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Reducing the frequency and severity of injuries for workers in food manufacturing.

ROI of $11.50 for every $1 spent.

This comprehensive case study presents an in-depth data analysis on how DataFit's PCA program drastically reduced both the frequency and costs of injuries within the different positions at multiple plants.

Comparing Total Costs Between DataFit Plants vs. Control Plants - All Injuries

DataFit Plants
Control Plants


Workplace injuries were more than just numbers; they were affecting the lives of employees and taking a toll on operational efficiency. The food manufacturing plants faced a critical challenge: high rates of injuries among manufacturing staff. This problem led to rising healthcare and operational costs. The objective was clear: significant reduction in both the incidence rates and financial burden of these injuries.


DataFit's PCA program was specifically tailored to meet the unique demands of the food manufacturing roles within the plants. Key metrics such as incident rates and average claim costs were chosen to evaluate the program's effectiveness vs. plants that did not institute the DataFit assessment. Candidates were evaluated on an isokinetic dynamometer. 

Medical chair


The manufacturer was grappling with alarmingly high rates of workplace injuries among specific job classes. These injuries were not only affecting employee well-being but also causing a significant financial drain.

Initial Incident Rates: Disturbingly high, affecting both employee well-being and operational efficiency.

Financial Burden: Skyrocketing claim costs were a growing concern. Each Control Plant spent on average 56 times more for their musculoskeletal disorder (MSD) strain/sprains in comparison to each DataFit Plant.

Comparing Average Cost By Location Between DataFit Plants vs. Control Plants - MSD

DataFit Plants
Control Plants


The process of integrating DataFit’s PCA program into the hiring mechanism was meticulous and well-planned. Full integration was achieved within 6 months, followed by a two-year assessment period to gather data and insights. Detailed Job Task Analysis were conducted for all positions that were required to go through the PCA.  Sixteen plants from the United States were included in this study.

Three plants received the DataFit PCA program (DataFit Group) and 13 plants did not (Control Group). All plants performed similar jobs, had similar turnover and similar hiring needs. The total workforce between the 3 DataFit plants and the 13 Control plants had approximately 4,500 employees. Both groups hired approximately the same number of employees (2,500 new hires) during the 2-year period.


The impact of DataFit’s PCA program was transformative: 

Significant Average Claim Cost Savings:

The average cost of an MSK overexertion injury for the Control Plants is more than 17 times greater in comparison to the DataFit Plants.

Comparing Average Cost Per Injury Between DataFit Plants vs. Control Plants

DataFit Plants
Control Plants

Drastic Reduction in Incident Rates:

The average number of all injuries and the average number of MSD overexertion injuries that occurred for the Control Plants were more than 3 times greater in comparison to each DataFit plant.

Comparing Average Frequency of Injuries by Location Between DataFit Plants and Control Plants

DataFit Plants Over Exertion
Control Plants Over Exertion
DataFit Plants All Injuries
Control Plants All Injuries

ROI Analysis

The cost-benefit analysis revealed that the upfront cost of implementing DataFit's PCA program was far outweighed by the long-term financial savings and enhanced workplace safety. The data shows a dramatic difference in number of injuries, total cost of the injuries and average cost per injury between the DataFit plants and the Control Plants.


If the Control plants had utilized the DataFit program, the net savings minus the cost of services over a two-year period would have been $8,114,279

Projected Savings of $8,114,279 Over Two Years

Projected Injury Costs
Actual Injury Costs


This case study goes beyond mere numbers to substantiate the high ROI of $11.50 for every $1 spent on the program and the effectiveness of DataFit’s PCA program, contributing to both a safer workplace and significant financial savings.

For organizations facing similar challenges, DataFit offers customized solutions that deliver tangible benefits.

To reap similar benefits and ROI for your organization,

Reach out to us today for a customized assessment.