iLSM Safety Issues & Improvements Update

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LTB 1033/11 iLSM Safety Issues & Improvements Update - Power Cable Connections, Motor Contactor & Tracking Issues:




No. 1033/11
Ref: RM1
Date: 6 December 2011

To: All Branches

Dear Colleagues

iLSM Safety Issues & Improvements Update - Power Cable Connections, Motor Contactor & Tracking Issues:

This is a summary update on the latest iLSM Health and Safety issues for Branches and in particular for the information of Operational Grades ASRs, Engineering ASRs and APRs.

Power Cable Connections
Earlier this year an incident occurred on an iLSM in Glasgow Mail Centre where one of the operators smelt burning. The machine was immediately shut down and isolated and an investigation undertaken. On Inspecting the machine what was found was that the iLSM power cables were over-heating due to loose electrical connection or poor terminations. As a consequence of this heat was being generated leading to scorching. This was unacceptable and a 100% iLSM machine check was undertaken as quickly as possible to remove a potentially serious safety risk. All connections were tightened to manufactures specification on all machines. The checks were completed by Royal Mail Engineers. Additionally the iLSM manufacturers, Solystic were instructed to undertake checks also to be doubly sure that the matter was resolved. A short term modification was also initiated by way of fitting 'ferrules' to each end of the power cable, at the isolator box and in the machine electrical cabinet. This work was carried out by ROMEC installation engineers. A quality review process has been established by Solystic to ensure that machines delivered to Royal Mail and installed in future meet the specification. Royal Mail has additionally requested an independent review on the power supply to these machines to confirm the standards are being met. An interim report is due to be published shortly. This incident was sadly not an isolated occurrence. There have since then been several instances of over-heating on electrical connections because they were not tightened properly by manufacturers Solystic, who have accepted the fact and have improved their internal quality control measures. Royal Mail have also added checks to the machine acceptance criteria. Following a period of months with no incident, a very similar incident occurred in Norwich Mail Centre. Solystic have been on site and have rectified the problem Royal Mail awaits their analysis and conclusion on how to ensure this incident is not repeated. Richard Moor Royal Mail Sortation Automation Programme Manager and Richard Stratford Royal Mail Engineering assure us that there is no danger posed to CWU members operating the iLSMs. They apologise for the fact that it has taken so long to conclude and but assure us that they will drive the power issue to conclusion ASAP.

Motor Contactor
The consequence of this part failing was that one of the safety "stop" buttons was locked in the open position. It has been emphasised at this point that these machines do comply with European Standards and the PUWER regulations. Therefore although the stop button failed, the design was never meant to be failsafe. The secondary system did work as planned. Investigations have found that although the machine was brand new the part was 10 years old! Royal Mail have undertaken and confirmed that no other parts relating to this supplier/contactor are more than 12 months older than the machine and it has been concluded that this was a 'stray part' within the iLSM project. However, this is subject to the same review as the Power Cable Connections, to validate Royal Mail's work. The final report on this is due to be presented in early January 2012.

Tracking
On a limited number of iLSMs (notably those with 224 boxes) there exists a tracking issue. This means some of the letters are not being held straight within the final few modules of the machine. Solystic have developed a retrofit modification to resolve the issue. Royal Mail will trial this modification on 2 machines (one that has the problem and one that does not) to confirm no detriment of service to the working machine and understand the impact on one of the poorer performing ones. The first modification has been fitted to two machines in Swindon and is working well. Royal Mail is working with Solystic on the final, definitive design prior to scheduling a rollout of the modification. Machines with tracking issues currently have been managed with additional tracking rollers and a change in software - there is little operational impact. It should be noted that Solystic will require uninterrupted access to each and every iLSM to carry out modification work and the exact details of how to minimize disruption are being discussed. It is expected that the rollout schedule to be published in the New Year.

iLSM Tray Holder Clips and Replacement Latches
There have been numerous incidents of the failure of tray holder retaining clips on sorter modules of iLSMs- notably the upper tier. The clips control the movement of tray holders that sit under each selection on the sorter module and if a particular clip fails on the upper sorting tier, trays can slide out unexpectedly and strike operators. This has resulted in minor injury to operators. The Trays can also drop/tilt prematurely onto the lower sorting tier causing machine damage to the parts underneath. Several modified clip versions were tested and trialled before Royal Mail working with manufactures 'Solystic' decided that the best solution is a 'latch mechanism' attached to the underside of the upper tier tray holders. This holds the holder in place and can only be released by activating a thumb catch as the tray holder is pulled out. After design testing, the final version was thoroughly tested by 'Solystic' in France before being passed to Royal Mail. This 'Solystic' tests were to prove that the latch mechanism had at least a 5 years' lifecycle - up to 50,000 activations. The plan is to fit these latches to iLSMs as soon as possible, replacing the single clips that govern the movement of the upper tray holders to remove the risk of further injury and damage. The 'latch mechanism' cannot slide until it is disengaged by an operator. This represents a change to operability on the upper level but eliminates the risk of injury and also dramatically reduces the risk of machine damage. The programme of fitting the latches modifications is underway. It takes up to 3.5 days to fit latches to the upper sorting tiers of 224 box iLSM machine and the opportunity will be taken to replace those module covers that were modified because of weak or missing gas strut welds. There will be a break from any modifications from the end of November to early in the New Year and this to give 'Solystic' time to produce latches in sufficient numbers to fit to all remaining iLSMs. The latch rollout will recommence in early January with the aim of completing the retrofit modified clips as soon as possible.

Royal Mail are satisfied that this rework modification removes a low level but long outstanding safety risk to machine operators. I would like to thank my CWU Engineering Safety Group team Kenny Wright, Steve Howlett and Dave Curtis (CWU Engineering Safety Reps) for the work done on this subject along with Richard Moor Royal Mail Sortation Automation Programme Manager and Richard Stratford Royal Mail Engineering for their attention to these matters.

If you have any concerns or queries please contact the Health, Safety & Environment Department.

Yours Sincerely

Dave Joyce
National Health, Safety & Environment Officer