Royal Mail Letters - Mk 3 [Hartwells] 'Lightweight' York

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No. 362/09
Ref C25/09
Date: 24 April 2009


To: All Postal Branches


Dear Colleagues

Royal Mail Letters - Mk 3 [Hartwells] 'Lightweight' York Container:



This is to update Branches and area safety representatives on the above subject and to inform you that it has been agreed between Royal Mail and the manufacturers to withdraw all 26,000 plus Mk3 Lightweight [Hartwell] York Containers from the Royal Mail Letters network on a phased basis in order to rectify a number of manufacturing quality issues with the containers that have been identified and to carry out modifications to the brake handle system.

As reported to Branches and area safety reps in LTB 016/08, the MK3 Lightweight York Containers, manufactured by "Hartwells" were introduced into the Network in the run up to Xmas 2008, following trials at Gatwick MC and there are now approximately 26,000 plus in service. The Mk3 Lightweight York Container is 10kg lighter, at 40kg than the Mk1 & Mk2 Yorks at 50kg.

A number of manufacturing quality issues have been identified with the MK3 York Containers by Royal Mail and in order to rectify these issues, a certain level of "hot work" (welding) will need to take place, which cannot be undertaken on operational sites. Therefore, Royal Mail Letters have agreed with the manufacturer that over the next few months, all remedial work on the MK3 York Containers will be completed at Hartwells manufacturers premises in Spennymoor in the North East of England.

Since the introduction of the Mk 3 'Lightweight' York Container, a number of issues have been raised from numerous area safety representatives regarding the brake handle mechanism, which were taken up with Royal Mail. These reports were primarily concerning the 'spring-loaded' brake handle, specifically the amount of force in the recoil of the brake and a perceived finger trap. The concern was the potential for the handle to either hit the operator’s hands and fingers causing an impact injury or to trap the operator’s hands or fingers between the brake handle and the container frame or small cross bar. It has now been agreed that in response to the concerns raised by staff using the containers, the manufacturers will undertake some improvements to the brake handle performance whilst completing the Quality improvements.

Royal Mail Letters will not be able to withdraw all 26,000 plus containers at once and they have said there is no need for any Mail Centre or Distribution Centre sites, other than those contacted directly by the Royal Mail Container Control Team, to take any action at the moment. The plan is that a number of sites primarily in the North East will be tasked to identify MK3 York Containers on a daily basis for the removal of manageable batches of containers to be taken back to Hartwell's. When the units are modified they will be inspected and returned to service. There will not be a general recall for all Royal Mail sites to implement at this time.

Royal Mail, RM Engineering and the manufacturer have concluded that they are satisfied that there were no serious safety concerns with the Lightweight York Containers but agreed to review and amend the Safe System of Work (SSoW) to highlight where hands need to be placed when using the brake. Royal Mail have stressed that the MK3 York Containers are NOT being recalled for any safety concerns and they remain completely safe to use and there is no risk of injury providing the Safe System of Work (SSoW) is correctly followed at all times. A revised 'interim' SSoW has been drawn up and issued with training instructions and a one page 'flyer' leaflet supporting this (See attached copies of "MK3 Lightweight York Container Safe System of Work and the 'flyer' which has been produced entitled "Interim instructions Applying/Disengaging the MK3 Lightweight York Container brake"). The attached documentation applies to existing MK3 York Containers. A review will take place once the modified versions are rolled out and a full review of the safety documentation for York containers is to be carried out later in 2009.

Any damaged MK3 York Containers should be notified through the usual York Container repair process.

Any local Management problems should be referred to Mark Wythe RML National Container Control Manager. Tel: 07753833528.
Email mark.d.wythe@royalmail.com

Yours Sincerely



Dave Joyce
CWU National Health, Safety & Environment Officer