The man was injured at Film & Foil Solutions Ltd, which makes flexible film used in the food industry, on 4 December 2023.

He was using a machine that converts and folds plastic film at the company’s site on Haydock Industrial Estate. He tried to stop the material becoming tangled by using his hand to stop the poorly guarded rotating shaft. However, in doing so, his right index finger made contact with a rotating part of the machine and became entangled.

He was taken to hospital and due to the seriousness of the injuries, surgery was carried out the following day to amputate part of the finger on his dominant right hand. In a statement provided to HSE, the employee, who doesn’t wish to be named, described the impact of the injuries.

He said: “I was unable to carry out normal daily tasks such as tying my shoelaces. My right hand is my dominant hand and I find it extremely difficult to write with that hand now.

“As a result of the injury I feel my job prospects have been affected, both now and in the future.”

An investigation by the Health and Safety Executive (HSE) found that Film & Foil Solutions Ltd failed to protect its employees, including ensuring the machinery being used to produce it had suitable guarding. The company had failed to carry out a suitable and sufficient risk assessment, resulting in a failure to provide suitable guarding arrangements on the machine and had failed to put in place an adequate safe system of work. It also revealed inconsistencies and inadequacies in the provision of information, instruction and training for those required to use the machine.

HSE guidance states employers must take effective measures to prevent access to dangerous parts of machinery or to stop the movement of any dangerous parts of it before any part of a person enters a danger zone. This will normally be by fixed guarding, but where routine access is needed, other measures may be needed to stop the movement of dangerous parts, for example by having interlocked guards, pressure mats and electro-sensitive protective equipment (ESPE). Further detailed guidance on safe working with machinery is available.

Film & Foil Solutions Ltd, of North Florida Road, Haydock Industrial Estate, Haydock, St. Helens, Merseyside, pleaded guilty to breaching Regulation 11(1) of The Provision and Use of Work Equipment Regulations 1998. The company was fined £20,000 and ordered to pay £2,932 in costs at Sefton Magistrates’ Court on 15 May 2025.

HSE inspector Sam Eves said “This incident could so easily have been avoided had the company taken simple steps to guard dangerous parts of machinery and implement safe working practices.

“Companies and individuals should be aware that HSE will not hesitate to take appropriate enforcement action against those that fall below the required standards.”

This HSE prosecution was brought by HSE Enforcement Lawyer Matthew Reynolds and supported by Paralegal Officer Imogen Isaac.

PPE plays a crucial role in protecting workers from life-altering injuries and fatalities. It safeguards the body’s most vulnerable areas, including the head, eyes, face, hearing, lungs, hands, and feet, acting as a critical line of defence when hazards cannot be fully eliminated.

Join the PPE Saves Lives Campaign: Share your story

To raise awareness about the critical importance of PPE, BSIF has launched the PPE Saves campaign. They invite workers, employers, and safety professionals to share their personal stories of how PPE has protected them or their colleagues in the workplace.

By sharing real-life experiences, BSIF aims to highlight the life saving power of PPE to encourage PPE compliance, promote a stronger safety culture, and ultimately prevent future accidents.

If you have a story to tell, join the conversation using #PPEsaves on social media or contact the BSIF to share your experience - [email protected]. Your story could help save lives.

The pair were diagnosed with the condition in November 2022 following repeated exposure to vibration from working for Rowes Garage Ltd at its bodyshop in Truro. They regularly used hand tools like random-orbital sanders and reciprocating saws for car body repairs.

Prolonged and regular exposure to vibration can affect a worker’s health resulting in painful and disabling disorders of the nerves, blood supply, joints and muscles of the hands and arms. These disorders are collectively known as HAVS and the risk of onset or worsening of it increases with daily exposure and varies widely between individuals. Health and Safety Executive (HSE) guidance can be found here.

One of the affected employees, who did not wish to be named, said: “It’s hard to say exactly how long I have had the symptoms for, but I think maybe about eight years.

“My fingers would go white and I’d lose feeling. This was particularly bad in damp or cold weather.

“I can say that over the years my symptoms seem to have got worse. The blanching has spread and I find it hard to pick up small items.”

The HSE investigation found that Rowes Garage had not put in place adequate management arrangements to assess and monitor the exposure of its employees to vibration. There was no suitable and sufficient risk assessment and control measures had not been implemented despite the likelihood of the exposure action value being exceeded.

Employees were not informed of the risk via information, instruction or training. Additionally, despite both employees reporting symptoms of ill health for a number of years, the company failed to take sufficient action to reduce their exposures.

Rowes Garage Ltd of Vertu House, Fifth Avenue Business Park, Gateshead, Tyne and Wear (since November 2023), pleaded guilty to breaching Section 2(1) of The Health and Safety at Work etc. Act 1974. The company was fined £204,000 and ordered to pay £8,099 in costs at Plymouth Magistrates’ Court on 8 May 2025.

HSE inspector Emma O’Hara said “Rowes Garage Ltd had been exposing employees to the risks arising from the use of vibrating tools for a significant period of time.

“They fell below expected standards which has been reflected in the fine that has been imposed. HAVS is a serious and disabling permanent condition and HSE will not hesitate to take action against employers that fall below the expected standard.”

The prosecution was brought by HSE enforcement lawyer Jonathan Bambro, and Paralegal Rebecca Forman.

The employee, who was 20-years-old at the time, was working for LP Ollier & Son on its potato farm when the incident occurred on 18 October 2023. While assessing a blockage in the potato harvester machine, the roller mechanism caught his right leg and pulled it into the device, causing serious injuries including crushing, fractures, nerve damage and skin damage. He has been unable to work in agriculture since the incident.

With Health and Safety Executive (HSE), Great Britain’s national regulator for workplace health and safety, highlighting that UK statistics around fatal workplace accidents plateauing over the past decade, experts from fields including architecture, manufacturing, media, charities, and those who’ve experienced life-altering accidents, offered valuable insights to help improve safety practices across industry.

The discussion, focused on the risks of working at height, revealed that despite advances in technology and attitudes around safety, fatalities remain each year. In 2024 alone, 138 people lost their lives in workplace accidents, 36% of which were due to falls from height. The current figures on non-fatal accidents have remained consistent for years, the current rate being similar to 2018/19 levels, further underscoring the need for change.

Key takeaways from the discussion include the importance of clear communication, accessible safety education, and the need for comfortable, well-designed personal protective equipment (PPE) that workers are more likely to wear. The panel also identified barriers such as human nature, poor equipment design, and budget constraints that may often hinder safety improvement efforts.

Panel member Jason Anker, who has dedicated his life to safety advocacy after a life-changing fall, emphasised that a total safety culture must be ingrained at every level of the industry when it comes to working at height - from designers to contractors and to workers themselves. 

Panellists agreed that engaging key stakeholders, improving PPE design, and making safety a priority from the beginning of a project are all critical steps in helping to foster a culture of safety.

The goal is clear: by driving communication, collaboration, and education, the industry can help reduce accidents and fatalities, ultimately creating a safe, resilient workforce. 

To download the insights paper or watch the full panel discussion, visit www.msasafety.com/whitepaper-creating-safer-workplaces

For many teams operating across international projects or in high-risk sectors, one of the most recognised benchmarks for safety understanding is an OSHA compliance certification.

Although OSHA is a United States regulatory body, its frameworks are widely referenced outside the U.S., especially by multinational companies and suppliers operating in sectors like construction, manufacturing, energy and logistics. These standards help define how workplaces can reduce accidents, improve incident response and meet training requirements in environments where workers face real hazards every day.

A safety culture through OSHA training

A certified workforce is not just trained to follow rules but prepared to act with confidence when conditions change. The value of an OSHA compliance certification lies in how it teaches people to identify risks, communicate clearly, and prevent incidents before they escalate. From proper equipment handling to understanding fall protection and hazard communication, the training provides a clear framework that reinforces not just what to do, but why it matters.

For safety managers, having employees who are OSHA-certified also means fewer gaps in understanding during audits, fewer mistakes during critical operations and a stronger foundation for team accountability. Certification is more than a box to tick; it's a signal that safety has been built into the way people approach their work.

Expanding access through online certification

In the past, accessing this type of safety training required travel or scheduled in-person sessions. That is no longer the case. Through OSHA certification online, teams can now access high-quality, standards-aligned training regardless of location. This shift has been especially important for organisations with distributed teams, contractors in remote areas, or new hires who need to complete onboarding quickly without interrupting site operations. Online certification follows the same regulatory structure as classroom-based training. The courses cover essential topics such as personal protective equipment, workplace hazard identification, confined space protocols, emergency planning, and electrical safety. Learners are assessed, and records of completion can be centrally managed to ensure compliance across departments.

FMTC offers comprehensive OSHA certification courses online, designed to meet regulatory standards while providing flexible learning options tailored to the needs of modern, distributed teams. For companies with international reach, the ability to train teams to OSHA standards without logistical delays creates an advantage. It builds consistency, avoids regional training gaps, and ensures that teams on the ground are working from the same safety expectations.

A Clear Investment in Prevention

Workplace incidents cost more than time and money. They affect morale, reputation and business continuity. Investing in structured safety training, particularly through programmes like OSHA compliance certification, is one of the most direct ways to reduce those risks; it sends a message that the organisation values preparation.

Safety should not be limited to checklists or occasional toolbox talks but must be embedded into how tasks are planned and executed, communication and how equipments are used. Training supports this by setting a standard that everyone on site can understand and follow.

Conclusion

As regulatory expectations continue to evolve and workplaces become more complex, clear and accessible training is essential. Programmes such as OSHA compliance certification provide both the structure and the credibility needed to ensure that teams are prepared for the real risks they face on the job. With the availability of OSHA certification online, that preparation is now easier to deliver across multiple teams and locations, creating safer, more resilient workplaces in every industry.

Stephen Pywell was working under the control of Affordable Lifestyle Design Limited at a site in Thurmaston on 18 March 2019. It was during the roof construction phase when the 59-year-old fell while walking on the beams. He had accessed the beams via a ladder, however there was no edge protection in place to prevent falls. He fell from a height of just under eight feet. He was taken to hospital where he underwent surgery, but died several weeks later on 13 May as a result of his injuries.

An investigation by the Health and Safety Executive (HSE) found that James Pitsillides, the director of Affordable Lifestyle Design Limited, had failed to manage the roof work. This included ensuring that roofing subcontractors, including Mr Pywell, were not exposed to health and safety risks.

Pitsillides pleaded guilty and was given a 20-week prison sentence, suspended for two years. The district judge also ordered him to complete 200 hours of unpaid work.

Working at height remains one of the leading causes of workplace injury and death and HSE has detailed guidance on working safely at height.

That guidance states that work at height must be properly planned, appropriately supervised and carried out in a manner that is safe. The “hierarchy of control” prioritizes collective fall prevention measures, for example scaffolding with suitable edge protection. If this isn’t feasible, fall mitigation measures like airbags or netting should be considered to reduce the consequences of a potential fall. In this case, none of these measures were used, and workers were accessing the roof with a ladder and no additional fall prevention measures in place.

James Pitsillides of Orchard Lane, Great Glen, Leicester, pleaded guilty to breaching Section 37 of the Health and Safety at Work etc. Act 1974, relating to an underlying breach of s.3(1) by his company. He received a 20-week prison sentence, suspended for two years and must complete 200 hours of unpaid work. He was also ordered to pay £10,000 in costs at Leicester Magistrates’ Court on 7 May 2025.

HSE inspector Phil Gratton said: “Every year, a significant number of incidents occur in construction as a result of poorly planned work at height.

“This was a wholly avoidable incident, caused by the failure to implement simple fall protection measures. Had the company used suitable work equipment or devised a safe system of work, Mr Pywell’s tragic death could have been avoided.

“Our thoughts remain with his family and friends.”

The airline was prosecuted by the Health and Safety Executive (HSE) following two separate incidents at Terminal 5 at Heathrow Airport.

On 25 August 2022, a 54-year-old employee had been unloading baggage containers from an aircraft when he slipped off a televator and landed 1.5 metres onto the ground below. He suffered serious back and head injuries, including a fractured vertebrae, as a result.

The HSE investigation found there were gaps between the televator’s guardrails and the aircraft fuselage, the size of which depended on the type of aircraft, creating the fall from height hazard. The gaps increased in size after the front of the televators’ platforms at Terminal 5 were extended – but additional measures to prevent falls from height had not been implemented.

At the time of the incident, British Airways had started a programme to retrofit extendable guardrails to televators in response to previous HSE visits. This was completed following the incident.

In the second incident a British Airways worker sustained head injuries, including a fractured jaw and bleeding on the brain, on 8 March 2023, while unloading baggage containers from an aircraft following its arrival from Seattle. The 43-year-old fell from an elevator and landed three metres onto the ground below.

Both employees were taken to hospital for treatment and had to take several months off work.

The HSE investigation into this incident identified a risk of employees falling from height from the front of the elevator platforms when they were being used during loading and unloading of some aircraft types. Flaps on either side of the platform would be left folded down leaving a gap between the platform and aircraft fuselage.

It also found that the elevator’s operator platform had not been fully extended towards the aircraft, creating a gap which employees could fall through.

Falls from height remain one of the leading causes of workplace injury and death. HSE has detailed guidance on working safely at height while the Civil Aviation Authority has guidance with input from HSE on ground handling activities, including aircraft loading, on its website.

British Airways PLC, of Waterside, Speedbird Way, Harmondsworth, Greater London, pleaded guilty to two charges under Regulation 6(3) of the Work at Height Regulations 2005.

The company was fined £1.33 million in relation to the August 2022 incident, and £1.875 million in relation to the March 2023 incident. The company was also ordered to pay £20,935 in costs at Southwark Crown Court on 15 May 2025.

HSE enforcement lawyer Rebecca Schwartz, who brought the prosecution said, “Falls from height present a real risk of death or serious, life-changing injury. Both employees are fortunate to be alive today.

“The risks of working at height and the necessary control measures are well established – in these cases adequate guardrails would have significantly reduced the risk of harm. This was a reasonably foreseeable risk that British Airways should have been aware of and therefore it should have done more to protect its employees.”

Moving baggage between an aircraft and the luggage carousel in the terminal building is dynamic and time-pressured. It therefore comes with a range of risks to baggage handlers. Several HSE inspections have taken place at Heathrow Airport, identifying risks with manual handling and maintenance of equipment as well as falls from height. Airlines and ground handling companies have needed to take action as a result of these visits. HSE guidance is available here.

This HSE prosecution was supported by HSE paralegal officer Melissa Wardle.

Fakenham-based Nat Pal Limited was visited by the Health and Safety Executive (HSE) in April 2023. Dust was found scattered across the floor, and the inspection identified failings in the company’s control measures to prevent exposure of their employees to wood dust and enforcement action was taken.

Bishop Bewick Catholic Education Trust and gardening services provider Nicolas Thépot (trading as ‘The Green Yem’) both pleaded guilty to health and safety breaches following the incident, which left a 68 year-old with serious injuries.

Gillian Gardner had been walking her dog on the pavement along West Road in Newcastle when she was hit by the falling branch, which, as a result of the impact, knocked her on to the road and into the path of incoming traffic.

The incident took place on 9 August 2022. Thépot had been contracted by the trust to fell two trees in the grounds of St Cuthberts Catholic High School on Gretna Road. He and a young apprentice set about the work and having climbed one of the trees, Thépot was using a chainsaw to remove branches and sections of the trunk. He had been using a rope to tie to the branches to be removed, with his young apprentice tasked with pulling each one inside the school boundary as they fell.

However, it was during this operation that the rope snapped, causing both it and the falling branch to crash into Mrs Gardner and her dog.

In a statement, she said her ordeal had left her unable to leave the house for several weeks, with the injuries sustained including several broken ribs.

“It probably took about a year to totally recover she said. “I still can’t carry anything heavy. I feel like it has all been downhill since my accident and I’ve lost confidence in what I can and can’t do."

An investigation by the Health and Safety Executive (HSE) found that Thépot had no training or qualifications in arboriculture or in the use of chainsaws. He was using an unsafe method to fell the tree, by carrying out aerial chainsaw work above the open footpath and road.

The investigation also found Bishop Bewick Catholic Education Trust had made no checks on Thépot’s experience, competence or qualifications. The trust had not checked how he intended to do the work in advance of awarding the contract, made no check on the method used during the work, and did not stop the work after the incident.

In fact, Thépot continued working on the tree the very next day using the same method. The only change made was that some cones and tape were placed on to the pavement. There was no way around the coned off area for pedestrians without stepping into the busy road, nor was there any signage in place to indicate risk. Members of the public were still walking underneath the tree while Thépot was working with a chainsaw – with the risk not immediately obvious to members of the public from the path. The trust did not attempt to stop him working in this manner despite the obvious risks and the incident the previous day.

The work was only stopped when HSE inspectors became aware of the incident, arrived on the scene, and served prohibition notices on both the trust and Thépot.

Bishop Bewick Catholic Education Trust, pleaded guilty to breaching their duty under section 3(1) of the Health and Safety at Work Act 1974 to conduct their undertaking in such a way as to ensure, so far as is reasonably practicable, that persons not in their employment are not exposed to risks to their health or safety. It was fined £20,000 and ordered to pay £4,344 in costs at Newcastle Upon Tyne Magistrates Court on 17 April 2025.

Nicolas Thépot, (of Netherwitton Way, Newcastle upon Tyne) as a self-employed person, failed to discharge his duties under section 3(2) of the Health and Safety at Work Act 1974, to ensure persons not being his employees are not exposed to risks to their health or safety. He pleaded guilty at South Tyneside Magistrates Court on 7 May 2025 and was given a 12 week prison sentence, suspended for 12 months. He must also complete 100 hours of unpaid work and ordered to pay £1,000 towards the prosecution costs.

After the hearing, HSE inspector Stephen Garner said: “This incident was completely avoidable had the tree been felled by a safe method with controls put in place to protect members of the public from being struck by falling branches.

“It is particularly concerning that, in this case, the work continued by the same method the very next day, even after a member of the public was injured.

“This prosecution demonstrates HSE will not hesitate to take action against those who put the public at risk through unsafe work methods.”