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New ways: Changes have been made to how telescopic handlers are built
JC Bamford Excavators has changed procedures on one of its main production lines after a worker was left with multiple injuries after being crushed during the assembly of a telescopic handler.
Roger Pearce, 56, was installing the vehicle’s offside light and mirror arm at the firm’s Rocester plant when the incident happened in June 2013.
Staffordshire Magistrates’ Court heard how Pearce had to crouch down, so he could not be seen by a colleague testing the steering, resulting in him being crushed between a wheel and the bodywork.
He fractured 10 ribs, damaged the bones at the base of his spine, and injured his bladder and kidney. He is still undergoing treatment and has not been able to return to work.
A Health and Safety Executive (HSE) investigation identified that, at the time of the incident, there was a designated area of the assembly track where hydraulic fluids were pumped into the machine and steering and other systems operated to force the fluids through the system.
HSE found the assembly sequence for the telescopic materials handler was changed, which led to the fitting of the front offside light and mirror arm being moved from a point when the hydraulics were not live, to a point when the hydraulics were live and functions such as steering were tested.
JC Bamford Excavators pleaded guilty to breaching health and safety at work regulations and was fined £25,000 and ordered to pay £1,390 in costs.
HSE inspector David Brassington said: “This was a serious incident. It was also a preventable incident. JCB had allowed the introduction of a serious hazard and failed to assess the risk from this change. The controls that were in place were inadequate and Mr Pearce suffered serious harm as a result.
“Since the incident, the fitting of the light and mirror arm has been moved back to earlier in the assembly sequence when the hydraulics are not operational. Other changes have included barriers around the assembly area and the introduction of a banksman to control personnel working within it.
“The risks associated with manufacturing involving large pieces of equipment should be assessed.”