Musculoskeletal injuries are a serious and prevalent issue in Australian workplaces, often resulting from physically demanding tasks involving heavy equipment. Recognizing this, our Operations Services (OS) Maintenance teams embarked on a mission to tackle these risks head-on. In 2020, we formed the OS Maintenance Redesign Team (MRDT) with a clear goal: to find practical and scalable solutions that enhance safety and reduce physical strain for maintenance crews across our operations.
The MRDT, drawing on their extensive technical, operational, and health and safety expertise, employed the structured problem-solving model of our BHP Operating System (BOS) principles. This approach has led to the successful implementation of over 400 safety initiatives across Minerals Australia since the project's inception. These initiatives are now seamlessly integrated into our OS Maintenance systems, supported by audits, and further enhanced by the Standardized Work App, ensuring a lasting impact on safety practices.
One of the standout injury-prevention initiatives is the introduction of lightweight sling and shackle sets. This innovative solution was born out of a real-life scenario where a team member sustained an injury while lifting a 30kg shackle overhead. In response, the MRDT collaborated with a local Mackay vendor, Soft Rigging Solutions (SRS), to develop sling and shackle sets using a lightweight material, reducing the lifting requirement to a mere 3kg - an incredible tenfold improvement!
This simple yet effective solution significantly reduced musculoskeletal risks and empowered a wider range of workers to perform the task safely. Following a successful trial at Goonyella, the initiative was rapidly adopted at multiple sites, including Peak Downs, Caval Ridge, and Saraji in Queensland, as well as Newman in Western Australia.
The MRDT's efforts were recognized with the Health and Hygiene award at our 2025 Health, Safety, Environment, and Community (HSEC) Awards. Their work exemplifies how thoughtful design can safeguard workers and elevate operational excellence across our operations.
But here's the real question: How can we further empower our frontline workers to take ownership of injury prevention and response strategies? Share your thoughts and ideas in the comments below!
