Manufacturing
If you work in the manufacturing industry, you are twice as likely to be involved in a workplace incident than any other industry. Top causes of fatalities are vehicle incidents, being hit by moving objects and long term contact with chemicals. Below you will find information about recent serious incidents and safety information to help protect you and your workplace.
Steel girder crush fatality (6 July 2020)
A 34-year-old worker was killed after being crushed between two steel girders. As one of the girders, nearly 30 metres long and weighing almost nine tonnes, was being lifted by chain slings, it shifted, crushing the worker.
The two girders and bridge crane involved in the incident
Safety information
Consider ‘reasonably practicable’ control measures to manage the risks associated with lifting large or heavy loads.
Before any lift, make sure:
- the licensed dogger or rigger determine a safe lifting method, by calculating mass and selecting lifting equipment and slinging techniques
- the plant, attachments and lifting gear have been designed for that specific task, and inspected and maintained according to manufacturer’s recommendations
- the attachments and lifting gear are appropriate for the item of plant, and properly fitted
- exclusion zones are established and maintained to protect everybody from falling objects and moving plant
- all crane operators and users of lifting equipment are appropriately trained and correctly licensed (where required).
During the lift, make sure:
- no-one places themselves within the vicinity of a suspended load
- there are no obstructions and you can always see the load during the lift - if the load is outside your view, the lifting process must be directed by a licensed dogger or rigger
- all loads are lifted, carried and stored in a manner that ensures the safety of the plant, and the security of the load and any attachments.
More information
Forklift tip over fatality (5 May 2020)
Date of incident: 5 May 2020
A 31-year-old worker was killed when his forklift tipped over and crushed him, as he was driving down a driveway.
This is the second forklift fatality in NSW during the past five months.
Safety information
Before operating a forklift, you:
- must hold a current high-risk work licence (class LF), be familiar with the operating controls and know the limitations of the forklift
- should always complete a pre-start safety check, such as:
- fluid levels (hydraulic oil, brake fluid and water)
- seat and seat belts
- steering, brakes, park brake, lights and operating controls
- hydraulic operations, such as lift, tilt and sideshift
- tyre condition and pressures (if applicable)
- fork tynes and attachments
- load-rating plate and safety decals
- test drive and function tests.
- should check that regular maintenance and servicing has been carried out
- must not be not be under the influence of drugs or alcohol, or suffering from fatigue, injury or illness,
When operating a forklift, you must:
- wear a seatbelt, unless a risk assessment indicates it’s not safe to do so and other controls prevent you being ejected from the forklift
- drive at a safe speed, noting site speed limits, load size, ground and weather conditions
- avoid aggressive driving, braking and steering, especially when turning
- never turn sideways on ramps or other sloping surfaces
- avoid driving on an incline with the load facing downhill
- never overload the forklift
- never drive with an elevated mast and load, unless you’re picking up or putting away the load
- ensure all loads are centred and secured.
When the forklift is left unattended, the ignition key should be removed, or ignition control locked off to stop unauthorised people from using it.
If the forklift does tip over your instinct may be to jump. This is likely to cause serious crush injuries or death. In a forklift tip over, you should:
- remain seated and don’t lean out of the forklift
- brace your feet, hold tight and lean away from the point of impact.
More information
Worker trapped in machinery (19 February 2020)
Date of incident: 19 February 2020
A 34-year-old worker was shovelling ice into a horizontal screw auger conveyor at a poultry processing plant at Tahmoor when his leg became trapped.
The investigation
The investigation
- SafeWork NSW inspectors responded to the incident.
- SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.
Safety information
Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.
Consider ‘reasonably practicable’ control measures to manage the risks associated with working on or around machinery.
Make sure you separate workers from moving machinery by having:
- permanently fixed guarding, where access is not required during operation
- interlocked guarding, where access is required during operation
If these options are not practicable, make sure the guarding can only be removed by using a tool.
Also, make sure the guarding:
- is solid and securely mounted
- is difficult to by-pass or disable, whether deliberately or accidentally
- can be removed for maintenance and cleaning tasks – but the machine can’t be restarted until the guarding is replaced
- doesn’t create a new hazard
- doesn’t make the machine more difficult to operate, which may result in the guard being removed or disabled.
Further information
- Guide to machine safety
- Machine guarding safety pack (factsheets, posters, toolbox talk form)
- Machine safety videos
- Code of practice for managing the risks of plant in the workplace
Glass sheets crush worker (27 November 2019)
A 53-year-old worker fractured his femur and pelvis after being crushed by unrestrained glass sheets, which fell from an A-frame, when a sheet he was cleaning shattered while suspended from a crane.
The investigation
- SafeWork NSW inspectors responded to the incident.
- SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.The investigation
Safety information
Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.
Consider ‘reasonably practicable’ control measures to manage the risks associated with working with glass. Make sure:
- you never attempt to restrain glass by hand
- you use a rack or transport frame to securely store, cradle, lift, transport and restrain glass sheets
- all glass sheets are restrained
- you never stand in front of glass sheets when loading or unloading from a rack, trolley or A-frame
- you always have a plan when lifting glass sheets – consider the work area, and the size and weight of the sheets
- you use the right mechanical aid – glass lifting grab, clamp, vacuum or suction cup lifter –depending on the size and weight of the glass sheets
- you keep mechanical aids in good working order
- no-one works under a suspended load or in any potential fall zones
- workers not involved in moving, cleaning or storing glass are kept away from the work area.
Further information
Forklift fatality
Two maintenance workers were doing electrical work using a forklift and workbox at a manufacturing site in Barooga in the Riverina region. The forklift accidentally lifted the workbox, crushing one worker between the workbox and the underside of the roof. The worker sustained fatal head injuries.
The investigation
- SafeWork NSW inspectors responded to the incident.
- SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.
Safety information
Businesses are reminded of their duty to identify hazards and manage risks to health and safety in accordance with the provisions of the Work Health and Safety Act 2011 and Work Health and Safety Regulation 2017.
Consider ‘reasonably practicable’ control measures when using plant not specifically designed to lift people, such as forklifts fitted with workboxes. Make sure:
- the workbox is fitted with overhead protection if there is a risk of collision
- the forklift driver holds a current, valid licence
- the forklift data plate includes the workbox model number
- the workbox is securely attached to the forklift, according to manufacturer’s instructions
- workers are trained to use the workbox safely and follow emergency procedures, so occupants can be rescued if necessary
- the forklift is on a hard, flat, level surface, with the park brake applied, controls in neutral and the mast is vertical
- the path is clear of overhead obstructions – do a test lift with an empty workbox
- the forklift driver stays at the controls when someone is in the workbox
- workers wear a safety harness in the workbox, if there is a risk of falling from a height.
Further information
Factory crush fatality
A 32-year-old man sustained fatal injuries when he became caught in a timber pallet-making machine at a factory in St Marys.
The investigation
- SafeWork NSW inspectors responded to the incident.
- SafeWork NSW commenced an investigation to determine the cause and circumstances of the incident.
Safety information
Consider ‘reasonably practicable’ control measures to manage the risk of plant in the workplace.
Use the following risk management process:
- Identify all foreseeable hazards associated with machinery, including mechanical hazards, such as entanglement, impact and cutting, and non-mechanical hazards, such as ergonomic, electrical, dust, confined spaces and the like.
- Manage the risks associated with these hazards.
- Use the most effective machine guarding, such as permanently fixed guards or interlocked guards, that don’t rely on human behaviour – make sure the guards can’t contact moving parts.
- Control access to dangerous areas, screen harmful emissions, minimise noise and prevent ejected parts from striking people.
- Program machine re-setting, particularly during maintenance, to prevent unexpected start-up or movement.
When working with machinery:
- Do a pre-start check before using, to confirm it’s safe.
- Make sure all guards are working.
- Use it for the purpose it was designed.
- Follow operating procedures when setting-up, operating, cleaning and maintaining.
- Don’t remove guards or bypass safety devices.
- Isolate the machine and make sure all stored energy has dissipated before accessing hazardous areas.
- When doing maintenance in ‘jogging mode’, make sure guards remain in place and are effective in managing risks.