CSS WSM's - Machine Stacker Cover Gas Strut Fail

[POSTMAN]

LTB 004/11 - CSS Walk Sequencing Machines - Machine Stacker Cover Gas Strut Fail

CSS Walk Sequencing Machines - Machine Stacker Cover Gas Strut Failure & Near Miss at South Midlands Mail Centre:

For the information of Safety Reps and those making enquiries on this matter the following can be reported.
A near miss was reported when a spot weld which holds a plate to support the gas strut on the stacker cover failed on a CSS Machine in South Midlands Mail Centre. The cover of the stacker then closed and could have resulted in a staff member becoming trapped. The Royal Mail project team discussed this with Solystic and the root cause was identified to a batch of machines suffering from a lack of weld penetration.

A gas strut is a type of spring that, unlike a typical metal spring, uses a compressed gas, contained in a cylinder and compressed by a piston, to exert a force. Gas struts are used in many applications to support the weight of doors or covers while they are open.

An Investigation was undertaken with manufacturers Solystic and the conclusion was that a limited number of machines in some specific sites are affected. Solystic's third party supplier changed during the CSS machines deployment due to Quality issues and hence the conclusion was that it impacts on a batch of CSS machines only.

However, the risk of injury was significant if a sequencing cover was to hit a member of staff. Therefore a safety bulleting/one point lesson was issued to be followed with immediate effect in every Mail Centre and MPU for all operators who were using the CSS machines. The aim being that once the size and scale of the problem was understood, standard operation for the CSS machines could be reverted to in unaffected sites with a retrofit programme initiated in affected sites.

Solystic subsequently identified a list of 16 sites where there was a potential problem with the CSS Machine's gas struts. These sites have all now been investigated and concluded on 16 December with remaining problems identified on machines in South Mids MC and Gatwick MC. The requirement for the modified safe working method was therefore withdrawn in all sites with the exception of those affected where subsequently replacement parts were fitted.

Full credit to Richard Moor Walk Sequencing Programme Manager and Solystic for dealing with the matter promptly.
As there have been a number of various Weld Failures on CSS Machines, all of which have been subsequently, promptly rectified, ASRs may wish to note this when carrying out Safety Inspections and speaking to Machine operators in order to promptly identify any new issues which may arise for attention.

Yours Sincerely

Dave Joyce
CWU National Health, Safety and Environment Officer