Workplace safety lessons from the Somers Forge fatality

Workplace safety compliance is essential for protecting lives and avoiding catastrophic consequences, as tragically demonstrated by the Somers Forge Ltd incident. Machinist Nick Hardiman lost his life in a preventable accident involving a lathe, highlighting the urgent need for robust health and safety measures in industrial settings.

The incident occurred on 8 December 2023 at Somers Forge Limited in Halesowen, West Midlands. Nick Hardiman, aged 54 and from Kidderminster, was using handheld emery cloth to finish a rotating component on a 20-metre-long lathe when he became entangled in the machine’s dangerous moving parts, suffering fatal injuries. Despite emergency efforts, he died later that evening. The Health and Safety Executive (HSE) investigation uncovered serious failings: the company did not prohibit hazardous hand-polishing practices on rotating machinery, failed to prevent access to moving parts through adequate guarding and lacked suitable risk assessments and safe operating procedures. HSE guidance clearly states that emery cloth should never be applied directly by hand to rotating equipment.

Somers Forge Limited pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974. At Walsall Magistrates’ Court on 18 February 2026, the company was fined £750,000 and ordered to pay £38,314 in costs. HSE Inspector Sophie Neale described the death as “entirely preventable,” stressing that proper controls could have eliminated the risk.

This heartbreaking case reminds businesses that workplace safety compliance is a legal and moral imperative. Neglecting it risks lives, leads to severe penalties, causes family devastation and damages reputations. In high-risk industries like forging and machining, rotating machinery such as lathes presents ongoing dangers including entanglement, crushing and drawing-in. Strong workplace safety compliance mitigates these threats, enhances productivity, reduces absenteeism and demonstrates commitment to employee wellbeing.

The Vital Role of Workplace Safety Compliance in Preventing Machinery Accidents

Under UK legislation, including the Health and Safety at Work Act 1974, Provision and Use of Work Equipment Regulations (PUWER) and Management of Health and Safety at Work Regulations, employers must provide safe systems of work, suitable equipment and adequate training. The Somers Forge tragedy shows what happens when these duties are overlooked. Proactive workplace safety compliance prevents such outcomes and builds a positive safety culture where employees feel valued and protected.

5 Essential Steps to Strengthen Workplace Safety Compliance

To safeguard your workforce and avoid similar incidents, focus on these key areas:

1. Perform Detailed and Regular Risk Assessments

Effective workplace safety compliance starts with comprehensive risk assessments. Identify hazards from machinery, processes and tasks, such as using handheld abrasives on rotating parts. Involve competent assessors, document controls (prioritising elimination and engineering solutions) and review assessments regularly or after changes. The absence of proper assessments at Somers Forge allowed unsafe practices to continue unchecked.

2. Provide Thorough Employee Training and Competency Checks

Train all staff on machinery hazards, safe operating methods and emergency responses. Cover specific prohibitions like hand-applying emery cloth to lathes. Use practical demonstrations, refresher courses and competency assessments. Well-trained employees recognise risks and follow protocols, significantly reducing accident likelihood.

3. Develop and Enforce Safe Systems of Work with Proper Guarding

Create clear, written procedures for every high-risk task. Implement fixed guards, interlocked enclosures, trip devices and emergency stops to prevent access to danger zones. Ban unsafe manual techniques and ensure PPE (if needed) does not introduce further risks, such as entanglement from loose gloves or clothing. Engineering controls must take precedence over administrative ones.

4. Maintain Full Adherence to HSE Legislation and Guidance

Keep abreast of HSE regulations, approved codes of practice and sector-specific advice. For lathes and similar equipment, comply with PUWER requirements for inspection, maintenance and operator safeguards. Workplace safety compliance involves ongoing monitoring to ensure standards are met, not just during audits or after incidents.

5. Establish Continuous Monitoring, Audits and Professional Support

Promote a safety-first culture through regular inspections, near-miss reporting, employee consultations and independent audits. Engage experienced health and safety consultants for objective evaluations and tailored recommendations. Continuous improvement identifies emerging risks and reinforces commitment to workplace safety compliance.

Partner with AL23 Safety for Expert Workplace Safety Compliance Support

At AL23 Safety, we help organisations across the UK achieve outstanding workplace safety compliance. Our consultants provide 24/7 guidance, bespoke risk assessments, accredited training programmes, safe systems development and preparation for HSE interactions. Specialising in manufacturing and engineering sectors, we prevent tragedies like the Somers Forge incident by addressing root causes before harm occurs.

Investing in workplace safety compliance protects your team, avoids fines and fosters trust. Contact AL23 Safety today to discuss how our services can strengthen your health and safety framework. Prioritise safety, ensure every employee returns home safely.