Frito Lay in San Antonio implemented the FIT for Work on-site ergonomics program in 1992. The program involved two parts: prevention and treatment. A carpal tunnel syndrome (CTS) prevention program was developed for packaging employees who were at high risk for CTS. The other part of the program involved an on-site early prevention and therapy program.

1. Workstation Analysis FIT for Work first conducted a review of statistics relating to injury and lost-time over the preceding five years. These were broken down by department and injury type to determine what area posed the highest injury risk. For Frito Lay, the packaging section was the area of highest risk. Following a symptoms survey of the workers, FIT for Workinterviewed packagers and videotaped them at work while conducting a job analysis. Using this information, FIT for Work developed a plan to prevent possible injuries on the job.

2. Hazard Prevention Utilizing data from the worksite analysis, FIT for Work identified other job-related hazards. These hazards were reduced by modifying existing equipment, installing anti-fatigue floor mats, reinforcing basic body mechanics for efficient job performance, maintaining appropriate postures during job tack and integrating stretching exercises into the normal work routine.

3. Medical Management An on-site therapy clinic encourages employees to report signs and symptoms early so that conservative treatment can begin and future problems or injuries can be avoided. When the case became serious enough for FIT for Work to refer to a physician, the treatment was provided on-site, and case management was activated. Workers with early signs or symptoms are treated conservatively and well within OSHA guidelines to prevent recordable injuries and illnesses.

4. Training and Education Employees are trained to reduce the risk of CTS by being shown how to maintain proper working postures and to identify improper or high-risk working habits. New employees are oriented to the safety culture as part of their normal training procedures.

5. Returns on Investment Implemented in 1992, Frito Lay appreciated a reduction in OSHA recordable injuries by 85 percent within the first two years. Workers’ compensation costs have been reduced by over 300 percent since the program began. The San Antonio site received OSHA's STAR Certification as well as "Best Practice" recognition for its ergonomic and medical management programs.

The on-site program began early in 1999 for the San Antonio Retail Support Center. With approximately 4,000 employees HEB realized a 50 percent reduction in their injury growth rate within the first six months. Historical comparison reveals this trend and injury reduction continues to move downward and the savings continue to increase.

This company of 500, which combines data entry, inbound telephone call centers and manufacturing saw an 85 percent reduction in recordable injuries with the first year of implementation. This equated to a 75 percent reduction in their incident rate. They also saw a reduction in insurance reserves of 50 percent and an estimated savings from the reduction in injuries of almost $170,400 for the first year. Checks in the Mail also noted a significant increase in productivity and employee efficiency measurements. These benefits have been consistent over the past five years.

Here's what some of our customers have to say:

HEB Grocery
Kevin Holguin, Corporate Safety Manager
Kevin has seen first hand effects of the program. "It provides employees with valuable types of information to treat and ease pain, Holguin says. The therapists make sure the employees know specific exercises, individualized treatments and the ergonomically correct ways to lift items."

Checks in the Mail
Gary Lenard, Director of Human Resources
"They really find out what is going on, what is wrong with a person, in total. Workers routinely suffered strained backs; however, the occupational therapists have intervened with an injury prevention regimen and reduced the company's recordable injuries by 85 percent."

Crystal Elliot, Human Resources Manger
"FIT for Work is more than consulting: they exhibit total team concern and integrity and were instrumental in exceeding our goal of reducing injuries by 85 percent the first year alone. They are constantly seeking to add value while they continue to provide more than they promised."

Block Distributing
Steve Hughes, Vice President of Operations
"I was the biggest skeptic, but from the beginning they proved to be efficient and effective. Overall, during the first three years we have saved almost $750,000 in direct cost, reduced our incident rate by over 75 percent, and reduced our workers compensation premium costs."

Frito Lay
Joe Kutach, SGE, Safety and Security Manager
"Fit for Work has provided on-site occupational health services to Frito Lay for over 11 years. During that time they have more than exceeded our expectations for injury reduction and cost containment for ergonomic related injuries and illnesses. In fact, their organization was instrumental in helping us achieve the OSHA VPP Star designation in 2000 at which time our ergonomics program received a "Best Practice" recognition. FFW provides both personable and professional consultative services of the highest standard."