The particulars of the charge provided:
The defendant failed to provide plant, to wit, Carding Machine 16, that was safe and without risks to health. In particular, it failed to securely fence an 8 millimetre nip point between the top of the burr belt pulley and the guard rail of the said plant.
2 There was an agreed statement of facts related to both charges as follows:
3. At all material times, the Defendant:
(a) Carried on the business of wool processing at the Riverina Wool Combing Plant situated at Byrnes Road, Wagga Wagga (the "Plant").
(b) Employed Colin Stibbard, 29 years of age, as a textile machine operator ("Stibbard").
(c) Employed Garry Hilton, 39 years of age, as a textile machine operator ("Hilton").
(d) Operated 16 carding machines in section 3 of the Plant.
4. At 7.50 am on 22 September 1997 at the Plant, Stibbard's left ring finger was degloved at the first joint when it was drawn into a burr belt pulley and its associated guide rail on carding machine No. 14 ("Carding Machine 14") (the "Stibbard Incident").
5. At 7.40 pm on 16 December 1997 at the Plant, Hilton's right little finger was lacerated when it was drawn in between the burr belt and the burr belt pulley on carding machine 16 ("Carding Machine 16") (the "Hilton Incident"). As a result of the accident, Hilton sustained tissue and minor bone damage to the top of his right little finger that required surgery. Other than slight loss of feeling in his fingertip, Mr Hilton has no ongoing disability associated with the incident.
6. On 31 December 1997 Inspector Mark Barber, in company with Inspector Hannah, conducted an inspection of the Plant. Photographs were taken and a Factual Inspection compiled. At the time of the inspection the whole of section 3 of the Plant was closed for maintenance. Inspector Barber made the following observations:
(a) Carding Machine No. 14 was one of 16 carding machines in section 3 of the Plant. It measured 11.8 metres long 2.7 metres wide and 2.0 metres high.
(b) Carding Machine 14 contained a series of rollers. There were 2 Morel burr belts located on Carding Machine 14, which ran in a clockwise direction parallel to the rollers.
(c) The burr belt was designed to carry out impurities that were extracted from the wool fibre going through Carding Machine 14. These impurities then go into a hopper and are removed from the area.
(d) A metal cover with a clear perspex window guarded the Morel burr belt pulley, which was located before the Breast Cylinder and Coarse Cylinder on the left-hand side of Carding Machine 14 (the one relevant to the Stibbard incident).
(e) The burr belt pulley in (d) measured 145 millimetres in diameter and 60 millimetres wide, and rotated at 60 revolutions/minute.
(f) The burr belt pulley accommodated a continuous flat belt that was 40 millimetres wide.
(g) On the belt were a series of plastic burr belt flippers, at 450 millimetre intervals.
(h) The pulley was 990 millimetres above ground level. There was an 8 millimetre gap between the top of the pulley and the guide rail above the pulley.
(i) General housekeeping was neat and tidy.
7. The configuration of Carding Machine 16 was similar to Carding Machine 14.
8. The carding machines in section 3 of the Plant had been in operation at the Plant since January 1994. The machines served two functions:
(a) To remove large pieces of vegetable matter from the wool and fibre.
(b) To commence the process of fibre alignment.
9. Burr build-up on the pulley bracket was a common problem of the carding machines. It was necessary to dislodge this build-up because it would eventually cause the burr tray to block and result in poor quality wool due to high vegetable content.
10. On the 22 September 1997 Stibbard conducted an inspection of the carding machines in section 3 of the Plant. He stopped and isolated carding machine No. 11 because it was completely blocked. After checking carding machine Nos. 12 and 13 that were clear, he observed a build-up of burr and wool on the plastic burr belt flipper cleaner situated on the burr belt pulley of Carding Machine 14. In contravention of training provided to Stibbard, the Defendant's isolation procedures and work instructions he reached down with his left hand to remove the burr build-up from the burr belt flipper cleaner However, upon doing so, the wool and his left ring finger were drawn into the revolving burr belt pulley and the guide rail causing the injury in paragraph 4.
11. Stibbard had been a Textile Machine Operator for approximately four and a half years. He had 12 months experience operating card machines. Stibbard's main duties consisted of him, in accordance with the Defendant's procedures, ensuring:
(a) maintenance and quality control aspects of the Card Machines;
(b) the care and pressing up of bi-products;
(c) a consistent flow of wool.
12. Prior to the incident, the Defendant provided Mr Stibbard with formal structured training in relation to the use of the carding machines. Mr Stibbard underwent that training prior to being allowed to operate carding machines. Amongst other things that training and the Defendant's work instructions required Mr Stibbard to stop and isolate the carding machine before performing any work on it. This training included:
(a) formal structured carding machine training module sessions on Carding Machine Safety (1 hour) on 20 May 1995 and 8 August 1997;
(b) A formal structured Carding Machine Operation Training Module (15 hours) on 8 August 1997;
(c) A Practical Skills Assessment on the safe operation of carding machines by Mr Stibbard including carding machine isolation procedures on 8 August 1997; and
(d) Instruction in Riverina's documented Carding Machine Work Instructions on 8 August 1997.
13. On 12 January 1998, Stibbard was interviewed in relation to the matter. Mr Stibbard stated during the interview that:
(a) He had performed the task of removing the build up of wool from around the plastic burr belt flipper cleaner whilst the carding machines were running on previous occasions.
(b) The number of times he was required to remove build-up from the burr belt flipper cleaner per shift would depend upon the blend of the wool.
(c) Stibbard thought it was safe to remove build-up from the plastic burr belt flipper cleaner at the end of the pulley but not the burr belt pulley.
(d) He understood that isolation procedures did exist in circumstances where the card machines were blocked, but not when there was merely a burr build-up on the plastic flippers.
14. Subsequent to the Stibbard incident the Defendant:
(a) Immediately had their production and maintenance supervisors conduct briefing sessions with all the Defendant's relevant employees stressing that no part of the employees' bodies were to enter the carding machines until they are isolated.
(b) Commenced trialing various prototypes guards to cover the burr belt pulley, however encountered difficulties in finding a suitable guard on the basis that the early prototypes blocked up the burr trays resulting in uncontrolled stoppage of the carding machines and the operators removing the guards to prevent this and because they were inconvenient; and
(c) Provided structured refresher safety awareness training to all relevant employees which included components on hand safety and isolation procedures.
15. On 16 December 1997, Hilton observed a build-up of burr and wool on a plastic burr belt flipper cleaner on the burr belt pulley on Carding Machine No. 16. In contravention of the training provided to Hilton, the Defendant's isolation procedures and work instructions he reached down with his right hand to remove the build-up, however, upon doing so, the burr, wool, and his right little finger were drawn in between the burr belt and the burr belt pulley.
16. Hilton had been a Textile Machine Operator for approximately 2 years. Hilton's main duties consisted of him, in accordance with the Defendant's procedures:
(a) Ensuring quality production;
(b) running the carding machines;
(c) operating the burr and sweeping systems.
17. Prior to the incident, the Defendant provided Mr Hilton with formal structured training in relation to the use of the carding machines. Mr Hilton underwent that training prior to being allowed to operate carding machines. Amongst other things that training and the Defendant's work instructions required Mr Hilton to stop and isolate the carding machine before performing any work on it. This training included:
(a) A formal, structured carding machine training module on Carding Machine Safety (1 hour) on 24 May 1996;
(b) The structured safety awareness session in paragraph 16(c) directly arising out of the Stibbard Incident on 27 October 1997;
(c) A formal structured Carding Machine Operation Training Module (15 hours) on 8 October 1997; and
(d) Instruction in the Riverina's documented Carding Machine Work Instructions on 5 September 1997.
18. Shortly subsequent to the Hilton incident:
(a) During its December closedown the Defendant, whilst not fully satisfied with the stage of development of the guards was satisfied that the potential for them to cause uncontrolled stoppages of the carding machines was limited, installed guards on the carding machines. Although, these guards continued to present the Defendant with further production difficulties and were subsequently refined and upgraded the guards over a period of approximately 3 months.
(b) The Defendant formally warned Mr Hilton about failing to comply with its safety and isolation procedures in accordance with its usual procedures relating to non-compliance with safety procedures.
19. On 12 January 1998, Hilton was interviewed in relation to the matter. Mr Hilton stated during the interview that:
(a) He would remove burr build-up from around the burr belt pulley up to 6 times per shift, depending upon the blend of wool.
(b) Hilton was aware that, following the Stibbard incident, the Defendant had instructed the operators to isolate the carding machines before removing the burr by hand from the burr pulley area. He conceded that he did comply with that instruction for a few months, but that once his production dropped he re-commenced the practice of not isolating the machines.
20. On 12 January 1998 Inspector Barber interviewed Brett Morgan in relation to both incidents. Morgan was the Defendant's Team Leader responsible for the supervision of both Stibbard and Hilton at the time of their respective accidents. Mr Morgan indicated during that interview that:
(a) The removal of burr and wool build-up may be required twice per shift, per machine, in circumstances where the wool blend had a heavy burr content.
(b) He was aware that persons operating the card machines would remove burr build-up with the machines running. However, he would not describe this practice as a common occurrence.
(c) At the time of the Stibbard incident he was not aware whether the Defendant had a procedure specifically related to the removal of burr build-up from the pulley belt area.
(d) It was his understanding that, prior to the Stibbard incident, if he or other employees were working inside the carding machines, then the machine must be stopped and isolated.
21. On 27 March 1998, Mark Hoolahan, who was authorised to speak on behalf of the defendant, was interviewed in relation to both accidents. Mr Hoolahan stated during that interview that:
(a) Carding machines had been in operation at the Plant since 1981.
(b) There was no history of like accidents involving Stibbard prior to 22 September 1997.
(c) To the Defendant's knowledge, carding machines used in other countries were not guarded around the burr belt area.
22. The defendant, RIVERINA WOOL COMBING PTY LTD (ACN: 001 799 935) , has had:
(a) the following convictions that are prior convictions for the purposes of both matter Nos IRC1511 and 1513 of 1999:
24.07.90 FSIAs27 FINED $2000
24.07.90 FSIAs44(a) FINED $2000
28.07.95 OHSs15(1) FINED $17,500
(b) the following convictions that are antecedents only for matter No. IRC 1513 and are prior convictions or the purposes of matter No. IRC 1511 of 1999:
23.09.97 OHS s15(1) FINED $9000
23.09.97 OHS s15(1) FINED $6000
(c) the following conviction that is antecedent only for the purposes of both matter Nos IRC 1511 and 1513 of 1999:
03.12.98 OHS s15(1) FINED $55,000
3 During the hearing as to penalty a correction was made to para 22(a) of the Amended Agreed Statement of Facts as to a date of the imposition of the fine under s15 of the Act which date was incorrect. The date should have read 1 December 1995 and not 28 July 1995. The correct date was confirmed by the WorkCover Authority during the proceedings and para 22(a) was amended.
4 The Amended Agreed Statement of Facts as to para 22 now reads: