Manufacturing Firm Fined £80,000 Following Serious Hand Injury Incident

A manufacturing company has been heavily fined after a worker sustained severe hand injuries when their hand became trapped in inadequately guarded machinery. The incident, which occurred at a facility in the North West of England, prompted an investigation by the Health and Safety Executive (HSE), culminating in a significant penalty for the company.

Liverpool Magistrates’ Court heard that on 20 June 2022, an employee of the unnamed manufacturing firm was attempting to clear a blockage on a ‘chiller’ machine. During this operation, the worker’s left hand became entangled in an unguarded rotating auger within the machinery. The resulting injuries were extensive, requiring multiple surgeries and leading to permanent impairment.

HSE Investigation Uncovers Critical Safety Lapses

The HSE investigation meticulously examined the circumstances leading to the incident. It was revealed that the chiller machine had been supplied with a removable interlocked guard. However, this guard was frequently removed by employees to clear blockages, a common occurrence during production. Crucially, the interlocking mechanism was found to be defective, allowing the machine to operate even when the guard was not in place.

Furthermore, the investigation identified a systemic failure in the company's safety management. There was no safe system of work in place for clearing blockages on the chiller machine, nor was there adequate training provided to employees on the safe operation and maintenance of the equipment. The company also failed to implement effective supervision to ensure that safety procedures, where they did exist, were being followed.

HSE Inspector Lisa Bailey commented on the case, stating, "This incident could have been easily avoided had the company ensured that the interlock on the guard was functioning correctly and that a safe system of work was in place for clearing blockages. The employee suffered life-changing injuries that will impact them for the rest of their life, all due to the company's failure to manage foreseeable risks."

Court Proceedings and Sentencing

The manufacturing firm 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.

In addition to the £80,000 fine, the company was ordered to pay costs of £4,800. The court emphasised the seriousness of the breach, highlighting the permanent nature of the injuries sustained by the worker and the clear negligence in maintaining machinery safety standards.

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This case serves as a stark reminder of the critical importance of robust machinery guarding and effective lockout/tagout procedures. The HSE continues to prioritise enforcement action against companies that fail to protect their workers from preventable hazards, particularly those involving dangerous machinery.

Preventing Machinery Accidents: A Continuous Challenge

Machinery-related accidents remain a significant concern across various industries in the UK and Ireland. According to HSE statistics for 2022/23, contact with moving machinery was responsible for 1,170 non-fatal injuries to employees, with 12 fatalities. These figures underscore the ongoing need for vigilance and proactive measures to mitigate risks associated with industrial equipment.

Key preventative measures include:

  • Thorough Risk Assessments: Regularly reviewing and updating risk assessments for all machinery.
  • Effective Guarding: Ensuring all dangerous parts of machinery are adequately guarded, with interlocks functioning correctly.
  • Safe Systems of Work: Developing and implementing clear, written safe operating procedures for all tasks, especially those involving maintenance, cleaning, or clearing blockages.
  • Training and Competence: Providing comprehensive training to all employees on machine safety, including the use of guards, emergency stops, and lockout/tagout procedures.
  • Supervision: Ensuring effective supervision to monitor compliance with safety procedures.
  • Maintenance: Implementing a robust preventative maintenance schedule to ensure machinery and safety devices remain in good working order.

Companies are urged to review their current practices and ensure they meet regulatory requirements to prevent similar incidents. The financial penalties and reputational damage associated with such breaches are substantial, but the human cost of severe injury is immeasurable.

For businesses seeking to enhance their machinery safety protocols and ensure compliance with UK health and safety legislation, specialised training is invaluable. Organisations like Abertay Training (https://www.abertaytraining.co.uk) offer a range of courses designed to equip employees and management with the knowledge and skills necessary to identify and mitigate workplace hazards effectively, including those related to dangerous machinery.