Menard, Inc.: OSHA inspections and violations

Incident on Feb 15, 2022 (fatal): Employee dies in fall from ladder

On January 8, 2022, Employee #1, a stocker, was positioning stock (product, plastic storage bins), while working from a rolling Cotterman ladder. Employee #1, stepped one foot off the ladder towards and onto the racking with the stock, and fell approximately 6-10 feet to the concrete floor below. Employee #1 was hospitalized with reported fractured ribs. Employee #1 died at 3:00 p.m. on February 15, 2022. The Medical Examiner reported death due to blunt force trauma to the ribs (2-9) and humerus. The Medical Examiner reported the death was an accident caused from an 8 foot fall from a rolling staircase.

Incident on Apr 22, 2021: Employee falls from elevated structure, sustains head and/or

At 4:06 a.m. on April 22, 2021, Employee #1, employed by Menard, Inc., was working at building no. 21 when he accessed elevated conveyance equipment at upper transfer car station no. 6 to clear a jam caused by a pallet blocking a photo eye sensor. After clearing the pallet, the roller conveyors and associated equipment resumed operation. While attempting to step off the rotating conveyor rollers onto the adjacent conveyor frame to avoid an oncoming pallet stack, the employee lost his footing and fell approximately 16 feet to the concrete floor below. The fall resulted in head and/or back injuries. Emergency services transported the employee to a local hospital, where he was admitted and received surgery for the injuries sustained.

Incident on Jan 9, 2020: Employee injures feet when repeatedly struck by robot pusher

At 4:30 a.m. on January 9, 2020, an employee and Coworker #1 were performing maintenance work drilling out and replacing bolts for an access panel on the pusher table of an auto depalletizing robot (Robot #2) within a robot cell. At the same time, coworker #2 was preparing to test the operational functions of the dunnage robot (Robot #1). Coworker #2 completed maintenance work on Robot #1 while the employee and Coworker #1 remained inside the robot cell. Coworker #2 exited the robot cell to reset the light curtains. The employee and Coworker #1 had entered the robot cell through the light curtains and that neither had isolated the electrical and pneumatic energy sources at the controls on Robot #2 or affixed lockout devices before performing maintenance work. Coworker #2 reset the robot cell perimeter light curtains for Robot #1 and Robot # 2 in preparation for a test run on Robot #1. The Robot #2 pusher table and robot arm turned on after the perimeter light curtains were reset and the run cycle was initiated in automatic mode on the operator control panel. The employee and Coworker #1 were both sitting on the Robot #2 pusher table while repairing damaged bolts on the table, so the pusher arm sensor for the Robot #2 pusher arm detected something on the table that needed to be pushed off. Coworker #1 managed to get off the pusher table without injury, but the employee was unable to move in time. The employee's feet had dropped down into the recessed area where they had removed an access plate from the table. His feet were repeatedly struck by the pusher arm as the robot tried to complete the normal programmed action of clearing materials from the table outgoing conveyors. His coworkers hit the emergency stop buttons on the outside of the robot cell and helped the employee get off the table and out of the robot cell. The employee was transported to a hospital and admitted to treat a laceration on one foot and extensive bruising and compartment syndrome on both feet.

Incident on Jul 5, 2019: Employee punctures thumb with staple

At 7:00 a.m. on July 5, 2019, an employee put a staple through her thumb, requiring hospitalization.

Incident on Mar 28, 2019: Employee incurs no injuries when struck by forklift

At 5:30 p.m. on March 28, 2019, an employee was struck by an automated forklift that was being operated by a coworker. No injuries were reported by the initial report; however, the employee was hospitalized.

Incident on Oct 30, 2017: Employee is struck by piv resulting in laceration and crushe

At 9:45 a.m. on October 30, 2017, Employee #1 was assisting in the loading of a tractor trailer for shipment, working near dock 99, building 21 at the distribution center. While loading, the employee was struck by a Yale ERP040VT powered industrial vehicle. The employee sustained a six inch laceration on his right foot and a crushed left big toe with laceration, requiring surgery and hospitalization.

Incident on Apr 3, 2017: An employee is struck by falling beam, falls to floor, and s

At 3:00 p.m. on April 3, 2017, an employee was working from an order picker disassembling metal racking at a height of approximately six feet and approximately seven feet from the fall protection tie-off point. A beam fell and struck the employee causing the employee to fall to the concrete floor. The employee's fall protection was not adequate for the working height and did not stop the employee's fall. The employee fell to the concrete floor. The employee sustained broken bones.

Incident on Jun 27, 2014 (fatal): Employee falls to floor and later dies

At 4:00 p.m. on June 27, 2014, an employee was stacking totes on pallets and moving them on a floor mounted roller system with the use of a dock hook. The employee tripped and hit their head on the concrete floor. The employee was found lying on the floor with a dock hook entangled in between his legs by a coworker. The employee was transported to the local hospital by ambulance where he underwent surgery. The employee died on June 30, 2014 due to bilateral subdural hematomas from his head injuries.

Incident on Jan 25, 2009: Employee dies of heart attack

On January 25, 2009, Employee #1 left work ill and had a heart attack while bein g escorted in a parking lot. Emergency responders were summoned. Employee #1 was transported unresponsive, to a hospital, where he was pronounced dead. The Medi cal Examiner indicated that the Employee #1 had significant heart disease.

Incident on Mar 19, 2008: Employee's hand is pulled into ripsaw, receives amputations

At approximately 2:30 p.m. on March 19, 2008, Employee #1 was operating a ripsaw . The ripsaw cut boards into lath. It was equipped with a power feed and had six blades that cut multiple laths at once. A piece of wood became jammed in the sa w while it was running. Employee #1 implemented the normal shut down procedure; however, he did not completely power down the saw. He lifted the interlocked cov er and guard, and secured it with a chain and then reached into the blades to cl ear the jam. As he reached into the blades with his right hand and cleared the j am, the blades grabbed his glove and pulled his hand into the moving blades. The blades amputated his middle and index fingers beyond the bottom knuckles and hi s thumb down to the first joint. He immediately called for assistance, at which time a coworker came to his aid. Employee #1 was transported by an ambulance to one medical center, but because of the severity of his injuries, he was flown to another medical center. At this medical center, he underwent treatment and was hospitalized.

Incident on Sep 11, 1998 (fatal): Employee killed under aircraft when landing gear collapses

Employee #1 was working on the actuator of the left main landing gear of a Beech craft 1900C airliner when a critical bolt was removed from the actuator rod. The over-center drag brace failed to support the gear in a down position and the la nding gear collapsed. Employee #1 was crushed against the wing cowling, and was killed.