Case Study
Port Otago Reduces High-Risk Movements by 56% with Real-Time Coaching
New Zealand's busiest port transforms stevedoring safety with wearable technology
Key Results
About Port Otago
Port Otago is New Zealand's busiest container port and a critical gateway for the country's South Island trade. Operating 24/7, the port handles a diverse range of cargo including containers, bulk commodities, and cruise ships, with over 300 employees working in stevedoring, logistics, and port operations.
The physical demands of port work—including container handling, cargo securing, and equipment operation—create significant ergonomic challenges. With a strong commitment to worker safety and wellbeing, Port Otago sought innovative solutions to reduce musculoskeletal injury risks in their operations.
The Challenge
Port operations involve inherently physical work with unique ergonomic challenges:
- Heavy manual handling: Stevedores regularly secure cargo, handle lashing equipment, and work in confined spaces with awkward postures
- Repetitive movements: Container operations require repeated bending, twisting, and reaching throughout long shifts
- Variable conditions: Work environments change constantly with different vessels, cargo types, and weather conditions
- Injury rates: Back and shoulder injuries were the most common workplace incidents, impacting both worker wellbeing and operational efficiency
- Training limitations: Traditional safety training wasn't providing the real-time feedback needed to change ingrained movement patterns
- Measurement challenges: Difficulty quantifying ergonomic risks and tracking improvement across diverse port operations
The SoterCoach Solution
Port Otago implemented SoterCoach's wearable technology across their stevedoring operations, starting with high-risk roles and expanding based on early success.
Implementation Approach
1. Pilot with Stevedores
Started with container lashing teams who had the highest injury rates and most physically demanding roles
2. Worker Engagement
Conducted hands-on demonstrations and emphasized the personal safety benefits and non-punitive coaching approach
3. Supervisor Training
Equipped shift supervisors with analytics tools to identify trends and provide targeted coaching support
4. Continuous Monitoring
Established regular review cycles to track progress, share learnings, and refine coaching strategies
Technology in Action
Workers wear a small, unobtrusive device that monitors body movements during their shifts. When high-risk movements are detected—such as excessive bending while securing cargo or awkward twisting when handling lashing equipment—the device provides immediate haptic feedback through gentle vibration.
This real-time coaching helps workers self-correct their movements before strain accumulates, creating lasting behavior change without constant supervision. Supervisors access aggregated data to understand team-wide trends and provide additional support where needed.
Measurable Impact
Within 12 months of implementation, Port Otago achieved significant improvements in safety outcomes:
Significant decrease in bending, twisting, and awkward postures during cargo operations
Substantial decrease in back-related injury incidents among stevedoring teams
High adoption rate with workers reporting increased awareness and confidence
Combined savings from reduced injuries, ACC claims, and improved productivity
Transform Your Port Operations Safety
See how SoterCoach can reduce injuries and improve safety culture in your operations
What the Team Says
"Working on the wharves, you're constantly bending and reaching to secure containers. SoterCoach has made me much more aware of how I move. The vibration feedback is subtle but effective—it reminds me to adjust my posture before I strain my back. I feel better at the end of my shift now."
"As a shift supervisor, the analytics dashboard gives me visibility I never had before. I can see which operations are creating the most ergonomic risk and have informed conversations with the team about safer techniques. It's changed how we approach safety from reactive to proactive."
"SoterCoach has been transformational for our safety culture. The technology provides objective data that helps us identify risks before injuries occur. The reduction in back injuries has been significant, and our team genuinely values the real-time feedback. It's an investment that's paying dividends in both safety and operational performance."
Sustained Safety Culture
Beyond immediate injury reduction, SoterCoach has driven lasting cultural change at Port Otago:
- Proactive safety mindset: Workers now think about ergonomics as part of their daily routine, not just during safety meetings
- Peer learning: Experienced stevedores share movement techniques with newer team members based on SoterCoach insights
- Data-driven decisions: Safety initiatives are now guided by objective movement data rather than assumptions
- Operational improvements: Insights from movement data have informed equipment placement and workflow design
- Industry leadership: Port Otago is sharing their success with other New Zealand ports to advance industry-wide safety standards
The port continues to expand the program to additional operational areas and integrate SoterCoach data into their broader health and safety management systems.
Ready to Transform Your Workplace Safety?
Discover how SoterCoach can help reduce injuries and improve safety culture