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, shared kits, 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 with depots in 135 locations
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: assessing enough of the work, often enough, across enough sites 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 across every site.
- 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 — with depots in 135 locations — has run more than 200,000 manual-task risk assessments to date.
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 coverage. A shared-kit model across a depot network is what makes organisation-wide assessment — and the role-demands data that powers return-to-work — reach the whole operation.
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