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A 57-year-old maintenance worker died after a 4,000-pound machine part crushed him while he performed maintenance inside of a sand core machine at a Warrensburg, MO, aluminum foundry.

Kingsville, MO-based Stahl Specialty Company did not use lockout devices and other machine safety procedures to prevent unintentional movement of the part — known as a ram — while the worker was inside the machine, said officials at the Occupational Safety and Health Administration (OSHA).

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OSHA investigators fined Stahl Specialty $105,000 and issued citations for one repeated and five serious safety violations, after the agency completed its investigation into the Feb. 15 death.

“An employee who had been with the company 40 years lost his life because his employer failed to follow safety procedures to prevent machine parts from moving during maintenance,” said Todd Sieleman, OSHA’s acting area director in Kansas City. “Foundries have inherent dangers and employers like Stahl Specialty need to review their safety procedures to protect workers on the job.”

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While investigating the fatality OSHA found Stahl Specialty Company:
• Failed to isolate all sources of energy in or to the equipment
• Did not protect employees from unexpected machine movements during maintenance
• Lacked machine-specific lockout procedures
• Failed to adequately train workers on proper lockout procedures
• Failed to coordinate lockout procedures with an outside contractor
• Did not correct illegible markings on a crane pendant control box

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