Company fined £750,000 over employee’s death

A manufacturing company was fined £750,000 after a worker died in an entirely preventable accident when he became entangled in a 20-metre long lathe whilst using emery cloth directly by hand on a rotating workpiece. This is a practice strictly prohibited by HSE guidance due to entanglement risks.

Manufacturing businesses face significant fines, legal costs, reputational damage, and serious consequences for workers, when basic machinery safety rules are not enforced. To reduce these risks and ensure your workspace remains compliant, speak to Croner’s Health and Safety experts today on 01455 858 132 for free, same-day initial health and safety support.

Reason for prosecution

Consequences for your manufacturing business

Our risk prevention process

Legal disclaimer

Reach out to an expert

Case background

In December 2023, a worker became entangled in a lathe whilst using an emery cloth in Halesowen, West Midlands. The incident was so serious that he passed away shortly afterwards from injuries. An HSE investigation into the matter revealed that the company had not put adequate control measures in place to minimise machinery-related risks and was fined £750,000 as a result.

Reason for prosecution

The most significant failure on the company’s part was improper prohibition standards on the use of emery cloth with machinery. HSE guidance states that emery cloth “should never be applied directly by hand”. This was a fundamental and easily preventable safety lapse, as workers had not been instructed on this basic yet highly dangerous prohibition.

Consequences for your manufacturing business

If you run a manufacturing or fabrication business, inadequate prohibitions, and lacking training can present serious legal and financial risks to your business, and to the wellbeing of your workers.

In particular, consequences for your business include:

• Heavy fines (e.g., £750,000 in recent UK cases for safety breaches).
• Additional court costs and legal fees.
• Regulatory investigation (HSE/OSHA) and possible citations/penalties.
• Increased insurance premiums.
• Reputational damage and potential loss of contracts/clients.
• Operational disruptions (downtime, halted work, enhanced safety requirements).

For the remaining workers:

• Severe emotional impact (grief, guilt, anxiety, lowered morale).
• Reduced productivity and job satisfaction.
• Fear of similar accidents, leading to stress or high staff turnover.
• Potential trauma requiring counselling or time off.
• Heightened safety scrutiny and changes in procedures.

Our risk prevention process

Under the Health and Safety at Work etc. Act 1974, all UK employers must ensure the safety and welfare of their workers in the workplace. If this business was yours, and you were a client of Croner’s specialist health and safety advisory service, our team of consultants and advisors would be available 24/7 to help you understand and evaluate all operational risks present, before such an incident could occur.

Our risk prevention process would include evaluating current risk assessments and assisting with any additions and/or adjustments required to them. In this specific instance, our team of specialists goes to work on specifically assessing machinery-related risks across 10 detailed sections:

1. Initial Site Survey & Hazard Identification: We would begin with a structured, in-person site survey (SafeChecks) of all lathes and rotating machinery (high risk areas). Our inspectors would observe live operations and interview operators, supervisors, and maintenance staff to gain insights into the potential procedural risks.
2. Formal Risk Assessment: We would then produce written, site-specific risk assessments for all high-danger operations under Regulation 3 of MHSWR 1999 – Our assessments would be designed according to your machinery, your processes, and your people. We do not provide generic templates!
3. Implementation of Hierarchy of Controls: Our team would apply a hierarchy of controls in strict order for each identified hazard – from elimination and substitution through to engineering controls, administrative controls, and PPE – documenting every decision and our reasoning throughout.
4. Development of Safe Operating Procedures (SOPs): Next, our specialists would assist your team in developing a full suite of site-specific SOPs for every significant/high-risk operation. 
5. Prohibition of High-Risk Practices: Where a practice cannot be made safe, such as applying handheld emery cloth to a rotating workpiece – we issue a formal written prohibition, backed by signed operator acknowledgements, physical signage, and a clear disciplinary framework.
6. Training, Competency Assessment & Supervision: Our team would then go to work on supporting the design and delivery of structured training programmes for all operators and supervisors, including practical competency assessments.
7. Near-Miss Reporting & Learning Culture: We would then help your company establish a formal near-miss reporting system for your site, supported by:
   1. Monthly trend reports presented to your senior management team.
   2. Structured root cause investigations.
   3. A no-blame reporting culture.

The above represents only a small portion of risks that our identification and evaluation system would uncover.

Legal disclaimer

The information provided above is for informational purposes only and does not constitute legal advice. It is imperative that you consult with a qualified professional or legal advisor to ensure that your organisation adheres to all relevant laws and best practices. Always prioritise the safety and wellbeing of those in your care.

Reach out to an expert

If you run a manufacturing business and you want to ensure your organisation is risk-free, give one of our Health & Safety specialists a call today for FREE, same-day advice.

Simply call 01455 858 132.