Logistics & postal
Sector composite · Coverage at scale, RTW & rotation
Manual-task risk at depot scale — assessment, role design and return-to-work.
The pattern behind managing manual-task risk across large depot networks — coverage, unit economics, and the role data that powers return-to-work.
This is a composite
Drawn from JointAction customer engagements across logistics and postal operations. The scale figures below come from one large customer who is anonymised in this claim.
200,000+
manual-task assessments at one large customer — 135 depots, 109 shared kits, under AUD $4 each
Situation
Logistics and postal operations run high-frequency manual handling across large, distributed depot networks — parcel handling, sortation, transport — with high injury frequency and constant workforce movement.
Complication
At that scale, the challenge is coverage and unit economics: assessing enough of the work, often enough, cheaply enough to actually manage the risk — and using the resulting role demands for return-to-work and rotation decisions.
Response
- Shared-kit assessment models that let a large depot network run assessments at very low unit cost.
- Documented role demands used to match return-to-work clearances against real physical requirements rather than ambiguous “modified duties”.
- Rotation and role design informed by where load actually falls, body region by body region.
Outcome
One large customer in this pattern — depots in 135 locations, 109 shared kits — has run more than 200,000 manual-task risk assessments to date, at a unit cost of less than AUD $4 per assessment.
The customer in this scale figure is anonymised. Earlier synthesised reduction figures for this sector are retired and are not used.
How this generalises
In high-frequency manual-handling environments, the program lives or dies on unit economics and coverage. A shared-kit model at a low cost per assessment is what makes organisation-wide assessment — and the role-demands data that powers return-to-work — actually affordable.
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