TURNING NUMBERS INTO SAFETY:
Reducing the frequency and severity of injuries for workers in food manufacturing.
ROI of $11.50 for every $1 spent.
This comprehensive case study presents an in-depth data analysis on how DataFit's PCA program drastically reduced both the frequency and costs of injuries within the different positions at multiple plants.
INTRODUCTION
Workplace injuries were more than just numbers; they were affecting the lives of employees and taking a toll on operational efficiency. The food manufacturing plants faced a critical challenge: high rates of injuries among manufacturing staff. This problem led to rising healthcare and operational costs. The objective was clear: significant reduction in both the incidence rates and financial burden of these injuries.
METHODOLOGY
DataFit's PCA program was specifically tailored to meet the unique demands of the food manufacturing roles within the plants. Key metrics such as incident rates and average claim costs were chosen to evaluate the program's effectiveness vs. plants that did not institute the DataFit assessment. Candidates were evaluated on an isokinetic dynamometer.
Challenges
The manufacturer was grappling with alarmingly high rates of workplace injuries among specific job classes. These injuries were not only affecting employee well-being but also causing a significant financial drain.
Initial Incident Rates: Disturbingly high, affecting both employee well-being and operational efficiency.
Financial Burden: Skyrocketing claim costs were a growing concern. Each Control Plant spent on average 56 times more for their musculoskeletal disorder (MSD) strain/sprains in comparison to each DataFit Plant.
IMPLEMENTATION
The process of integrating DataFit’s PCA program into the hiring mechanism was meticulous and well-planned. Full integration was achieved within 6 months, followed by a two-year assessment period to gather data and insights. Detailed Job Task Analysis were conducted for all positions that were required to go through the PCA. Sixteen plants from the United States were included in this study.
Three plants received the DataFit PCA program (DataFit Group) and 13 plants did not (Control Group). All plants performed similar jobs, had similar turnover and similar hiring needs. The total workforce between the 3 DataFit plants and the 13 Control plants had approximately 4,500 employees. Both groups hired approximately the same number of employees (2,500 new hires) during the 2-year period.
RESULTS
The impact of DataFit’s PCA program was transformative:
Significant Average Claim Cost Savings:
The average cost of an MSK overexertion injury for the Control Plants is more than 17 times greater in comparison to the DataFit Plants.
Drastic Reduction in Incident Rates:
The average number of all injuries and the average number of MSD overexertion injuries that occurred for the Control Plants were more than 3 times greater in comparison to each DataFit plant.
ROI Analysis
The cost-benefit analysis revealed that the upfront cost of implementing DataFit's PCA program was far outweighed by the long-term financial savings and enhanced workplace safety. The data shows a dramatic difference in number of injuries, total cost of the injuries and average cost per injury between the DataFit plants and the Control Plants.
If the Control plants had utilized the DataFit program, the net savings minus the cost of services over a two-year period would have been $8,114,279.
Conclusion
This case study goes beyond mere numbers to substantiate the high ROI of $11.50 for every $1 spent on the program and the effectiveness of DataFit’s PCA program, contributing to both a safer workplace and significant financial savings.
For organizations facing similar challenges, DataFit offers customized solutions that deliver tangible benefits.
To reap similar benefits and ROI for your organization,