Case Study
How automotive manufacturer ADVICS North America reduced workers' compensation costs by 65% through wearable technology and real-time coaching
ADVICS North America, Inc. is a leading manufacturer of automotive brake systems and components, operating a state-of-the-art facility in Lebanon, Ohio. As part of the global ADVICS group, the company supplies brake systems to major automotive manufacturers worldwide.
With over 500 employees engaged in manufacturing operations, ADVICS North America faced typical challenges of the automotive industry: repetitive manual tasks, heavy lifting, and ergonomic risks that contributed to workplace injuries and rising workers' compensation costs.
ADVICS was experiencing injury rates that were impacting both employee wellbeing and operational efficiency. Musculoskeletal disorders (MSDs) were the primary concern, particularly affecting the back, shoulders, and upper extremities.
The financial impact of workplace injuries was significant, with workers' compensation costs rising year over year. The company needed a solution that would not only prevent injuries but also demonstrate measurable ROI.
Despite implementing traditional ergonomic assessments and safety training programs, ADVICS found it difficult to change ingrained work habits. Workers would revert to risky movements when not being directly observed, and the company lacked real-time data to identify and address high-risk behaviors.
The safety team needed objective, quantifiable data to identify which tasks and movements posed the greatest risk, and to measure the effectiveness of interventions over time.
ADVICS implemented SoterCoach's wearable technology and AI-powered coaching system to address their safety challenges. The solution provided real-time feedback to workers and comprehensive analytics to the safety team.
Workers wore small, lightweight sensors that monitored body movements throughout their shifts. The devices provided gentle vibration alerts when high-risk movements were detected, enabling immediate behavior correction.
The instant feedback system helped workers develop safer movement patterns without requiring constant supervision. Workers could self-correct in the moment, building muscle memory for safer techniques.
Safety managers gained access to comprehensive analytics showing risk trends by department, shift, and individual worker. This data enabled targeted interventions and process improvements.
The system automatically calculated ergonomic risk scores based on movement patterns, providing objective metrics to track improvement and identify high-risk tasks requiring engineering controls.
ADVICS began with a pilot program in their highest-risk department, introducing the technology to a select group of workers. This allowed the team to refine the implementation process and demonstrate early wins.
The company conducted comprehensive training sessions to help workers understand the technology and its benefits. Emphasizing that the system was designed to help them stay safe—not to monitor or punish—was crucial for gaining acceptance.
Following the successful pilot, ADVICS expanded the program across all manufacturing departments. The phased approach allowed for continuous learning and adjustment.
The safety team used the analytics dashboard to identify trends and implement targeted interventions. Regular review sessions with department managers ensured ongoing engagement and improvement.
ADVICS saw a dramatic decrease in recordable injuries, with musculoskeletal disorders dropping significantly across all departments.
The financial impact was substantial, with workers' comp costs dropping by nearly two-thirds, delivering significant ROI on the technology investment.
Objective measurements showed workers were consistently performing tasks with better body mechanics, reducing long-term injury risk.
Workers became more engaged in safety initiatives, with increased reporting of near-misses and proactive identification of ergonomic hazards.
"SoterCoach has transformed how we approach safety at ADVICS. The real-time feedback helps our workers develop safer habits, and the data gives us the insights we need to make informed decisions about process improvements. The reduction in injuries and costs has been remarkable."
"At first I wasn't sure about wearing the device, but now I can't imagine working without it. It's helped me realize when I'm bending wrong, and I've noticed my back doesn't hurt at the end of the day like it used to."
"The gentle vibration reminds me to adjust my posture before I strain something. It's like having a personal safety coach with me all day."
"I've been able to use the data to show management exactly where we need better equipment or process changes. It's made my job as a supervisor much easier."
"The technology is easy to use and doesn't get in the way of my work. I actually feel safer knowing it's helping me avoid injuries."
The success of SoterCoach at ADVICS has been sustained over multiple years, with injury rates remaining low and safety culture continuing to strengthen. The technology has become an integral part of the company's safety program.
Beyond the immediate injury reduction, ADVICS has seen improvements in productivity and employee morale. Workers appreciate the company's investment in their wellbeing, and the objective data has helped resolve disputes about workplace ergonomics.
The company continues to use SoterCoach data to drive continuous improvement in their manufacturing processes, identifying opportunities for automation and ergonomic enhancements that benefit both safety and efficiency.
Join ADVICS and other leading manufacturers in reducing injuries and costs with SoterCoach
