Manufacturing Firm Fined £80,000 After Worker Suffers Severe Hand Injuries

A manufacturing company has been heavily penalised following a serious workplace incident that left an employee with life-changing hand injuries. The Health and Safety Executive (HSE) brought the prosecution after an investigation revealed significant safety failings at the company's premises.

The incident occurred on 12th March 2022 at a facility in the North West of England. An employee was operating a manufacturing machine when his hand became entangled in moving parts, resulting in severe crush injuries requiring extensive surgery and ongoing rehabilitation. The HSE investigation highlighted inadequate guarding and a lack of proper risk assessment for the machinery in question.

Details of the Incident and HSE Investigation

The worker was performing a routine task on a bespoke manufacturing machine, which was designed to process materials. During operation, his hand was drawn into an unguarded section of the machinery, leading to the immediate and severe injury. Emergency services were called to the scene, and the worker was transported to hospital.

The subsequent investigation by the HSE found that the company had failed to implement suitable and sufficient measures to prevent access to dangerous moving parts of the machinery. Specifically, it was determined that:

  • The machine's guarding was inadequate and could be easily bypassed.
  • There was no effective system of work in place to ensure the machine was isolated from power before intervention.
  • Risk assessments for the operation of the machinery were not up-to-date or comprehensive enough to identify and control the specific hazard that led to the incident.
  • Training provided to employees on the safe operation of this particular machine was found to be insufficient.

HSE Inspector Jane Smith commented on the case, stating, “This incident was entirely preventable. The company failed in its duty to ensure the safety of its employees by not adequately guarding dangerous machinery and by not carrying out a proper risk assessment. The consequences for the injured worker have been devastating, resulting in permanent impairment and a significant impact on his quality of life. This prosecution should serve as a stark reminder to all employers that the safety of their workforce must be paramount.”

Legal Proceedings and Sentencing

The company, which cannot be named for legal reasons at this stage of reporting, pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974. This section places a general duty on employers to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all their employees.

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At a hearing at Manchester Magistrates' Court on 15th February 2024, the company was fined £80,000. In addition to the fine, the firm was also ordered to pay costs of £5,600. The judge, in delivering the sentence, emphasised the severity of the injuries sustained and the company's clear failure to adhere to established safety standards and regulations.

The HSE continues to stress the importance of machine guarding and robust safety procedures across all industries. According to HSE statistics for 2022/23, there were 53,000 non-fatal injuries to employees reported under RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations). Of these, injuries to the hand and arm remain a significant proportion, often linked to contact with machinery.

Preventing Future Incidents

This case underscores the critical need for employers to proactively manage workplace risks, particularly those associated with machinery. Key preventative measures include:

  • Thorough Risk Assessments: Regularly review and update risk assessments for all machinery and processes, ensuring they identify all potential hazards and outline effective control measures.
  • Effective Guarding: Ensure all dangerous parts of machinery are adequately guarded to prevent access to moving parts. Guards should be robust, fixed where possible, and interlocked where access during operation is required.
  • Safe Systems of Work: Implement clear and documented safe operating procedures, including lockout/tagout procedures for maintenance and intervention.
  • Comprehensive Training: Provide all employees with appropriate training on the safe operation of machinery, emergency procedures, and the importance of reporting defects or safety concerns.
  • Regular Maintenance: Ensure machinery is regularly inspected and maintained to prevent breakdowns or malfunctions that could lead to unsafe conditions.

The HSE’s guidance on 'Safeguarding machinery' provides detailed information for businesses on how to comply with their legal duties and prevent similar incidents. Employers are encouraged to consult these resources to ensure their workplaces are safe and compliant.

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