During the service on a press, a fork lift truck (FLT) driver lowered a section of the plant back into the machine and trapped the foot of a fitter causing severe bruising which resulted in an LTI. The image below shows the area where the fitter's foot, which had been securing a spanner, was trapped between the beam being lowered and the press.
The factory's overhead crane would normally be used for this task but it was already being used. The FLT was used because there were no other suitable anchor points for other types of lifting gear.
The fitter was located within the press housing, carrying out the maintenance task and monitoring the lowering of the plant section to ensure that it remained straight. The FLT driver could not tell whether the beam was straight from his position in the cab.
A miscommunication between the FLT driver and fitter led to the section of plant being lowered and trapping the foot of the fitter. The fitter's foot was severely bruised. Although a point of work risk assessment had been completed it did not recognise entrapment as a hazard.