Head Of Training, The Healthy Work Company

October 12, 2016

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Star Wars film maker fined £1.6 million for injuring Harrison Ford


The makers of Star Wars: The Force Awakens have been sentenced after failing to protect the actors and workers while on set during filming, after actor Harrison Ford was struck by a heavy hydraulic metal door on the set of the Millennium Falcon at Pinewood Studios.

Mr Ford suffered a broken leg and deep lacerations when he was knocked off his feet and pinned to the floor of the Millennium Falcon set, as a prop door closed on him. HSE’s investigation found that there was no automatic emergency cut off, to protect those on set, instead relying on the reactions of the prop operator(s) to bring the door to a stop.


Aylesbury Crown Court heard how a combination of preventable events, starting with how the door was designed, led to the incident.

During dress rehearsals on the 12 June 2014 Harrison Ford walked back towards the entrance ramp of the Millennium Falcon and pressed the prop door button to ‘close’ the door. As the cameras were not rolling he did not expect it to close. The production crew member who was operating the prop believed they were in full rehearsal and closed the door.

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Download the HSL report

Download the HSE investigation report

The door’s steel frame was overlaid with sheets of metal and had a tapered edge. It’s operation moved from ceiling to floor in a sharp downward motion. It did not have any automated safety mechanisms to cut out if a person was unexpectedly under the door.

A spokesman for the Health and Safety Executive (HSE) compared the power of the door’s drive system “to the weight of a small car”.


The risk of the door causing a serious injury or death had been highlighted by one of the health and safety officers for the production company. Foodles Production (UK) Ltd should have put a system in place to ensure the actors and production workers were protected. A different design with inbuilt safety features or using a different material could have guarded against any possible miscommunication on a busy film set.

Foodles Production (UK) Ltd, who had pleaded guilty at a previous hearing to Section 2 and Section 3 (1) of the Health and Safety at Work etc. Act 1974, were today fined £1.6 million and ordered to pay costs of £20,861.22 at Aylesbury Crown Court.


HSE’s Divisional Director Tim Galloway said: “This incident was foreseeable and preventable and could have resulted in more serious injury or even death.

“The power and speed of the door was such that, had Mr Ford or anyone else had been struck on the head by the door as it closed, they might easily have been killed.

“It was only the almost instantaneous actions of the prop operator in hitting the emergency stop that prevented the door from continuing to press down on Mr Ford as he lay on the floor.

“I think everyone would accept that all the people who work in the film industry have a right to know that the risks they take to entertain us, including when making action movies, are properly managed and controlled.”

Previously in a statement, Foodles said it had provided “full co-operation” through the HSE investigation, saying: “The safety of our cast and crew was always a top priority throughout the production”.

Download the specialist report

Download the HSL report

Download the HSE investigation report

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7 years ago

I believe it is also important to discuss the human error which also played a role in the above incident. It is also clear they did not have a safety plan, nor clear communication among-st the team of what was happening on set that day. I am curious if they had a safety toolbox chat with ALL members on set? To ensure clear communication about the plans for the day, and discuss risks and hazards to be aware of. Design and technology does help reduce the probability, however even with a different design (with inbuilt safety features) or using a… Read more »

7 years ago

According to the BBC’s report (http://www.bbc.co.uk/news/uk-england-37637453) Judge Francis Sheridan is reported to have said:

“The greatest failing of all on behalf of the company is a lack of communication, a lack because, if you have a risk assessment and you do not communicate it, what is the point of having one? That is the most serious breach here.”

The comment clearly reiterates the fact that, as we all know too well, risk assessment is not just a tick box exercise! Unfortunately something that many organisations fail to comprehend, often despite the best efforts of our profession!

Tamara Parris
Tamara Parris
7 years ago
Reply to  Robin

Here, here Robin! Thank you for the great points. I agree, it is so unfortunate that many times our professional advice falls to the side as people say the phrase “ya ya, you don’t need to worry about it, it will be all fine”

I wonder how fine the worker – Harrison Ford – felt a he was struck by the heavy hydraulic metal door!

famous or not, unsafe actions and lack of safety planning lead to workers being harmed.