Every superhero has a superpower, and ours is learning from what went wrong. Instead of just battling hazards, we dig into real accidents and incidents to uncover the lessons hidden inside.
With Olly the Safety Pup sniffing out the stories, we turn workplace mishaps into insights that help teams train smarter, stay safer, and build resilience.
Workplace Injury Costs LCBO $80,000 — Training Gaps at Fault
$375,000 Fine After Fatality — Inadequate Crane Safety Measures
Workplace Injury Costs LCBO $80,000 — Training Gaps at Fault
A worker was critically injured during powered pallet lift‑truck training when proper instruction and supervision were missing — leading to an $80,000 fine for the LCBO. Click to see the insights and lessons this incident reveals for safer workplaces.
$60,000 Penalty: Worker Hurt by Falling Metal Rods
$375,000 Fine After Fatality — Inadequate Crane Safety Measures
Workplace Injury Costs LCBO $80,000 — Training Gaps at Fault
A worker was injured when improperly stored metal rods fell during inventory — leading to a $60,000 fine for a Milton distributor. Click to see the insights and lessons this incident reveals for safer workplaces.
$375,000 Fine After Fatality — Inadequate Crane Safety Measures
$375,000 Fine After Fatality — Inadequate Crane Safety Measures
Lockout Failure Causes Injury and $100,000 Fine for Manufacturer
A worker was fatally injured when a propane tank swung unexpectedly during crane operations — leading to a $375,000 fine for a Toronto company. Click to see the insights and lessons this incident reveals for safer workplaces.
Lockout Failure Causes Injury and $100,000 Fine for Manufacturer
Lockout Failure Causes Injury and $100,000 Fine for Manufacturer
Lockout Failure Causes Injury and $100,000 Fine for Manufacturer
A worker was injured when a machine restarted during maintenance at Alugard Ltd.’s Mississauga facility. Investigators found that lockout and blocking procedures were bypassed, and the employer obstructed the investigation. The company pleaded guilty and was fined $100,000. Click to explore the root causes, costs, and proactive strategies this case highlights for safer maintenance practices.
Forklift Blind Spot Leads to Fatality and $200,000 Fine
Lockout Failure Causes Injury and $100,000 Fine for Manufacturer
Worker Falls Into Operating Baler Hopper — $175,000 Fine
A worker was fatally struck by an industrial forklift at Janco Steel’s Stoney Creek facility when safe‑operation procedures were not followed. The company pleaded guilty and was fined $200,000. Click to review the root causes, human and financial costs, and proactive strategies this case underscores for preventing similar tragedies.
Worker Falls Into Operating Baler Hopper — $175,000 Fine
Lockout Failure Causes Injury and $100,000 Fine for Manufacturer
Worker Falls Into Operating Baler Hopper — $175,000 Fine
At Marvara Farms Ltd.’s Drayton facility, a worker was critically injured after slipping into a running cardboard baler hopper while attempting to clear a jam. Investigators found that hazardous motion was not prevented before maintenance, leading to a $175,000 fine. Click to review the root causes, costs, and proactive strategies this case highlights for safer recycling and factory operations.
Workplace Injury Costs LCBO $80,000 — Training Gaps at Fault
The Incident: Training Gone Wrong
On June 20, 2022, at a LCBO warehouse in London, a worker was critically injured during powered pallet lift‑truck training. Without proper instruction or supervision, the worker lost control while practicing turns and collided with a steel storage rack.
The Fallout: Real‑World Consequences
Violation of OHSA section 25(2)(a): employers must provide information, instruction, and supervision to protect worker health and safety
- Critical injury to the worker
- $80,000 fine plus 25% victim surcharge (conviction entered August 28, 2025)
Behind the Breakdown
- Training led by a seasonal worker with no certification
- Incomplete instruction on inspection and safe operation
- First‑time operator left unsupervised
- Employer failed to ensure qualified trainers and up‑to‑date protocols
- Systemic failure to provide adequate information, instruction, and supervision
What Could Have Prevented This?
- Certified trainers for all equipment instruction
- OHSA/CSA‑aligned operator training
- Updated protocols based on manufacturer’s manuals and OHSA requirements
- Competent supervisors overseeing all practical sessions
- Routine audits of training programs and qualifications
- Mandatory refresher training for supervisors, trainers, and workers
- Clear documentation of worker training records
Olly’s Safety Sniff
“Training isn’t just practice — it’s protection. Make sure your heroes are properly equipped before they step into action!”
$60,000 Penalty: Worker Hurt by Falling Metal Rods
The Incident: Storage Gone Wrong
On December 10, 2022, at Fidelity PAC Metals Ltd., an administrative worker was injured while taking inventory in the warehouse bar storage area. A bundle of metal rods slipped from an upper rack as a forklift operator removed another bundle, striking the worker below.
The Fallout: Real‑World Consequences
Violation of OHSA section 25(1)(c) and Regulation 851/90, subsection 45(b): employers must ensure materials are stored to prevent hazards.
- Worker injured by falling bars
- $60,000 fine plus 25% victim surcharge (conviction entered July 24, 2025)
Behind the Breakdown
- Racks spaced too tightly, leaving no safe clearance
- Bundles not properly centered or secured
- No marked exclusion zones for pedestrians near forklift traffic
- Damaged equipment left in service
- Employer failed to enforce safe storage and traffic management protocol
What Could Have Prevented This?
- Certified audits of rack spacing and storage practices
- Clear exclusion zones separating pedestrians and forklifts
- Replacement of damaged equipment before use
- OHSA/CSA‑aligned forklift and inventory safety training
- Hazard assessments built into routine operations
- Leadership awareness programs to enforce safe traffic management
- Documented inspections and refresher training for all staff
Olly’s Safety Sniff
“Storage isn’t just stacking — it’s safeguarding. Keep your racks aligned and your heroes out of harm’s way!”
$375,000 Fine After Fatality — Inadequate Crane Safety
The Incident: Controls Left Live
On November 17, 2023, at a Toronto commercial property, a worker replacing a 1,000‑gallon propane tank was fatally pinned against a brick wall when the crane swung unexpectedly. Without proper precautions, the tank became a deadly hazard.
The Fallout: Real‑World Consequences
Violation of OHSA section 25(1)(c) and Regulation 851, section 76: employers must ensure effective precautions for crane operations.
- Worker fatally injured
- $375,000 fine plus 25% victim surcharge (conviction entered September 8, 2025)
Behind the Breakdown
- Crane controls not disengaged; stop button left unused
- Worker positioned with no safe clearance between tank and wall
- Limited site space created unsafe positioning options
- No enforced procedures to prevent inadvertent crane movement
- Employer failed to assess hazards and enforce safe crane practices
What Could Have Prevented This?
- Mandatory lockout/stop protocols for crane setup
- Site‑specific safe work procedures for lifting operations
- Certified OHSA/CSA‑aligned crane training for operators and workers
- Leadership awareness programs to enforce exclusion zones
- Hazard and risk assessments for restricted‑space lifts
- Routine audits of crane operations and stop‑button compliance
- Documented inspections and refresher training for supervisors and crews
Olly’s Safety Sniff
"Crane power isn’t just muscle — it’s risk. Shut it down before you step in, and keep your heroes clear of the swing!"
Lockout Failure Causes Injury and $100,000 Fine
The Incident: Safety Shut‑Off Ignored
On October 3, 2022, at Alugard Ltd. in Mississauga, a worker troubleshooting a malfunctioning aluminum jamb machine leaned into the cutting area while the equipment was still energized. With safety devices disabled, the machine cycled unexpectedly, trapping and injuring the worker.
The Fallout: Real‑World Consequences
Violation of OHSA section 25(1)(c) and Regulation 851/90, section 76: employers must ensure precautions to prevent machine start‑up during maintenance.
- Worker critically injured
- $100,000 fine plus 25% victim surcharge (conviction entered February 5, 2025)
Behind the Breakdown
- Safety devices disabled and moving parts left unguarded
- No lockout/tagout procedure applied during troubleshooting
- Worker exposed to energized equipment while clearing debris
- Inadequate supervision of maintenance activities
- Employer failed to enforce guarding and lockout/tagout requirements
What Could Have Prevented This?
- Mandatory lockout/tagout procedures for all maintenance tasks
- Certified OHSA/CSA‑aligned lockout/tagout training for workers and supervisors
- Supervisor oversight during troubleshooting and repair
- Routine audits of machine safety systems and guarding compliance
- Clear written procedures for maintenance and troubleshooting
- Leadership awareness programs to strengthen compliance culture
- Documented inspections and refresher training for high‑risk equipment
Olly’s Safety Sniff
“Machines don’t wait — they act. Lock it out, tag it out, and keep your heroes safe from surprise moves!”
Forklift Blind Spot Leads to Fatality and $200,000 Fine
The Incident: Hidden Hazards in Motion
On April 26, 2022, at Janco Steel Ltd. in Stoney Creek, a worker offloading a steel coil was fatally struck by a large industrial forklift. The operator’s view was obstructed, and without a signaller or clear traffic plan, the blind spot became deadly.
The Fallout: Real‑World Consequences
Violation of OHSA section 25(1)(c) and Regulation 851, section 56: employers must ensure prescribed safety measures for forklift operations.
- Worker fatally injured
- $200,000 fine plus 25% victim surcharge (conviction entered April 4, 2023)
Behind the Breakdown
- Worker entered the path of a moving forklift with obstructed visibility
- No signaller or guiding device used when operator’s view was blocked
- Inadequate traffic management plan for shared work areas
- Employer failed to enforce safe work procedures around mobile equipment
- Organizational gaps in hazard assessment and safety enforcement
What Could Have Prevented This?
- Mandatory use of signallers whenever forklift visibility is obstructed
- Clear pedestrian exclusion zones and traffic management procedures
- OHSA/CSA‑aligned forklift training for operators and workers
- Leadership awareness programs to enforce mobile equipment safety
- Hazard and risk assessments for material‑handling tasks
- Visual aids such as mirrors, floor markings, and barriers to reduce blind spots
- Routine audits of forklift operations and compliance with signaller use
Olly’s Safety Sniff
“Forklifts don’t see — operators do. When vision is blocked, bring in a guide and keep your heroes out of harm’s path!”
Worker Falls Into Operating Baler Hopper — $175,000 Fine
The Incident: Jam‑Clearing Without Shutdown
On January 10, 2023, at Marvara Farms Ltd. in Drayton, a worker was critically injured after slipping into an operating cardboard baler hopper while attempting to clear a jam. With the machine left running and no lockout/tagout applied, the hazard turned fatal.
The Fallout: Real‑World Consequences
Violation of OHSA section 25(1)(c) and Regulation 851/90, section 76: hazardous motion must be prevented before maintenance or jam clearing.
- Worker critically injured
- $175,000 fine plus 25% victim surcharge (conviction entered November 15, 2024)
Behind the Breakdown
- Worker stood on conveyor equipment to clear jam, with machine still energized
- Hazardous motion not stopped before accessing dangerous areas
- No lockout/tagout procedure applied
- Inadequate supervision of troubleshooting activities
- Employer failed to enforce hazard assessment and safe jam‑clearing protocols
What Could Have Prevented This?
- Mandatory lockout/tagout procedures for all jam‑clearing tasks
- Supervisor oversight during troubleshooting and maintenance
- Clear signage and exclusion zones around baler hoppers
- OHSA/CSA‑aligned lockout/tagout training for workers and supervisors
- Routine audits of recycling equipment safety systems
- Written procedures for troubleshooting and maintenance tasks
- Leadership awareness programs to strengthen compliance culture
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