When the Plan Unravels: Swinging Loads & Missing Procedures

The JHA was done. The OEM procedure was on the table. The crew were trying to do the right thing. And a worker still ended up on the ground with a serious leg laceration. In this episode, Pete and Drew break down Safety Alert SA24-04 from NSW Resources Regulator — a haul truck rear strut replacement that went wrong the moment the plan changed and there was no documented fallback to catch the team.

Running the incident through the JEBS PCR Triad, Pete and Drew unpack how a fit-for-purpose lifting jig sitting unused on site exposed a critical gap in procedure and training, how the cost of a procedure rewrite before the job dwarfs the operational and human toll of not doing it, and how the absence of hold points left a partially-pinned, hundreds-of-kilogram strut with nothing stopping it from pivoting into a worker on the access platform.

When the lift method stops working mid-job, your procedure needs to have an answer. This one didn't.

Break Tip: Before your next cylinder, suspension, or driveline component replacement hits the board — pull the procedure and ask whether it calls out an independent means of restraint at every stage of the lift. If the lifting jig isn't referenced and your crew hasn't been trained on it, that's your gap. Close it before the job starts.

The full Safety Alert details can be found here: https://www.resources.nsw.gov.au/sites/default/files/2024-10/safety-alert-sa24-04-haul-truck-rear-strut-injures-worker.pdf

Det här avsnittet är hämtat från ett öppet RSS-flöde och publiceras inte av Podme. Det kan innehålla reklam.

Avsnitt(24)

Operational Readiness: Why the Work Before the Work Determines Everything

Most sites focus on maintaining assets once they're running. Operational Readiness is everything that has to happen before the first shift starts — and when it's skipped, the performance gap costs mor...

22 Juni 10min

Asset Management Plans: The Ultimate Operational Handshake

In this episode, Pete and Drew demystify the Asset Management Plan (AMP), to reveal why it is the ultimate alignment tool between operations and maintenance. They break down how combining your Operati...

8 Juni 8min

Still Running… But is it reliable?

Is your plant running because it's reliable — or because your team is holding it together with workarounds and tribal knowledge? In this episode, Pete and Drew tackle one of the most common misconcept...

11 Maj 9min

No Visibility, No Control: Fixing the Off-Site Repair Process

You send a gearbox out the gate and it vanishes. No status update, no confirmed lead time, and an invoice that lands like a lead balloon much larger than you expect. Sound familiar? In this episode, P...

27 Apr 7min

When Jumpstarts Become Normal: Chronic Failures & the Cost of Looking Away

Nobody questions the jump-start ute — until someone does. In this episode, Pete and Drew break down a chronic breakdown event where a dedicated vehicle and fitter were burning up to eight hours a shif...

13 Apr 6min

Single Point of Failure: Guardrails, Modifications & the EX5600 Incident

Four metres. That's not a stumble — that's a life-changer. In this episode, Pete and Drew break down Safety Alert SA26-02 out of the Hunter Valley, where a worker fell from a Hitachi EX5600 excavator ...

30 Mars 7min

The 15-Year Crane Problem: When Chemistry Beat Mechanics

For fifteen years, a primary production rail crane was the site’s biggest headache. Availability sat at just 65%, improvement projects kept failing, and the team had started accepting the problem as “...

16 Mars 8min