Double Deck Trailer (DDT) Urgent Safety Alert

[TrueBlueTerrier]

No. 031/16
Ref: C25/16
Date: 19 January 2016


To: All Postal Branches

Dear Colleagues

Double Deck Trailer (DDT) - Urgent Safety Alert Issued By PFW Following A Top Deck Near Miss - (Incident Alert: PF/2016/IA/001)

An 'Urgent Safety Alert' has been issued by the Head of Safety, Health and Environment for Parcelforce Worldwide following an Accident 'Near Miss' involving the new 95 York Container, Dual Use Double Deck Trailer which could have caused serious injury.

The Safety Alert explains that the lower deck of a double deck trailer was being loaded with the loaded top deck being elevated to the raised position. During the loading of the lower deck, the loaded top deck started to creep downwards at which point everyone was evacuated from the trailer.

The initial investigation identified that the “yellow flag” locks (chocks) where deployed as per the SSOW. However, as these are chocks, they will allow some movement of the top deck which may come to rest on the chocks. The chocks are designed to stop the top deck, whether loaded or not, from creeping down any further. The investigation also identified it is possible to partially deploy the chocks if the top deck has not be raised and left above the green line.

The Key Messages in the Safety Alerts are:-
1. Only Trained and Authorised personnel, as per SSOW, to raise and lower the top deck.
2. Full load: when raising the upper deck to its upper raised position – raise it above the green line and don’t lower it to sit on the chocks, as this may result in only a few chocks being fully deployed.
3. If the upper deck is raised, only enter double deck trailers if the “yellow flags” are visible.
4. The “yellow flags” will not be visible if fully loaded until the rear of the load has been removed up to the first “yellow flag” stanchion, where full deployment of chocks can be confirmed.
5. In the event that the “yellow flags” chocks have not or do not deploy, prevent entry into the trailer and report the matter to the line manager, where the manager will lower the top deck and retry.

The Key Actions in the Safety Alert are:-

1. Ensure only trained and authorised personnel operate top decks and that for the upper position they do so by raising and leaving the top deck above the green line (SSOW to be amended).
2. Make sure the yellow flags are visible before entering a lower deck and then confirming the chocks are fully deployed before proceeding any further.
3. “Yellow flags” not deployed: prevent access into the trailer, report to line manager, manager will lower deck and retry. If not successful trailer to be removed from service and escalated.
4. Confirm the Alert key message and actions have been read, understood and communicated.

Managers are being asked to ensure that the attached Incident Near Miss Safety alert is communicated to all staff involved in double deck trailer operations on their site, particularly those involved in unloading of these Trailers, ensuring that records are maintained and the Communications Tracker is updated once completed.
 
This alert follows a “near miss” late last week involving the top deck of the new 95 York Container, Dual Use Double Deck Trailer, in which the subsequent investigation identified a weakness within the SSOW. The SSOW is to be amended and it is imperative that this safety alert and the SSOW are used together when providing future training, information and instruction.

A joint PFW/CWU investigation is underway in conjunction with the Trailer manufacturers 'Cartwrights' to determine if there is a fault with the system controlling the upper deck which requires re-work and modification. Additionally, a joint review of the Safe System of Work will be carried out to determine if any changes are required and further reports will be published in due course.
 
If Managers have any queries regarding this matter they should contact:-
Stuart Harrison Head of Safety, Health and Environment (PFW & RMSS)
Royal Mail Group Safety, Health and Environment Team    
Mobile: 07776 993 273
Email: stuart.harrison@royalmail.com
 
Yours sincerely
 

Dave Joyce
National Health, Safety & Environment Officer