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Ergonomics

 Preventing musculoskeletal injuries in New Zealand’s retail sector and supply chain

Improving workplace ergonomics is key to reducing injuries, boosting productivity, and enhancing worker well-being.

The growing impact of poor ergonomics

Musculoskeletal injuries, includings sprains, strains, and discomfort, are increasingly common across the retail, manufacturing, logistics, and transport sectors in New Zealand. These injuries not only impact workers’ health but also cost businesses millions in lost productivity and ACC claims.

In 2023, injuries resulting from activities like lifting, carrying, twisting, pushing, and pulling led to an ACC rolling average cost of $71.6 million across the sector. For workers unable to return to work for five days or more, the total ACC rolling average cost was $30.5 million.

Our approach

At ShopCare, we partner with industry leaders and subject matter experts to design, implement, and amplify interventions that effectively reduce musculoskeletal injuries.

We promote innovative, early interventions to ensure a healthier and more productive workforce and improve overall operational efficiency.

A woman with her back to the camera sitting in an ergonomic chair at a desk by a window.

How ShopCare can help your business

  • Support with developing knowledge, skills, and tools to design, implement, and scale intervention practices.  
  • Implementing proven practical solutions to reduce musculoskeletal injuries experienced by workers.
  • Increased efficiency through improved manual handling practices.
  • Implementing our solutions will not only reduce workplace injuries but also lower ACC levies and improve worker satisfaction.

By implementing proven ergonomic practices, businesses can improve workplace efficiency, increase employee satisfaction, and contribute to a reduction in ACC levies across the sector.

New initiatives

ShopCare is driving several initiatives to improve ergonomics within the retail sector and its supply chain. These projects aim to reduce injury risks and promote a safer, healthier work environment.

Proactively addressing discomfort or pain in the workplace

Developed in collaboration with industry experts, ShopCare has developed Early Notification and Intervention of Discomfort or Pain good-practice guidance to support workers and organisations to recognise and address physical discomfort or pain early. Taking the correct action at the first signs of discomfort or pain can prevent minor issues from escalating into injuries or longer-term musculoskeletal disorders. Watch this ShopCare webinar with industry experts from ASB, Nestle and Harvey Norman.

Our good-practice guidelines and downloadable resources provide workers and frontline leaders with actionable knowledge and practical tools to identify and address musculoskeletal risks early. By focusing on intervention, organisations can promote safe movement, improve worker wellbeing, and foster a culture of care.

Download your copy of the guidelines as well as the companion documents in a printable format.

Design thinking in ergonomics

ShopCare takes a user-focused approach to address specific ergonomic challenges within the sector. It involves pilot programmes targeting non-AEP retailers, manufacturers, and transporters in Aotearoa New Zealand and partnerships with technology providers and ergonomic experts to develop practical and innovative long-term solutions.

We’re proud to partner with Soter Analytics, a global leader in safety technology whose AI-driven wearable devices, video analysis, and expert injury prevention help boost productivity, efficiency and safety culture.

Interested in becoming a Soter Analytics customer? Click here to receive an exclusive discount as part of the ShopCare community.

 

Return-to-Work best practice for GPs and employees

ShopCare is working with businesses and GPs to improve the return-to-work process for injured workers. We are currently developing resources for businesses to use when working with GPs.

Reviewing the approaches taken by some of our key stakeholders, this project will develop good practice guidance to improve worker rehabilitation outcomes at work. We are working with ACC to ensure we align our practice and promote the extensive work ACC has completed.

If you have a successful return-to-work process or learnings that you would like to share with the ShopCare community, please email us.

Case studies: Ergonomics in action

Learn how two New Zealand businesses are using ergonomic principles to reduce injury risks and improve workplace systems.

Participative ergonomics in action - Harvey Norman

Faced with a rise in manual handling injuries, Harvey Norman partnered with ShopCare to try something different – putting workers at the centre of the solution.

This case study explains how a co-designed ergonomics pilot, shaped by frontline staff, delivered practical changes like redesigned trolleys, new training approaches, and early discomfort reporting. The result: a 40% drop in ACC claim costs and zero ergonomics-related incidents since rollout.

Thanks to Harvey Norman, we can share a proven model that other organisations can adopt – combining worker input, smart design and practical tools to transform safety outcomes.

Read how Harvey Norman used co-design to reduce injuries and embed safer practices. 

Improving return-to-work outcomes – Industry Med

This case study showcases a practical, proven approach from Industry Med that has improved return-to-work and recovery-at-work outcomes in a rural manufacturing setting.

Industry Med demonstrate how a coordinated, holistic healthcare model with onsite and virtual clinic support can support better outcomes for workers, businesses, and the wider system.

Whether your business has an established return-to-work programme or is just starting out, this case study offers useful insights into what’s working, and can be applied across other industries.

Read about the innovative solutions that Industry Med put in place.

Stay informed

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WorkSafe

It’s important to know the expectations of WorkSafe for PCBUs (person conducting a business or undertaking):

  • Implement good work design principles and practices in the work environment, which eliminate musculoskeletal risks or minimise them, so far as is reasonably practicable
  • Engage with workers when identifying musculoskeletal risks and their controls, including when changing work processes
  • Monitor the health of workers and the conditions at work to prevent WRMSDs (Work-Related Musculoskeletal Disorders developing)

To support businesses to do this effectively, WorkSafe have created a range of helpful resources to help you improve outcomes for hazardous manual tasks. See these quick links below:

In addition, WorkSafe Queensland has a huge range of code of practice, tools and guides.

Valuable resources

  • National Safety Council (USA)

    Download a white paper detailing interventions that reduce musculoskeletal injuries at work.

    Download
  • Health and Safety Executive (HSE) toolkit

    Britain’s national regulator for workplace health and safety has a helpful toolkit for assessing the risk of musculoskeletal disorders.

    Click to view
  • Canadian Centre of Occupational Health & Safety

    A helpful recommended weight limit calculator.

    Click to view
  • ShopCare: Early intervention of discomfort or pain

    Watch this ShopCare webinar with industry experts from ASB, Nestle and Harvey Norman.

    Watch Now
  • ShopCare: Ergonomic wearables with Arnaud Daurat CEO APAC of Exxovantage
    Watch Now
  • ShopCare: Wearable robotics in the workplace with Arnaud Daurat, CEO APAC of Exxovantage
    Watch Now