At the Australian Trucking Association’s Technology and Maintenance Conference (TMC) held in Melbourne in October, industry experts gathered to address the critical topic of making truck workshops safer. The session featured insightful presentations from prominent leaders in the field: Lyndon Watson, CEO of the Watson Group; Edwin Higginson, a workshop consultant with IPWEA Fleet; and Dennis Roohan, Group General Manager of AJM Transport. Here are the key points from their discussion, covering the workshop environment, common safety risks, and strategies for managing high-risk tasks in truck maintenance.
The Importance of Workshop Safety in Truck Maintenance
Dennis Roohan opened the session, highlighting the inherent risks in truck maintenance workshops. These spaces are filled with heavy machinery, specialised tools, and equipment requiring careful handling. The nature of these hazards, from manual handling injuries to potential equipment malfunctions, underscores the need for robust safety practices. Roohan reminded attendees that, legally, businesses and managers must ensure the health and safety of their workers “as far as reasonably practicable.” However, this often raises questions about what “practicable” means in day-to-day operations.
Common Workshop Risks and Mitigations
Edwin Higginson shared his insights on managing workshop risks, drawing on his extensive experience in fleet maintenance management and his current role with IPWEA Fleet. He discussed the importance of the “Hierarchy of Controls” in addressing safety risks:
- Elimination: While complete elimination of hazards, such as shutting down a workshop, may be unrealistic, substituting risky practices with safer alternatives is often feasible. For example, open pits are a common hazard in workshops, so using truck hoists can be a safer alternative where possible.
- Engineering Controls: Installing safety equipment like tyre cages, mechanical lifts, and designated workspaces can significantly reduce risks associated with heavy machinery. Some modern workshops employ tire cages and hook jacks that isolate hazards effectively.
- Administrative Controls: Implementing policies, procedures, and regular training for employees ensures that safety measures are followed. Higginson pointed out the importance of simple, well-documented safety procedures to aid in risk management.
- Personal Protective Equipment (PPE): As a last line of defence, PPE like safety glasses and gloves can mitigate risks, especially in high-hazard tasks.
These layers of controls are critical in keeping workshops safe. Higginson emphasised that implementing them need not be expensive or complex—many safety improvements can be achieved with practical solutions.
The Role of Documentation and Policy
Higginson stressed that documented policies and procedures are essential for any organisation serious about workshop safety. Risk assessments, safety reviews, and incident monitoring are vital for continuous improvement. He recommended keeping policies concise and accessible, enabling all employees to understand and follow safety protocols easily.
A significant aspect of managing risk involves the ongoing assessment of safety policies.
“If your documentation is outdated, it might fail to account for new risks,” Higginson noted, encouraging attendees to revisit their policies regularly, especially in light of evolving safety standards.
Practical Safety Measures in Workshop Environments
Lyndon Watson, CEO of the Watson Group, provided a practical perspective based on his company’s safety initiatives across their various facilities. Watson described the different setups of their workshops across Australia, from their primary site in Derrimut, Victoria, to rented facilities in Sydney and Brisbane.
Customised Safety Solutions: Each site presents unique challenges, necessitating customised safety measures. At Derrimut, the Watson Group invested in state-of-the-art facilities, including drop-in pits, which allow for safe oil drainage and limit potential hazards associated with traditional open pits. In Brisbane, the company had to improvise with a “COVID tent” setup due to limited resources at the rented site. This tent provided shade and a designated workspace, minimising the risk of accidents in an otherwise open environment.
Managing Third-Party Contractors: Watson highlighted challenges related to managing safety with third-party contractors, who may be on-site temporarily or operate under different safety standards. He advocated for clear communication and safety inductions to align contractors with company standards, ensuring consistency across all locations.
Addressing Psychosocial Risks
The speakers recognised that workshop safety extends beyond physical risks. In recent years, there has been growing awareness of psychosocial risks, especially in high-stress environments like trucking and logistics. Higginson noted that the trucking industry has a unique challenge: workers often operate in isolation, which can exacerbate mental health issues. Companies must provide accessible resources, such as mental health hotlines or support services, to assist employees in managing these risks.
Watson added that his company had identified apprentices as a vulnerable group needing additional support. New apprentices often face pressure to perform tasks with significant responsibilities, sometimes without sufficient preparation. In response, the Watson Group has allowed apprentices to work at a slower pace in less demanding environments when necessary, providing them with a controlled space to build their skills without overwhelming pressure.
High-Risk Task Management: Safety Measures for Specific Tasks
The discussion also touched on managing high-risk tasks, such as heavy lifting, maintenance on large vehicles, and work on roadside breakdowns. Workshop environments often involve lifting heavy components like wheel hubs, which can strain workers. Higginson and Watson both highlighted specialised tools like wheel-end platform jacks and magnetised gloves as simple yet effective tools to make handling smaller parts safer and more efficient. These tools reduce the physical strain on workers and lower the risk of injuries over time.
Watson shared that his team in Brisbane has also implemented innovative lockout procedures for trucks to prevent accidental movements during maintenance. When vehicles require wheel-end or underbody work, a series of safety measures, such as using trailer locks and disconnecting airlines, are employed to secure the vehicle and protect the mechanics.
Safety Audits and Continuous Improvement
An external safety audit can provide valuable insights into potential blind spots within an organisation’s safety practices. Regular audits help companies identify overlooked risks and address them proactively. Higginson encouraged attendees to seek third-party audits when possible, noting that “an external party can often spot risks that may become invisible to those working in the same environment every day.”
The Significance of Industry Collaboration
Both Higginson and Watson emphasised the value of sharing safety knowledge and resources within the industry. IPWEA Fleet, for instance, offers numerous resources to its members, including training materials, safety management systems, and equipment guides. By fostering an open dialogue around safety, organisations can adopt best practices from their peers and continuously improve their safety protocols.
Practical and Proactive Safety
Workshop safety in truck maintenance is a multifaceted challenge requiring a proactive, practical approach. Through the combined insights of industry leaders, the TMC session underscored that effective safety management is not about implementing costly systems but about making practical improvements that can be sustained long-term. From investing in engineering controls to revising documentation and supporting workers’ mental well-being, the trucking industry has a shared responsibility to prioritise safety.
