Case Study: Strengthening Injury Prevention and Return to Work Outcomes at Visy Glass Auckland

Client: Visy Glass Auckland 

Industry: Manufacturing 

Role interviewed: Paul Kelly, Regional Claims Manager NZ ACC/AEP 

Challenges 

Visy Glass Auckland was facing several operational and workforce health challenges that were impacting productivity, safety performance, and injury management efficiency. 

1. Limited access to timely physiotherapy support 

The site needed urgent physio care for both workplace and non‑workplace injuries, with a strong focus on enabling safe, timely return to work. Without consistent onsite support, employees often experienced delays in assessment and treatment, contributing to extended lost time and reduced production capacity. 

2. Under‑resourced Manual Handling Training 

Visy did not have the internal resources to deliver high quality Manual Handling Training across the site. This training is essential for reducing injury risk in a heavy manufacturing environment and must be provided to all employees every two years. 

3. Insufficient capacity for workplace risk assessment activities 

Critical workplace assessments including Manual Handling Risk Assessments, Job Task Analysis and Workstation Ergonomic Assessments were not being completed at the volume required. 

Solution 

Visy Corporate brought Bodycare Workplace Solutions on board as its injury prevention and occupational health partner. The Bodycare team introduced a proactive, clinically led model designed to strengthen safety outcomes and improve return‑to‑work performance. 

Bodycare’s support included: 

• Proactive onsite physiotherapy with assessment, treatment and exercise planning. 
• Full delivery of Manual Handling Training for all employees. 
• Comprehensive workplace assessments including Manual Handling Risk Assessments, Job Task Analysis and ergonomic evaluations. 
• Improved communication, clearer reporting and earlier escalation of suspected incidents. 
• One‑on‑one engagement with workers through proactive roaming. 

"Bodycare’s proactive RTW support helped us address a complex injury in a thorough and practical way pre-claim. This avoided the need for an ACC claim and led to a completely successful outcome. Bodycare considered the physical demands on the worker and introduced several engineering and visual modifications, all carried out with full support from Visy and the worker’s managers" - Paul Kelly, Regional Claims Manager, Visy NZ 

Impact 

Since partnering with Bodycare, Visy Glass Auckland has experienced measurable improvements. 

Reduction in injury rates 

Visy’s TRIFR has improved from 55.00 in 2022 to 14.94 as at January 2026. Paul believes, “Bodycare’s Manual Handling education and proactive on‑floor engagement has contributed to these positive trends.” 

He also notes fewer recordable injuries are supported by consistent education and one‑to‑one coaching during proactive physio roaming. These interactions helped workers understand safer movement options during their day‑to‑day tasks.