A serious incident involving workplace transport at a West Midlands textile processing factory has underlined the critical importance of managing vehicle movements on site – and the devastating consequences when this is neglected.
In March 2023, a worker was struck by a telescopic handler while operating a ride-on electric pallet truck inside the company’s Bilston facility. The 42-year-old man sustained severe leg injuries, resulting in life-changing consequences.
Following a Health and Safety Executive (HSE) investigation, the company was fined £300,000 and ordered to pay £7,732 in costs after pleading guilty to breaching section 2(1) of the Health and Safety at Work Act.
The incident
The injured worker had been assisting with stock movement in the ‘goods-in’ area. While returning an empty cage using his pallet truck, he was hit by a telescopic handler driven by a colleague. CCTV footage captured the moments leading up to the collision and revealed unsafe working practices in the lead-up.
Root causes
The HSE found the company had failed to properly organise and control vehicle movements within the workplace. This included:
– no effective separation between pedestrians and vehicles;
– inadequate risk assessments related to workplace transport; and
– failure to implement simple, industry-standard safety measures to prevent collisions.
Key lessons
1. Workplace transport needs proactive – not reactive – management
This case illustrates how routine activities – such as moving stock – can become dangerous without proper planning. A clear traffic management plan should be in place and regularly reviewed.
Takeaway: Ensure site layouts are designed with safe routes, barriers, and visual controls that clearly separate people from moving vehicles.
2. Risk assessments must be fit for purpose
Risk assessments should account for all types of vehicles, their operating areas, visibility challenges, and pedestrian interactions. Takeaway: Review your workplace transport risk assessments frequently, especially when workflows or equipment change.
3. Line managers must be equipped to spot hazards
In this case, poor working practices went unchecked. Supervisors play a key role in enforcing safe behaviours. Takeaway: Train line managers and supervisors to identify unsafe practices and take corrective action immediately.
4. CCTV reveals patterns – use it proactively
While CCTV helped piece together what went wrong, its value is even greater when used proactively to spot trends and intervene early. Takeaway: Review CCTV footage regularly as part of safety audits — not just after incidents.
5. Follow the HSE’s workplace transport guidance
The regulator provides detailed guidance on vehicle-pedestrian separation, vehicle routes, reversing, and driver competency.
‘This incident highlights the dangers to safety from inadequate management of workplace transport,’ said HSE inspector Gail Bell. ‘A man suffered very serious injuries due to the failure to put suitable control measures in place.’
Source – IOSH
