Industry
Manufacturing
Challenge
A heavy manufacturing operation was suffering from a high work-related MSD injury rate. Ergonomic injuries represented 35% of their lost work days. The out-of-work time and workers' compensation costs were impacting employee morale and the company's bottom line.
Results
In the first year of implementation, the company experienced a 100% reduction in MSD injuries. They maintained zero MSD injuries in year two, representing a savings of $524,109.
Key Product
Industrial Sports Medicine™, Onsite Physical Therapy
The Challenge
A heavy manufacturing operation faced rising workplace safety challenges driven by a high rate of work-related musculoskeletal disorders (MSDs). Ergonomic injuries alone accounted for 35% of all lost workdays, creating significant operational disruptions and placing added strain on production teams and frontline employees.
The rising injury trend was not only disrupting daily operations, but also taking a toll on employee morale and driving up workers’ compensation costs, putting pressure on the company’s overall profitability. Recognizing that reactive measures were no longer sufficient, leadership began seeking proactive solutions to reduce injuries, improve workplace ergonomics, and create a safer, more sustainable environment for employees.
The Solution
A comprehensive Briotix Health Industrial Sports Medicine™ program was implemented to address rising MSD injury rates. The solution, known as PIES, delivered a proactive, four-part strategy focused on reducing risk, supporting employees, and creating long-term ergonomic improvements across the facility.
PREVENTION
Ergonomic assessments were conducted throughout the plant to identify tasks and workstations with elevated ergonomic risk factors. Using these findings, targeted prevention strategies and customized intervention programs were developed to address high-risk movements, repetitive tasks, and strain-inducing job functions before injuries occurred.
INTERVENTION
Early discomfort management services were introduced to address physical strain before it progressed into recordable injuries. Employees gained direct access to guided stretching programs, movement coaching, onsite physical therapy, and ergonomic education, all designed to improve body mechanics, encourage early reporting, and support faster recovery.
ENGAGEMENT
A robust safety concern and improvement suggestion system was implemented to actively engage employees in the injury prevention process. Team members were encouraged to report ergonomic concerns, identify potential risks, and contribute ideas for workplace improvements, helping foster a stronger culture of safety, ownership, and continuous improvement across the organization.
SOLUTIONS
Engineering and process improvement solutions were deployed to reduce physical strain, repetitive motion, and manual material handling demands associated with key job tasks. Enhancements included lift-assist devices, adjustable workstations, workflow modifications, and other ergonomic improvements designed to create safer work environments while supporting employee performance and productivity.
The Results
The impact of this program was both immediate and sustained. Within the first year of implementation, the company achieved a 100% reduction in MSD injuries, a result that continued through year two with zero reported MSD injuries. Together, these outcomes delivered a savings of more than $524,000 while also helping create a safer, healthier workplace for employees.
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