and struck the operator on the head.

Pay attention! This one can bite.

Two willful violations were cited for pedestal grinder violations:

  • Lack of properly adjusted safety guards;
  • Lack of properly adjusted work rests;

OSHA placed Advantage Powder Coating in its Severe Violator Enforcement Program (SVEP), which mandates targeted follow-up inspections to ensure compliance with the law. Advantage Powder Coating was placed in the program for receiving two willful violations covered under the agency's National Emphasis Program on Amputations.

Pedestal grinders are a foundational piece of equipment in precision machining shops. It is up to us to assure that the potential hazards that they can present are controlled. Here are four tips from my experience to keep your shop grinders in compliance:

  • Don't allow wheels to get out of dress.
  • Assure that the proper clearance and no more exists between properly dressed wheel and front tool rests
  • Assure that all grinders have all guards in place. If guards are missing- LOCK IT OUT!
  • Assure that the grinder is mounted to the floor if the pedestal was designed to be bolted to the floor. If no bolt holes are present, then bolting down is not necessary.

The safe use of grinders is a key part of our craft. It is up to us to keep the potential hazards that grinders can present safely controlled by insisting on safe grinder practices and inspections to assure guards are in place and properly adjusted.

Editor's Note: CR4 would like to thank Milo for sharing this blog entry, which originally appeared here.

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#1

Re: Pedestal Grinders, OSHA, And You

08/09/2011 10:34 AM

Speaking in a very general sense, and not specifically of the Advantage Powder Coating incident:

It is sad, very sad, that a shop must be fined hundreds of thousands of dollars before they will pay diligent attention to shop safety. It is heartbreaking that a man must be killed before a plant will pay diligent attention to shop safety.

I have seen it; I would guess most of us have. A safety inspection (OSHA, insurance guy, fire department...), a few write ups. Paint a few lines on the floor, replace a few burned out bulbs, replace a few machine guards... within a few days the guards are removed again, the fire escape door has a pile of something blocking it again, the homemade 200 foot extension cord comes out of hiding, and the grinder is adjusted "the way I like it, not the way that %#$@& OSHA guy wants it". And the shop foreman, trying to keep things happy, tolerates these infractions.

And management, not hearing complaints from the floor, tolerates the tolerance.

Sad, sad, sad.

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#2
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Re: Pedestal Grinders, OSHA, And You

08/09/2011 3:04 PM

I've got a similar, but slightly different take.........................it's called self responsibility. The shop foreman shares some responsibility, but depending on the size of the crew, there's no way that the company or the foreman can make sure that everyone is working within OSHA regulations. The workers themselves share the resonsibility........................we all know that there is a faster way to do something, and a safe way to do something. Many Most professionals take the faster way if no one is looking.

I've run 100 people on new construction, installing paint and glass over about 50 acres in different buildings. I had weekly safety meetings and they knew the rules. Did they follow them? They did if they knew I was in the area, otherwise, who knows? I doubt it.

As far as Uncle OSHA is concerned, if they're going to slap fines that large on companies.....................in cases like this, it should go directly to the man's family. If he was doing this against the rules, he was likely doing it to look out for the company's bottom line.

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#4
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Re: Pedestal Grinders, OSHA, And You

08/10/2011 7:24 AM

It was far more than just the grinder missing a few guards

Here's the one that shows the company didn't care about safety

Two other-than-serious record-keeping violations include failing to record work-related injuries that occurred in 2008 and 2009. Advantage Powder Coating faces total proposed penalties of $159,600.

the lack of care for the overhead lifting & rigging is further evidence

the workmans comp carrier, for APC undoubtedly paid the workers family [who probably sued besides]

having the occasional coffee break safety meeting is no substitute for inspecting & maintaining equipment.

when you allow that there is the right way & the fast way, you are not cultivating a culture of safety

construction sites are being drug kicking & screaming towards safe work practices as evidenced by the accident rates

safety is not optional

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#5
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Re: Pedestal Grinders, OSHA, And You

08/10/2011 8:53 AM

In a perfect world.

There's a good chance that fine will put the company under. I'm not excusing them, but everybody knows those guards get covered with crap and you can't see what you're doing. I'd be willing to bet that anyone here on CR4 that's used a bench grinder for any length of time, has been guilty of pushing those guards out of the way.

I mean, how often do the wheels explode? Not very.

In fact, I've always assumed those guards were for eye protection, not containing exploding grinding wheels.

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Re: Pedestal Grinders, OSHA, And You

08/10/2011 9:48 AM

most likely failure is having a part wedge between the tool rest & the stone, [the gap should be an 1/8 or less], fracturing the wheel

the incident may not have happened at that time

the grinder should be inspected before every use, it's nice to have clear signage highlighting the critical points

if you can't see through the shields you need to clean or replace them, but you're right they won't protect you if a 2"x10" wheel turning at 3000 rpm launches

I get it guards are a pain

wheels don't disintegrate very often...

I worked with a guy who had a 1" come apart, when he was dressing it

he had a lightening bolt shaped scar on his forehead

I always stand to the side when I'm able

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Re: Pedestal Grinders, OSHA, And You

08/10/2011 10:07 AM

I've had a cut off wheel explode while turning 10,000rpms on an angle grinder, (no guard).............................scary stuff.

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Re: Pedestal Grinders, OSHA, And You

08/10/2011 10:16 AM

Ever use one of those chainsaw motor with a cut off wheel saws?

if the wheel isn't disintegrating, you're lighting something or someone on fire

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Re: Pedestal Grinders, OSHA, And You

08/10/2011 10:57 AM

Nope..........................I don't have any desire to try one out either.

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#3

Re: Pedestal Grinders, OSHA, And You

08/09/2011 11:46 PM

Ya sure, ya betcha. Just bankrupt the bastards; then the workers can look for jobs elsewhere, including perhaps overseas, where conditions may be even less safe. Improved safety measures will be even harder to implement with $159,000 less money.

That'll show 'em.

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