Crown USA Inc.
Outcome
Crown USA Inc. was cited for 8 serious and 6 other-than-serious OSHA violations and fined $98,699 after a 37-year-old maintenance technician was crushed inside an unlocked hooding palletizer while servicing the machine at the Woodbury, Ohio facility.
Details
Crown USA Inc. — Maintenance Technician Crushed Inside Unlocked Palletizer (2024)
Outcome: A 37-year-old maintenance technician at Crown USA Inc.'s Woodbury, Ohio facility was crushed inside a hooding palletizer while servicing the machine because it had not been locked out; OSHA cited 8 serious and 6 other-than-serious violations and proposed $98,699 in penalties.
A 37-year-old maintenance technician employed at Crown USA Inc.'s Woodbury, Ohio manufacturing facility was servicing a hooding palletizer machine when he was crushed inside the machine enclosure. The palletizer had not been locked out to prevent it from moving or energizing while the worker was inside it.
OSHA's investigation found eight serious violations: inadequate machine guarding that failed to prevent access to struck-by and crushed-by hazard zones; failure to train employees on energy control and lockout/tagout procedures; failure to inspect energy control procedures to ensure they were being followed; respiratory hazard exposure from airborne particles and dust; inadequate personal protective equipment for eye and skin protection in the production environment; and improperly labeled hazardous material containers. Six other-than-serious violations were also issued. OSHA proposed $98,699 in penalties.
Primary Source: US Department of Labor cites Woodbury resin maker for safety failures that caused 37-year-old maintenance technician's fatal injuries
How Crucible Prevents This
Palletizer maintenance is a standard caught-in fatality scenario requiring specific lockout procedures to isolate all energy sources — electrical, pneumatic, hydraulic — before any worker enters the machine enclosure. A Crucible pre-task gate requiring documented energy isolation verification for the specific palletizer model, confirmed training completion records for the technician, and signed confined-entry authorization before any palletizer maintenance work is released would have prevented this fatality.
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