Lessons from the Inghams Enterprises Prosecution: Preventing Workplace Incidents through Safety and Compliance

The recent prosecution of Inghams Enterprises Pty Ltd serves as a critical reminder of the importance of workplace safety, particularly in high-risk environments. In February 2020, a worker at Inghams’ North Ryde plant suffered serious injuries after becoming trapped in a horizontal auger within an ice-making freezer room. Following an investigation by SafeWork NSW, the company was charged under section 32/19(1) of the Work Health and Safety Act 2011 and was fined $450,000 by the District Court in December 2023. This incident highlights key safety issues that businesses must address to prevent similar incidents and protect their employees.

Key Learnings from the Incident

The Inghams Enterprises incident underscores several critical areas where safety measures may have fallen short, revealing essential lessons for other businesses operating in high-risk environments:

1. Machine Guarding and Safety Controls:

   - The incident involved a worker being trapped in a horizontal auger, a type of equipment commonly used in industrial settings for moving materials. Augers and similar machinery pose significant risks due to their moving parts, making it essential to install protective guards and interlocks that prevent accidental access to dangerous areas.

   - Machine guarding should be a top priority, especially in high-risk zones like ice-making freezer rooms or areas where rotating machinery is in operation. Safety barriers, automatic shutdowns, and emergency stop systems are crucial measures to prevent unintended contact with machinery.

2. Risk Assessments and Hazard Identification:

   - A comprehensive risk assessment is essential for identifying potential hazards and implementing preventive measures. Inghams’ incident reveals the importance of regularly evaluating workplace risks, particularly for equipment that could cause entrapment or severe injury.

   - Risk assessments should consider the design and location of equipment, the likelihood of human interaction with machinery, and the specific hazards present in cold or confined environments like freezer rooms.

3. Clear Safety Procedures and Access Control:

   - Workers need clear procedures for safely accessing and operating machinery. In this case, entering an area with moving machinery, especially without adequate safety measures, posed severe risks.

   - Access to hazardous machinery should be restricted, and clear protocols should dictate when and how equipment can be accessed safely, including requirements for lockout/tagout (LOTO) procedures to isolate energy sources before maintenance or repairs.

4. Regular Maintenance and Inspections:

   - Routine maintenance and inspections are vital to ensure that all safety features are functioning properly. For instance, machinery should be routinely checked to confirm that guards and emergency stop buttons are operational.

   - Businesses should establish a maintenance schedule that includes not only functionality checks but also tests of all safety interlocks, guards, and control systems.

5. Comprehensive Training and Supervision:

   - Training employees on safe operating procedures and reinforcing the importance of following protocols are essential in preventing incidents. Workers should be trained on the risks associated with specific machinery and the steps required to avoid injury.

   - Supervision also plays a vital role, as trained supervisors can observe and correct unsafe practices, ensuring adherence to protocols, particularly in hazardous areas.

How Businesses Can Prevent Similar Incidents

To avoid incidents like the one at Inghams Enterprises, businesses must adopt a proactive approach to workplace safety, particularly when dealing with high-risk machinery. Here’s how organisations can bolster their safety practices and comply with WHS standards:

1. Conduct Thorough Risk Assessments and Update Regularly:

   - Implement a risk assessment framework that identifies potential hazards associated with machinery, particularly in high-risk environments. Assessments should be updated regularly or when changes occur, such as equipment upgrades or layout modifications.

   - The assessment should evaluate all potential interaction points between workers and machinery, focusing on control measures to eliminate or reduce exposure to hazards.

2. Enforce Machine Guarding and Access Control Measures:

   - Install appropriate machine guarding and safety controls, including interlocks, physical barriers, and emergency stop mechanisms. Ensure that guards are secure and cannot be bypassed.

   - Implement strict access control policies, ensuring only trained and authorized personnel can access areas with dangerous machinery. Consider using automated locking systems to restrict access while machinery is in operation.

3. Implement and Enforce Lockout/Tagout (LOTO) Procedures:

   - Lockout/tagout procedures are critical for controlling hazardous energy during maintenance, repair, or cleaning activities. All workers should be trained on LOTO, and protocols should be strictly enforced.

   - Ensure that all relevant machinery has clearly defined LOTO procedures, and conduct regular drills or refresher training to reinforce these practices.

4. Schedule Routine Maintenance and Safety Inspections:

   - Machinery should undergo routine maintenance and inspections to verify that all safety features, such as guards and emergency stop systems, are functioning correctly. Inspection logs should be kept to track maintenance schedules and identify any recurring issues.

   - Regular audits of safety controls help businesses identify areas for improvement and ensure that all equipment is maintained according to industry standards and manufacturer guidelines.

5. Provide Comprehensive Training and Ongoing Supervision:

   - Training should cover the specific risks associated with all machinery, safe operating procedures, and what to do in an emergency. Workers should be trained before starting their roles and receive regular refresher training.

   - Supervision is essential to ensure that employees follow safety protocols consistently. Supervisors should be empowered to enforce safety policies and conduct on-the-spot corrections to prevent risky behaviour.

6. Foster a Safety-First Culture:

   - A strong safety culture encourages employees to prioritize safety and feel comfortable reporting hazards or unsafe practices. Management should lead by example, demonstrating a commitment to WHS compliance.

   - Engage employees in safety initiatives and invite feedback on potential safety improvements. Recognizing and rewarding safe behaviour can help reinforce positive practices across the workforce.

The Inghams Enterprises incident is a reminder of the devastating consequences that can result from inadequate workplace safety measures, particularly around high-risk machinery. This case highlights the importance of machine guarding, rigorous risk assessment, and consistent adherence to safety protocols in ensuring worker safety. By following these lessons and implementing robust safety practices, businesses can protect their employees, comply with WHS standards, and prevent similar incidents from occurring in their workplaces.

Proactive safety management, continuous improvement, and fostering a safety-first culture are essential to creating a safer working environment and avoiding the costly consequences of non-compliance with WHS obligations.