Royal Mail have developed and completed an initial trial of a white plastic sleeve insert for Yorks and they will now enter the full Royal Mail network from the 30th May. Managers are required to deliver a operational WTLL to all staff which covers the design and use of the new sleeve insert and associated equipment.
Safety Requirements
In preparation of the safe introduction into the network, managers are required to complete the following activity:
all staff to be briefed on the Safe Working Instruction with documented evidence.
all staff to watch the training video with documented evidence.
#We have the right amount of s**t-but not enough shovels.
31 May 2023
To All CWU ASR in Royal Mail Group:
Colleagues,
Re: Royal Mail – National Roll Out of York Container White Correx Plastic Sleeves
Introduction:
Further to previous reports to ASRs, this is an update on Royal Mail’s decision to go ahead and roll out the new reinforced
White ‘Correx’ York Container reinforced plastic sleeves.
Whilst we have no major safety objection to these sleeves being introduced into the ‘Automation Operation’, the ludicrous and backward step of introducing these ‘bottomless’ sleeves, into the ‘Manual Operation’, instead of continuing with the jointly developed, ergonomically, well designed, ‘Red Mk2A, Auto-Level Packet, (ALP)’ sleeves, is strongly objectionable and does not have the support or agreement of the CWU/HQ Health, Safety & Environment Department. This introduction and roll out has been done unilaterally by ‘diktat’
Consultation – No Agreement:
Consultation has taken place with the Health, Safety and Environment Department, during which we have repeatedly expressedour serious concerns and reservations regarding the replacement of Red Mk2A Auto-Level Packet (ALP) York Container Sleeves with these ‘bottomless’, White ‘Correx’ Plastic Sleeves in the ‘Manual Sorting Operation’ and we expressed the view that if Royal
Mail was to introduce them, then they should be used in the ‘Automation Operation’ only. Royal Mail Operational management rejected that idea and want to drive the ‘Correx’ sleeves in everywhere.
History and Development of the York Container and Auto-Level Packet/Parcel (ALP) Sleeve:
Prior to this latest turn of events, under Royal Mail’s new senior management ‘regime’, Royal Mail through the Assets and Containers Team have jointly spent a lot of time over the years working together with the CWU and manufacturers (K.Hartwall – Containers and Jacon - Sleeves) testing, trialing, developing and delivering into service the ‘optimum’ roll container and sleeve,
namely the Mk3 York Container and the Mk2A ‘Red’ ALP (Auto Level Packet) Sleeve which combined has given Royal Mail a good, safe, ergonomically sound, all-round performance in both the Manual and Automation operations.
With the ALP Sleeve, we have a sleeve which is ergonomically tested with an adequately controlled risk assessment level which is Safe and sound for manual sortation. It provides a ‘robust’ combination that stands up well to the rough, tough, arduous wear and tear life in the Royal Mail network and in road and rail modes of transportation, having stood the test of time.
That’s all now been abandoned virtually overnight by the new Royal Mail Operations ‘regime’ running the company in a way that indicates a backward step to a strategy of ‘profit and productivity before safety and health.’
White ‘Correx’ Plastic Sleeves’ Begin To Appear:
At the beginning of the month these ‘White Correx Plastic Sleeves’ along with the forerunner ‘Black Plastic Prototype Sleeves’ began appearing in Mail Centres and Delivery Offices around the country and the trickle gradually became a flood over the last four weeks. No one was consulted or fully informed of this intention and Offices were flooded with them, causing a state of ‘Bedlam’. These white Correx Plastic Sleeved York Containers have descended on the Royal Mail Offices like a ‘plague of locusts’ – returning an old disease of the past, which we have worked so hard to rid of in the company.
As you’ll know strong representations were made to Royal Mail regarding these sleeves, due to there being no Risk Assessment and Safe System of Work in place and no Information, Instruction and Training for staff.
The Head of Assets positively responded by issuing an ‘Mandatory’ ‘Action Flash’ number CPC (2023) 016, which instructed all Office Managers to immediately withdraw and return all ‘Correx’ Sleeved Yorks to the NW Super Hub at Warrington until a Trial had been completed in consultation with the CWU. However this instruction was simply ignored and ‘overridden’ by the new Royal Mail Operations ‘regime’s’ ‘Project Team’ and the ‘Correx Sleeves’ continued to flood into the network. This unofficial, but what seemed to be quite intentional, unofficial, roll- out has now become the Official roll-out as of yesterday 30 May. Offices can expect to see ever increasing numbers of these white Correx Plastic Sleeved Yorks arriving as the days and weeks go by.
Manufacturing and Production of the ‘Correx’ Sleeves: In March/April four new state of the art “VeloBlade Nexus 2516” digital die-cutter, plastic cutting machines were purchased and installed in the new North West Super Hub and subsequently in the new Midlands ‘Super Hub’. The VeloBlade Nexus machines enable operators to cut any shape or structure directly from a design and the ‘Correx’ plastic Sleeves are now in full production, with the Hubs pushing out ‘Correx’ sleeves in high numbers.
Correx Sleeves Trial:
On 27 March and 4 May discussions took place with the Director RM Operations Programmes and it was agreed to set up a ‘closed loop’ trial of the ‘Correx Sleeves’ to test Manual handling issues and solutions. It was suggested that the trial would test ‘a garden rake’ and ‘a snow shovel’ as tools to empty small parcels from the lower levels of the white ‘Correx Plastic Sleeves’. Sceptical as we all were, with the support of the North West Region CWU ASRs a Trial was set up. Needless to say, the trial (between the Warrington Mail Centre and Warrington Delivery Office) was a complete failure and was heavily criticised by members participating in the trial at Warrington Delivery Office. The opinion of the Warrington DO workforce that took part in the trial, was in summary that;
· The Correx York sleeves were not fit for purpose as a Delivery Office piece of equipment. They are too low, with no self- levelling bottom,
· The rakes/shovels seemed little or no use most of the time and posed tripping and striking hazards. Potential eye and facial injuries from the rakes/shovels handles was an issue working in a tight ‘Bull Ring’ with four people and limited space.
· The ‘perstop letter trays placed on the floor in front of the Sleeves, for collecting the parcels from the bottom third of the sleeves, to be raked/shovelled into, were never designed for this purpose. They were not suitable, too small and
shallow and were a tripping hazard, positioned in front of the York Containers.
· After a short time working/sorting out of the sleeves, all the staff taking part in the trial noticed they were feeling discomfort in the lower back and knees causing lower back ache/pain after approximately 20 minutes working out of them.
· The staff participating in the trial also had concerns that they had a full delivery to complete afterwards, having endured the fatigue of working from the ‘Correx’ Sleeved ALPs.
· Striking against injuries occurred as staff found they grazed knees, arms and hands on the sides as the material which can be too sharp. Some members of staff had visible cuts and grazes due to contact, striking the course/rough edges/sides of
the sleeves.
· Slimmer and smaller packets keep getting stuck between side and floor of the Correx Sleeves. This was another regular problem causing awkward bending and stretching to retrieve the items.
· The Sleeve access aperture has been reduced in size (from the full width of the York fitted with an ALP) and this makes sorting from a ‘Correx’ sleeve awkward due to the design of the Sleeve at the front.
· The Velcro points on bottom doors can come undone and cause the lower door to be trip hazard.
· Yorks were arriving with damaged Correx sleeves regularly.
· One York Correx Sleeve front section burst open as it wasn’t robust enough to retain the load.
· Parcel damage was noticed on a number of items. It was thought that this may be due to items dropping full height from Parcel Sorting Machines and hitting the hard York base with nothing to cushion the fall.
· Repatriation is an issue, as drivers have not had training how to load, nest, strap and move ‘Correx Sleeved Yorks.
· Empty Correx Sleeved Yorks cannot be strapped together, to be moved around as per the SSoW.
However, instead of considering the Trial outcome before proceeding any further, the Trial process was truncated and unilaterally
abandoned with the decision taken to press on with the roll-out of the ‘Correx White Plastic Sleeves’ irrespective of the Trial outcomes and conclusions making the whole exercise nothing but a ‘sham’.
It is clear that yesterday’s ‘go-live date of 30 May rolling out the ‘Correx’ sleeves nationally via both the automation and manual operations had always been the pre-determined outcome. Clearly it would appear that the national RM operational management project team are ignoring everything and everyone!
Ergonomic Evaluations:
Both internal and external ‘Ergonomic Reports’ were undertaken and all came to similar conclusions – that the manual operation process contains a level of risk when manually sorting from these ‘Correx’ sleeves.
Risk Assessment and Rating Level (SAC1):
The RMG Safety Team who in our view are not supportive of this ‘Correx’ Sleeve idea, (although they can’t say it) were told to make it safe and they have done their best to build in mitigations but in my opinion and they have had to make a ‘Silk Purse out of a Sows Ear’ and attempt to turn something inferior into something looking attractive and of value to the business.
As you’ll be aware, there are five risk levels in the Royal Mail Group risk assessment process (SAC1) process;
(a) Adequately Controlled,
(b) Tolerable Risk,
(c) Moderate Risk,
(d) Substantial Risk,
(e) Intolerable Risk.
The outcome of the ‘Correx White Plastic Sleeves’ is ‘Moderate Risk’ and this is the first, one and only SAC1 which has come out and been introduced in RMG at this risk level rating. We pointed out that the aim of the risk assessment process when introducing change should be to achieve a ‘risk neutral’ outcome or better – not to go backwards, changing the process to a higher risk process which is what’s happened with the ‘Correx’ Sleeves.
A ‘Moderate’ Risk rating is one where efforts should be made to reduce the risk and further task assessments and/or task re-design may be necessary to achieve suitable control measures!
Back Pain and Musculoskeletal Issues and Sick Leave in Royal Mail: It seems ironic and perverse’ that whilst 154,000 days were lost to sick leave from Royal Mail last year due to ‘Back Pain’ costing
£16 million and whilst the Union continues the battle against Low Level Letter Boxes – Royal Mail should introduce work equipment and a work method in which there is a musculoskeletal risk that can only make that situation worse, increasing the musculoskeletal, manual handling risks to those employees forced to sort from these sleeves, taking safety in Royal Mail backwards
Royal Mail’s Environmental Policy and ‘Plastic Pollution’: Royal Mail boasts about its ambitious long-term ‘green’ plan for the business – reducing overall emissions to zero through initiatives, reducing the amount of natural resources the operations consume, working towards a circular economy, by cutting waste, pollution and emissions from the business and yet it is on route to producing around a million ‘Correx’ Plastic York Container sleeves. World Environment Day 2023 on 5 June has the theme “Beat Plastic Pollution”. The United Nations is calling upon nations and companies to make efforts to reduce plastic pollution. The UN states that ‘Plastic Pollution’ is regularly in the news due to its terrible consequences on the environment and human and animal health, laid bare by documentaries such as “Blue Planet.” Heavy use of plastic increases the pollution in the environment. The world is being inundated by plastic. More than 400 million tonnes of plastic is produced every year. Royal Mail are just started adding to it!
Safety Materials & Documentation for ‘Correx’ Plastic York Container Sleeves:
Safety materials have been produced by the RMG Safety Team and the RMG Ergonomist to support the roll out of these Sleeves and use in the manual operation. See attached:-
Ø SAC1 – Safety Concurrence/Risk Assessment (copy attached)
Ø WTLL – Work Time Listening and Learning Managers Briefing (copy attached)
Ø SWI – Safe Working Instruction (copy attached)
Ø A Training Video (Accessed through link in the WTLL Document attached)
Managers must ensure that you staff are fully competent and have completed the training including:
Ø Being briefed on this SWI (Safe Working Instruction).
Ø Have undergone Manual Handling Training within the last 3 years.
Ø Been trained on the York Container White Correx Sleeve Insert and Slider/Snow Shovel Tool and watched the training Video.
Duty Rotation:
The ‘Mandatory’ SWI sets out that there must be a ‘rotation’ of duties, restricting sorting from/to Correx Sleeved York Container to a maximum of 1 hour on/1 hour off.
Monitoring & Health Surveillance:
The RMG Safety and Health team will monitor the introduction and impact of the Correx Sleeves with health surveillance and questionnaires.
HSE:
The HSE may well frown upon Royal Mail’s backward step. We intend to test the Businesses claim of legal compliance and adequate risk Control with the HSE.
Conclusion:
Not unsurprisingly the early signs are that the workforce are not happy and are complaining about having to sort from the ‘Correx’ Plastic Sleeves. We expect the situation to worsen as the number of ‘Correx’ Plastic York sleeves increases in circulation . The ‘clumsy’ and awkward standard operating procedure, lack of Management support and safety leadership, inadequate attention to ensuring correct safety procedures, poor safety communication and compliance may lead to allowing widespread unsafe work practices to happen when sorting from the ‘Correx’ Sleeves which is a real concern. We will be closely monitoring the impact of the ‘Correx’ Plastic sleeves and reaction in the workplaces on the proposed “safest way possible to manually empty the white ‘Correx’ sleeved York Containers, the tools and rotations.
Important ASR/WSR Action:
Please immediately trawl all workplace sites to reinforce the key messages. Carefully monitor safety compliance, work practices and feedback through regular safety inspections and spot checks, submitting safety inspection reports to management, logging Inspections are important as they allow you to listen to and record legitimate concerns of workers and supervisors. Gain further
understanding of difficult tasks. Investigate potential hazards and complaints by employees relating to their health, safety and welfare. Make representations to management and submit written safety inspection reports to management on matters affecting the health, safety and welfare of members. Get it on the record!
Regards and Best Wishes.
Yours sincerely
DJ Sig
From Dave Joyce | National Health, Safety & Environment Officer
