MINUTES OF THE 26 SAFETY FORUM

MINUTES OF THE 26TH MEETING OF THE MOTOR VEHICLE REPAIR HEALTH AND
SAFETY FORUM
Wednesday 9th April 2014 – 10.30 am
HSE Birmingham office, Advantage House, Quinton Business Park,
Birmingham, B32 1AL
Present:
Representing:
Paul Billinger
Brian Spratt
Bud Hudspith
David Innes
David Oldham
Graham Threlfall
Ian Lewis
Malcolm Tagg
Mark Champelovier
Nick Ovenden
Paul Cooper
Phil Thirsk
Paul Smith
Steve Mason
Ray Engley
Stan Rudowski
Stephen Green
Steve Grantham
Terry Crampton
Wendy Williamson
Celia Flannigan
HSE – Forum Chair
Independent Automotive Aftermarket Federation (IAAF)
Unite the Union
Scottish Motor Trade Association
Safety Assessment Federation (SAFed)
Bodyshop Magazine
Thatcham Research
Vehicle Builders & Repairers Association (VBRA)
Retail Motor Industry Federation (RMIF)
Institute of Vehicle Recovery
Motor Dealers Safety Group
Bridgestone Tyres
HSE
HSE
Road Haulage Association (RHA)
ATS Euromaster
Association of Colleges
Cooke & Mason
IVR (UK) Ltd
Independent Automotive Aftermarket Federation (IAAF)
HSE (Minutes)
Apologies:
Representing:
John Graham
Alison Higginson
Ruth MacIntyre
Aslam Vaid
Safety Assessment Federation (SAFed) Profit from Training Thatcham Research Retail Motor Industry Federation (RMIF) 1
Actions from the meeting.
1.
Min 9.9 Mr Smith would report back to members regarding the delay with the work on
diesel engine exhaust emissions.
2.
Min 9.10 Volunteers were still required for the truck bed liners research. Anyone
wishing to volunteer should contact Paul Smith.
3.
Min 9.10 Members were invited to submit any other information regarding paint
technologies.
Outstanding actions from meeting of 18 September 2013
1.
Members to contact Paul Smith if they had any further concerns about the revision of
HSG261 before going to limited external consultation.
2.
Unite had no further information regarding contact details for the new Forum member
to represent their members in bus and coach MVR.
Mr Smith had received some communication, which he would follow up.
1. Welcome and Introductions.
1.1 Chair welcomed everyone to the meeting. Members introduced themselves and stated
which organisations they represented.
2. Actions from the last Meeting.
2.1 (Min 5.4 (c)) and (Min 9.4). Members to inform Paul Smith if they had any further
concerns about the revision of HSG261 before going to limited external consultation.
2.2 Unite had no further information about contact details for the new Forum member to
represent their members in bus and coach MVR. Mr Smith had received some
communication, which he would follow up.
2.3 The minutes of the last meeting were agreed as an accurate record of the meeting.
3. Hybrid and Electric Vehicles.
3.1 Steve Mason, HSE Specialist Inspector (Electrical Engineering) gave a presentation
informing members of the growth in environmental awareness, leading to an increase in
numbers of hybrid and electrical vehicles and increased work on such vehicles. Four
key generic areas of work were:
• non technical work – eg sales or valeting
• vehicle recovery and emergency services
• repair and maintenance to parts of vehicle not related to high energy electrical
system
• repair and maintenance of high energy electrical system
Mr Mason spoke of differences between electric vehicles (EVs) and hybrid vehicles
(HVs) and of the many variations to exact configuration between makes and models.
Highlighted were the dangers of electric shock on the body and the amount of current
that would be potentially fatal.
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Greater exposure to potentially serious risks included:
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higher voltages (up to 650 Volts) than that of a standard (12V) vehicle
multiple sources of energy
different designs of vehicles
possibly larger, heavier batteries presenting manual handling risks
motors may move independently, even when isolated due to containing large
magnets
• pacemakers could be affected by vehicles’ electrical systems
• requirement for different types of worker competencies
Other risks involved in maintenance, repair and recovery include:
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shock
arc or flash over
explosion
fire
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burns
falls
unexpected start-ups
heart failure
A number of safe working practices and precautions to take when carrying out work on
EVs and HVs were emphasised, as well as the need for competent workers.
There was discussion among members about:
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raising awareness of risks among technicians – including bus engineers
getting relevant information and guidance across to the industry
manufacturers training schemes, specialist kits, colour coded parts
buying/leasing batteries – what happens when the car is sold on
franchise dealers and non franchise dealers
- warranty cover/greater awareness of risks (franchise)
- non franchise organisations of questionable competency – undertaking
repair work when no longer under warranty
Members were informed of liaison, consultation and research taking place with
manufacturers and various organisations. Additionally, information being produced
aimed at raising awareness within the industry of potential risks of working on these
types of vehicles as well as information/guidance planned for HSE’s website, structured
in the four key generic work areas (see above).
4. Graham Threlfall – Bodyshop Safety – body repair
4.1 Mr Threlfall, Bodyshop Magazine presented this item. He gave an overview of the
magazine and its circulation figures. He told of a bodyshop directory, produced annually
and a fleet managers’ guide to bodyshop services circulated twice a year.
He spoke of their events awards schemes, citing the International Bodyshop Industry
Symposium (IBIS) – a two-day conference that would take place in Barcelona during
May 2014 comprising representatives from the insurance industry, manufacturers,
distributors and paint companies from approximately thirty-two different countries. There
was also attendance at smaller conferences and Steering Group meetings, which
provided networking opportunities to engage with other professional organisations.
Additionally, liaison with the Institute of Automotive Engineer Assessors (IAEA).
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He gave a summary of the market regarding:
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number of claims
estimate market value/UK aftermarket value following body repair
number of primary bodyshops
total number of core body repairs (excluding very small enterprises)
average staff turnover
Mr Threlfall went on to outline some of the bigger issues surrounding bodyshop safety
and body repair. Included were:
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profitability
- investment – new technology, computerisation, skills
- limited resources
management capability
- work volumes
compliance
- how to manage
structured health & safety management system
- use of consultants
- auditing
- dedicated resources
- staff welfare
- awareness
- requirement by insurers to meet British Standards
The above was in contrast to organisations whose attitude towards health and safety
was indifferent. Perceptions of health and safety in certain parts of the industry needed
to change. Mr Threlfall informed members of a health and safety Q&A that had been
conducted by Bodyshop that would be repeated on a regular basis, and advised
members of their new website being built. It would contain free services and tools to
help educate and raise awareness of specific issues in the industry, breaking down
barriers and communicating best practice. Some members felt greater targeting by HSE
was necessary, taking enforcement action and applying FFI as a deterrent.
5. PM85 and Training.
5.1 Nick Ovenden, Institute of Vehicle Recovery (IVR) presented. Formed to set training
standards for the vehicle recovery industry, IVR was appointed in 2006 as administrators
of the Highways Agency Scheme for the training and registration of roadside assistance
and vehicle recovery technicians.
Mr Ovenden spoke of the requirement for drivers of commercial vehicles over 3½ tonne
to complete thirty-five hours of periodic training by 10th September 2014 to obtain the
CPC training card, unless exempt.
He went on to inform members of IVR’s modular training system. He told of “core”
modules, which were mandatory, and a series of additional modules for specific job role
descriptions, advising of the number of days/hours to achieve each module. Most
training was carried out at approved training centres although some training could be
delivered at the workplace provided there were suitable facilities. Mr Ovenden also
referred to IVR’s “train the trainer” courses at which most of IVR’s instructors had
attended. He informed members that some training providers were delivering courses
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that were not regarded as a registered qualification, advising that there are no QCFs in
IVR’s training modules.
The presentation also covered breakdown and recovery of commercial vehicles, risks
associated with winching, dynamic risk assessment and lane closure. Furthermore, of
IVR’s involvement with National Express, Ryder, NTDA, MOD and the Army.
6. Commercial Tyre Inflation Safety.
6.1 Mr Rudowski presented and gave background information about ATS Euromaster and
its UK operations. The principal hazard when inflating truck tyres was tyre explosion.
On average, there was one truck tyre explosion per 21,000 inflations. He told of some
tell tale signs that a tyre was going to explode and showed members video footage, in
slow motion, of a controlled tyre explosion.
He told of ATS Euromaster’s approach to safe tyre inflation citing the City and Guilds
Truck Award (or competency assessed to the same standard) and inflating tyres at a
distance of three metres for added safety, instead of two metres. He spoke of their
hierarchy for safe tyre inflation, which was:
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7. 7.1 in a tyre safety cage
bolted back onto a vehicle
restrained using a ratchet strap
Commercial Vehicles – roadside safety.
Phil Thirsk, Roadside Technician and Training Manager, Bridgestone Tyres presented
this session. He informed members of Bridgestone’s two-day training course delivered
to tyre technicians for roadside tyre fitting. He outlined specific modules, which were:
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health and safety
- multi question paper covering aspects of Health & Safety at Work Act,
COSHH, noise, lone working etc
customer service
- overview of customer needs
assessment of roadside situation
- dynamic risk assessment
The training arose as a result of IVR’s approach to vehicle recovery. Bridgestone had
adopted a similar training scheme for tyre technicians. He told of Bridgestone’s liaison
with a number of organisations and of the need for the tyre industry to become more
transparent and share information across the industry. He informed members about:
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number of faults/breakdowns
number of wheel/tyre issues (blowouts, flat tyres, shredded tyres)
problems of debris on highways
increasing number of lay-by incidents
hard should injuries/hard shoulder fatalities (not all involved tyre fitters)
customers/passengers helping/hindering
vehicle jacking
cost of incidents
lane closures
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Mr Thirsk spoke of both management’s and technicians’ responsibilities; ie management
to ensure technicians carry appropriate fault-free tools and their photocard ID. PUWER
and LOLER were relevant. Technicians were required to check equipment/PPE, safety
devices (cones, beacons, etc) and carry out a risk assessment. He outlined best
practice when technicians attended roadside incidents, eg lead in tapering of cones,
technicians parking a specific distance from the broken down vehicle. He told of the
“dos” and “don’ts” when working at customers’ premises.
Members were shown a DVD on safe working practices at the roadside. The DVD
would be launched at the Commercial Vehicle show.
8. HSE in MVR (Triennial Review, FFI and Inspection).
8.1 Chair updated members and provided figures for the first year of FFI. The number of
invoices issued was gradually increasing due to legacy work being completed. The
average cost of a single invoice remained approximately the same (£500), unless
investigation work was involved. Members were shown a breakdown of the number of
invoices issued by industry sector. Manufacturing and construction generated the
greatest amount. Full details see website.
The disputes process for FFI was changing. From 1 April 2014, queries are considered
by a panel of HSE personnel (managers who are independent of the management chain
responsible for the work that generated the invoice). The next and final dispute stage
will now have an independent external representative on the panel. Full details see
website.
8.2 The outcome of the Triennial Review of HSE led on behalf of DWP by Martin Temple,
Chair of EEF - the manufacturers’ organisation was published in January 2014. The
purpose of the Review was primarily to consider the continuing need for HSE’s
functions. Much was positive about HSE and the Review concluded that the functions of
HSE continue to be necessary and that it should continue to operate as an executive
Non-Departmental Public Body. HSE Chair Judith Hackitt had commented on the near
universal praise for the work of HSE voiced by the many stakeholders who responded to
the Review.
The Review made a number of recommendations for how HSE should operate in the
future. One of the recommendations was that in addition to its regulatory role, HSE
should explore commercial opportunities building on the reputation of HSE/HSL at home
and overseas. As part of this work, Leo Enright has been appointed as Commercial
Director to provide additional resource and commercial expertise to help HSE explore
opportunities for taking this forward. From July 2014, HSE would charge for advice
relating land use planning (LUP) enquiries.
Discussion followed about commercialisation. There was speculation whether HSE
would adopt a ‘consultancy’ role, selling its services to large organisations willing to pay
for inspections. HSE advised various initiatives were being considered but much was
still to be decided.
Strong comments were received from certain stakeholders about FFI throughout the
Review. Some felt it had damaged HSE’s reputation for acting impartially and
independently and of its integrity as a regulator.
A formal Government response to the Review will be made in May.
Update: The response would now be delayed until a date in June.
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9. Updates/Issues.
- Lifting – Project
- Fatals (provisional) & PRs
- Review of Guidance & HSG261
- Isocyanates & Research
- Two Post Lifts
- Diesel Engine Exhaust Emissions
9.1 Chair reported concern about the number of fatal accidents involving lifting operations.
The activity was responsible for one-third of fatalities from 2005-2013. When analysed
causes were:
• movement/collapse of a non supported or incorrectly supported load (not a
vehicle)
• planning issues
• vehicle movement/collapse of some type
• loading and unloading of a vehicle
• equipment failure
Possible next steps to take to address the issue were:
• more operational guidance for inspectors
• sector specific additional guidance/webpages
• raise the profile
- trade associations and dutyholders
- include as a topic at SHADs
- stakeholder initiatives
• future FOD inspection initiative
This was still a significant issue in the MVR sector. In 2013/2014, four fatalities occurred
within two months, two of them to the self-employed.
Chair sought members’ views regarding existing industry guidance and enquired if it was
sufficient and whether it addressed practical issues in the industry. Whilst HSG261 was
due for review this year, members generally felt the existing guidance was sufficient.
He welcomed suggestions for ways and means to help reduce these incidents.
9.2 Members were informed of five fatalities during 2013/2014 (provisional) and of the
circumstances surrounding them. Three crush injuries were identified as non-RIDDOR
reportable. Six prosecutions cases were highlighted. They involved crush incidents,
burns when decommissioning a large petrol tank, a fatal lifting incident with an air jack
and a garage owner who killed a customer when reversing down a driveway.
All prosecution reports can be found on HSE’s website.
9.3 HSG261 will be reviewed this year. Existing issues were:
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pit markings in photos
update isocyanates guidance
update welding guidance
new legislation and other guidance
new tyre safety cages
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Members were advised to contact Paul Smith if they had any further concerns about the
revision before going to limited external consultation.
9.4 The Consultative Document (CD268) sets out proposals from HSE to amend the
following Approved Codes of Practice (ACoPs):
• Provision and Use of Work Equipment Regulations 1998 (PUWER) (L22)
• Safe Use of Power Presses (L112)
• Safe Use of Woodworking Equipment (L114)
The consultation began on 31 March and ends on 23 May 2014. Access the
Consultative Document here.
9.5 Two revised health and safety regulations had taken effect from 1st October 2013.
Changes to the Reporting of Injuries, Diseases and Dangerous Occurrences
Regulations (RIDDOR) 1995 came into effect that clarify and simplify the reporting
requirements. The main changes are:
• classification of ‘major injuries’ to workers has been replaced with a shorter list of
‘specified injuries’
• existing schedule detailing forty-seven types of industrial disease replaced with
eight categories of reportable work-related illness
• fewer types of ‘dangerous occurrence’ require reporting
More information is available at http://www.hse.gov.uk/pubns/indg453.pdf
The Health and Safety (First Aid) Regulations 1981 have been amended to remove the
requirement for HSE to approve first aid training and qualifications. More information is
available at http://www.hse.gov.uk/pubns/books/l74.htm
9.6 The following new Approved Codes of Practice (ACoPs) have been revised and
published online:
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Safety in the installation and use of gas systems and appliances (L56)
Workplace health safety and welfare (L24)
Legionella (L8)
Control of substances hazardous to health (L5)
Managing and working with asbestos (L143)
Dangerous substances and explosive atmospheres (L138)
This second edition of L138 brings together the advice from the previous five ACoPs
(L134, L135, L136, L137 and L138). The withdrawn ACoPs are:
- L134 Design of plant, equipment and workplaces
- L135 Storage of dangerous substances
- L136 Control and mitigation measures
- L137 Safe maintenance, repair and cleaning procedures
HSG265 – Managing for health and safety has been replaced by online guidance
http://www.hse.gov.uk/pubns/books/hsg65.htm
HSE has published revised young people at work guidance. More information is
available on HSE’s Young people at work website.
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9.7 The following recently launched MVR guidance is now available on HSE's website.
• Safety in isocyanate paint spraying http://www.hse.gov.uk/pubns/indg388.pdf
• SMART paint spraying - How to control health and safety risks
http://www.hse.gov.uk/pubns/indg473.htm
• Isocyanate paint spraying – safely managing spray booths and rooms
http://www.hse.gov.uk/pubns/books/hsg276.htm
With regard to HSG276, there is an error near the top of page four, second sentence –
“It is not absorbed through the eyes or skin ….” which will be corrected.
The respirator filters research to establish if cartridge filters protect against isocyanates
consists of three phases:
• phase one, laboratory testing
• phase two, workplace simulation to ascertain if they were effective in a typical
work environment
• phase three, field visits to ascertain which industries use them and for what
9.8 The HSL report on two post lifts has been approved internally and awaiting publication.
BS EN 1493:2010 recommendations for change. Only three out of seven lift posts met
the BS standard re locking mechanism – four out of five having 180o gear and block
failed, only one passed. Both lifts using 360o met the standard.
The next step would be publication for industry, importers and suppliers.
BS EN 1493 is to be reviewed concerning possible revision in Europe – including visual
testing specification and arm lock tests.
9.9 The diesel engine exhaust emissions (Operational Circular) had been delayed.
Mr Smith would report back to members.
9.10 Isocyanates - Volunteers were still required for the truck bed liners research. Some
sampling had been carried out but more volunteer organisations were required for
further site visits. Anyone wishing to volunteer should contact Paul Smith.
Alternative paint chemistries in spraying research – item ongoing – to help make an
informed judgement of ongoing issues, eg:
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blocked isocyanates
what chemistries are involved
what industries are involved other harmful substances monitoring – being planned
literature review
HSE had met with British Coatings Federation (BCF) and a member of industry to
discuss paint technologies. BCF had provided a list, which HSL were reviewing to
establish if there were any associated health issues. Members were invited to submit
any other information.
Chair advised that with regard to isocyanates, “micro” business bodyshops would be a
priority for inspectors’ visits.
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10.
AOB and Next Meeting.
10.1
There were no items of other business.
10.2
The date and venue for the next meeting is to be confirmed.
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