Inspection Detail

Inspection: 310198569 - Merle Norman Cosmetics, Inc.

Inspection Information - Office: Van Nuys District Office

Investigation Summary

The employer is a cosmetic manufacturer but manufactures no cosmetics at the facility. They manufacture plastic compact cases, lipstick cases and bottle for lotions and perfumes for their line. The process involved using plastic molding extrusion. The equipment used utilizes an oil hydraulic system to force the molten plastic into the mold and also to operate the extruder. There is a tank at the back and bottom of the machine that houses nitrogen gas. The gas is used to increase the hydraulic pressure. The tank has a rubber bag inside called a "bladder"; therefore the tank is known as a "bladder tank". Approximately once or twice per year, the bags develop a leak and have to be replaced. There is another tank above the bladder tank called an "evaporator tank". At the time of incident, Employee #1, the maintenance man, who has performed this repair and replacement procedure several times, was asked by the molding dept manager that a new employee was assigned to help him. Employee #1 told the manager that he didn't need anyone to help. The bladder tank was removed without incident. The new bladder was put in by Employee #1 at the maintenance shop and then brought back by forklift to the machine for installation. According to both Employee #1 and the witness, the tank was placed on the forks of the industrial truck and was prevented from rolling by bolts placed vertically on the forks. The tank was raised to the proper level but a wood 2-in. by 4-in. plank was placed between the bladder tank being raised and the evaporator tank that was permanently affixed to the machine. Employee #1 had placed a "U" bracket on both sides of the bladder tank. On the left side, as you are facing the tank, he was putting anchor bolts through the "u" bracket. Employee #1 had his left hand above the "U" bracket and his right hand below the "U" bracket between the bracket and the bladder tank. According to Employee #1, the 2-in. by 4-in. plank split in half causing the forks to raise enough to have his right hand crushed between the "U" bracket and the tank. Employee #1 had his middle, annular and pinky finger crushed which resulted in a partial amputation of all fingers involved. Employee #1 was hospitalized.

Keywords: MAINTENANCE, AMPUTATED, REPAIR, FINGER, CRUSHED, INDUSTRIAL TRUCK