Lack of non-standard work system nearly causes death

Essential Supply Products Limited, a Worcestershire-based manufacturer was fined £22,714 (inc. costs) after a worker nearly lost his life when a door collapsed and pinned him to a baler.

The circumstances were:

• On 5 May 2015, two maintenance workers were replacing the bottom of a heavy sectional door at the factory.
• Managers had failed to recognise the risks involved in the maintenance work that was taking place. 
• There was no appropriate equipment, instruction or training provided to the workers to ensure the method of work was safe.
• While removing the hinges and brackets the door collapsed, pinning one of the workers between it and a baler that was next to the door.
• The worker suffered serious injuries including broken ribs and asphyxiation which led to a lost of consciousness for eight hours. He has since made a full recovery.

This is a classic example of non-standard work. Refer to SSS White Paper 23 for how to control non-standard operations.