Musculoskeletal injuries are one of the most common workplace health risks in Australia. These injuries often occur when workers perform physically demanding tasks that involve handling and maintaining heavy equipment. 

Recognising the need for a systematic approach to reduce these risks in our Operations Services (OS) Maintenance teams, we launched our OS Maintenance Redesign Team (MRDT) in 2020. Their goal? To find practical and scalable solutions to improve safety and reduce physical strain for maintenance crews across the company’s operations. 

Drawing on their broad technical, operational, and health and safety expertise, the project team uses the structured problem-solving model of our BHP Operating System (BOS) principles to design practical and replicable solutions.  

This has resulted in the delivery of more than 400 safety initiatives across Minerals Australia since the project’s inception. These are now embedded into OS Maintenance systems and supported by audits and the Standardised Work App to help create long-term impact.  

A frontline-led injury response strategy  

One of the most impactful injury-prevention initiatives has been the introduction of lightweight sling and shackle sets. This solution was developed after a team member sustained an injury while lifting a 30kg shackle overhead. In response, the OS Maintenance Redesign Team   partnered with local Mackay vendor, Soft Rigging Solutions (SRS), to produce sling and shackle sets using a lightweight material, reducing the lifting requirement from 30kg to just 3kg - a tenfold improvement.  

This significantly lowered musculoskeletal risk and enabled a broader range of workers to safely perform the task. Following a successful trial at Goonyella, the initiative was rolled out across multiple sites, including Peak Downs, Caval Ridge, and Saraji in Queensland, as well as Newman in Western Australia. 

The winner of the Health and Hygiene award in our 2025 Health, Safety, Environment and Community (HSEC) Awards, the OS Maintenance Redesign Team demonstrates how thoughtful design can safeguard workers and strengthen operational excellence across our operations.