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Manufacturing
In manufacturing environments, minor discomfort can quickly become a larger operational and financial problem if it is not addressed early. Safety-focused employers like this manufacturer partnered with WorkCare to implement an on-site Incident Prevention program focused on preventive education, ergonomic assessment and solutioning, early intervention, and wellness-based support. Over time, the program helped employees access support earlier, resolve many issues through self-care, and reduce the need for more costly downstream care.
Industry: Manufacturing
Challenge: The client needed a more proactive way to address discomfort, reduce injury-related costs, support employees earlier, and bring more structure to ergonomic training and preventive services.
Solution: WorkCare deployed an Industrial Athlete Program built around three core strategies: preventive education, ergonomic assessment plus solutioning, and early intervention. The program included health promotion support, ergonomic education, wellness exercise programs, job-task evaluation, functional movement screening, first-aid-based discomfort resolution, and onsite support designed to reduce unnecessary emergency room and urgent care utilization.
Preventive education to promote safer movement, healthier behaviors, and improved resilience to physical job demands
Ergonomic assessments and solutioning to identify root-cause risk factors in tasks and work areas and recommend practical improvements
Early intervention to address minor musculoskeletal discomfort before symptoms affected work performance or progressed into more serious cases
Functional movement screening to identify muscular compensations before they became symptomatic
On-site first aid support to resolve discomforts early and reduce avoidable off-site care
Group and individual wellness activities covering topics such as fatigue management, hydration, weight management, heart health, and nutrition
WorkCare’s Industrial Athlete Program delivered value in several ways: reducing projected injury costs, expanding ergonomic support, resolving discomfort more quickly, and increasing workforce engagement in prevention.
That represents a combined estimated cost savings of ~$585,759 over the measured period. The occupational estimate was based on 46 occupational cases, an 86% self-care rate, and a case mix of 76% medical-only cases and 24% lost-time cases. The non-occupational estimate was based on 10 non-occupational cases, a 100% self-care rate, and an assumed ~$15,000 average cost per claim.
For the shorter period of January 2025 to September 2025, the program was associated with an additional estimated:
That represents ~$248,499 in total estimated cost savings in 2025 year-to-date during that measurement window.
Estimated total cost
savings from Nov. 2023
to Sept. 2025
Of services were
preventive, not reactive
Of discomfort cases
closed in 14 days or less
Individual ergonomic
assessments/trainings
delivered
Across the full reporting period, WorkCare provided:
Using the market-rate assumptions in the deck, that equates to an estimated:
Combined, that is ~$186,650 in estimated ergonomic training value delivered during the period.
For January 2025 to September 2025 alone, WorkCare delivered approximately:
That equals ~$49,450 in estimated ergonomic training value in 2025 year-to-date.
Across the reporting period:
These metrics matter because they point to a program that is not just active, but effective. Employees were engaging with support early enough for many cases to be addressed through self-care and short-duration intervention rather than becoming more disruptive, more complex, or more expensive.
During the reporting period, WorkCare delivered 650 group activities involving 3,295 participants, with an average group size of 5. Common prevention topics included:
The detailed prevention breakdown also shows a wide mix of services, including stretch-and-flex programming, health coaching, ergonomic coaching, safety training, ergonomic evaluations, mindfulness training, work hardening, and preventive maintenance. That breadth matters because it shows the program was not limited to reactive case handling. It created an ongoing prevention presence tied directly to job demands and employee well-being.
Partner with WorkCare to enhance workforce safety, reduce injuries, and achieve measurable ROI through proactive injury prevention strategies. Contact WorkCare today.
