Shoulder Injury Prevention Program
A multi-site initiative designed to reduce shoulder injuries by targeting key risk factors in high-force push/pull tasks. The program combined data-driven analysis, ergonomic principles, and behavioral coaching to support employee well-being and reduce injury rates across industrial settings.
CLIENT
Industrial
Manufacturer
PROJECT DURATION
6 Months
PROJECT TYPE
Program Development
ROLE
Ergonomic
Specialist
PROBLEM
A large-scale industrial manufacturer, experienced a growing trend of upper extremity injuries, with rotator cuff strains and tears accounting for 67% of all shoulder cases. Nearly half of these were associated with push/pull strain, which was shown to increase the risk of RTC injuries by over three times. These incidents were most common in tasks involving high-force material handling and overhead work. The organization needed a proactive, scalable intervention that addressed these biomechanical risks while fitting seamlessly into existing production routines.
SOLUTION
The team designed and implemented a shoulder strengthening program tailored to the specific injury patterns identified in the data. The program emphasized rotator cuff and scapular stabilizer strengthening. The intervention was delivered through a combination of onsite training, instructional posters, QR-linked video demonstrations, and weekly educational messaging. Site supervisors and employees received ergonomic coaching focused on exercise technique, soreness management, and warm-up integration. Accessibility considerations included modifications for varying fitness levels and additional one-on-one guidance where needed.
IMPACT
Within one year, participating sites experienced a 30% reduction in OSHA-recordable shoulder injuries. Supervisors reported increased awareness around safe push/pull mechanics and more consistent early reporting of discomfort. The strengthening program became a common pre-task routine, reinforced by regular video content, and ongoing coaching efforts.
APPROACH
The project followed a structured rollout strategy informed by injury data and ergonomic best practices:
Targeted Exercise Design: A progressive Theraband-based routine addressing shoulder stability and injury prevention.
Pilot and Feedback: Initial testing with the Northeast region helped refine instructional materials and delivery methods.
Multi-site Rollout: Hands-on training sessions and visual tools were deployed across regions for consistency.
Reinforcement Strategy: Weekly video messaging campaigns and in-person ergonomic support sustained participation.
SUMMARY