80% Reduction in Workcover claims for Musculo-Skeletal Disorder
Industrial Physio has been implementing a Physiotherapy early intervention program at BOC Rocklea site for over 3 years now.
The site has approximately 130 employees and they engage in various manual duties based around refilling gas bottles of varying sizes with several different gas types. The main injuries seen are to the wrists, shoulders, knees and lower back.
When he first started there, they had on average 5-6 Musculo-Skeletal Disorder (MSD) Workcover Claims per year. Since implementing the program they have only had one claim per year for the last 3 years. That is over an 80% reduction in claims, not to mention the reduced Loss Time Injury (LTI) hours, increased productivity, reduced absenteeism and overall increase in morale.
Background
The BOC Rocklea site, employing approximately 130 staff, is a high-risk manual handling environment centred around the refilling of gas bottles of various sizes and gas types. Prior to 2020, the site was experiencing an average of 5–6 WorkCover claims per year related to Musculo-Skeletal Disorders (MSDs), predominantly affecting the wrists, shoulders, knees, and lower back. These injuries not only impacted employee well-being but also resulted in significant operational disruptions, increased claim costs, and Lost Time Injury (LTI) hours.
To address these concerns, an early intervention program led by Physiotherapist Scott Hewett was introduced.
Objectives
- Reduce MSD-related WorkCover claims and injury rates
- Improve early reporting and injury management
- Educate employees on injury prevention, ergonomics, and manual handling
- Foster a proactive safety culture
- Enhance productivity, employee retention, and morale
Program Overview
Since 2018, Scott Hewett has been delivering an on-site Physiotherapy Early Intervention Program at BOC Rocklea. The program includes:
- Weekly on-site physiotherapy sessions
- Early assessment and treatment of musculoskeletal concerns
- Individualised injury prevention strategies
- Ergonomic reviews and workstation adjustments
- Educational sessions on safe manual handling techniques and posture
- Ongoing health and wellness support for employees
The program emphasizes early reporting and proactive care, aiming to reduce the severity of injuries and prevent them from progressing to claims.
Key Results
Over the past three years, the program has delivered measurable and meaningful outcomes:
- 80% reduction in MSD WorkCover claims (from 5–6/year to 1/year)
- Significant decrease in Lost Time Injury (LTI) hours
- Noticeable drop in absenteeism and improved productivity
- Improved employee retention, with reduced turnover in manual roles
- Enhanced KPI performance, contributing to operational efficiency
- Increased employee engagement and morale
Employee Education
A core element of the program is empowering staff with knowledge and practical tools. Employees have been educated on:
- Injury prevention techniques tailored to site tasks
- Basic ergonomic principles for lifting, standing, and repetitive movements
- Safe manual handling procedures to reduce physical strain
- Importance of early injury reporting and proactive treatment
This has helped foster a culture of accountability, self-care, and safety awareness across the workforce.
Employee Feedback
The human impact of the program has been strongly positive. Employees have expressed appreciation for having immediate access to professional care and report feeling more supported by their employer.
“I used to just work through the pain. Now, I know I can get it looked at early and stop it from getting worse.”
— Production Operator
“The physio support has made a real difference—it’s helped us feel that our health matters.”
— Team Leader
Sustainability and Expansion
Due to its continued success, the program is now being viewed as a model for potential rollout at other BOC locations. With strong data supporting its effectiveness, the early intervention approach is proving to be both a health and business asset.
Conclusion
The Early Intervention Physiotherapy Program at BOC Rocklea has significantly reduced injury rates and claims while creating a healthier, more engaged workforce. It stands as a leading example of how investing in preventative care can yield both human and operational benefits.
