Unsecured Cart Causes Worker Injuries

An injury occurred when three workers at the ACME Label Plant were in the process of rolling four 11-inch cartwheels. Each of the cartwheels were loaded with 15,000 feet of paper from a staging table onto a pallet. The pallet was lying on a cart, which was used to transport the rolls to various parts of the plant. The injured worker’s job was to assist in placement of the cartwheels on the pallet. Two of the cartwheels had been placed onto the pallet and they were attempting to roll the third one on when it caught the edge of the pallet and pushed it and the cart away from the table. There was no established means of keeping the cart stationary during the process without hampering the flow of the process. The movement caused the loaded pallet to shift and fall from the cart. The worker attempted to get out of the way but was struck by the falling pallet and the out-of-control cart. He received injuries to his shoulder, thumb, and shins. 

The investigation also revealed the following facts:

• The employer had tried, without success, various means of keeping the cart stationary without interfering with the flow of the process. 
• As a result of wheel replacement, some of the carts used are different heights.

Recommended Actions

1. Design some type of locking mechanism that would secure the pallet to the cart.
2. Design a mechanism that would make the cart stationary during loading but would not hamper production.
3. Replace worn or damaged wheels on the cart with the same size that came off the cart.
4. Create a Lessons Learned on this incident and circulate throughout the workplace.
5. Conduct safety meetings emphasizing the dangers associated with this job.