Manual Handling Training Success:  Case Study – NZ Safety Blackwoods 

Client Snapshot

• Industry: Industrial Supplies and Safety Equipment Industry (with DC’s and Trade Centres).  
• Workforce Size: 550.
• Locations:    x 3 DCs in Auckland, 1 in ChCh and 35 trade centres nationally. 
• Context: Team members in Distribution Centres and Trade Centres regularly perform repetitive manual handling tasks involving a diverse range of items varying in size, shape, and weight.
• First engaged Provention: 2023.

The Impact

Measured Impact in Supply Chain Team (June 2023 – June 2024 vs Previous Years)

• 70% reduction in First Aid Injuries.
• Elimination of Lost Time Injuries.
• Increase in Early Pain and Discomfort reporting – reflecting improved awareness and proactive behaviour.
• Early intervention supported by Alison’s individual case management has led to tailored exercises, workstation adjustments and reduced MTIs and LTIs.

Since launching the First Move programme in April 2023, NZ Safety Blackwoods has made significant strides in embedding safe movement principles across its Supply Chain operations. Between June 2023 and June 2024, the programme trained:

• 148 Supply Chain team members across multiple Distribution Centres, including warehouse team members, team leaders and supervisors.
• 7 certified Train-the-Trainers who have delivered consistent and tailored training nationally.
• Teams now diligently complete daily warm-ups and stretches, making safe movement a routine part of their day.

In 2025, the programme was successfully extended to the Trade Centre network, with:

• Training delivered to 35 Trade Centres nationally.
• 152 Trade Centre team members trained, including Trade Sales Assistants, Trade Centre Supervisors, and Trade Centre Managers.

Teams across both networks now diligently complete daily warm-ups and stretches, with strong participation and ownership.

Team Feedback

“Reaching out to the team this afternoon to share my experience with the First Move Warm-Up Stretches. As the Stretch Champion for Takanini, I decided to get excited about it and get the team members who’ve experienced the exercises here excited too. I’ve been loving it and noticing it helps me throughout the day with all the lifting and moving we do. For the first few weeks I was crispy, crunchy, and crackly—but that’s no longer the case. We only get one body (unless someone knows of a cloning system for spare parts?) and taking a few minutes out of your day to help it perform better is a no-brainer. Why wouldn’t you? What have you got to lose? Let’s go team!” – Hayley Bridge (Trade Sales Assistant).

“As the HSW Business Partner, I’ve seen a noticeable shift in team engagement since First Move was introduced. Teams are taking ownership of their movement routines, warm-ups are becoming embedded in daily practice, and conversations around wellbeing are more open and proactive. I’ve personally witnessed team members starting their stretches before their shifts begin, and the pure joy on their faces is a testament to how much this programme means to them. The increase in early reporting shows that our people are more aware, more confident, and more supportedand that’s exactly the kind of safety culture we want to build.” – HSW Business Partner Reflection – Yasmin Khan.

Key Takeaway

Implementing the First Move programme has been a game-changer for NZ Safety Blackwoods. It’s not just about reducing injuries, it’s about creating a culture where movement, wellbeing, and proactive care are part of everyday life. As the HSW Business Partner, I’ve witnessed firsthand the transformation in our teams. From early stretches before shifts to genuine joy on team members’ faces, the programme has sparked a sense of ownership and pride in personal wellbeing. The increase in early reporting and engagement shows that our people feel supported, informed, and empowered to take care of themselves and each other. First Move has become more than a safety initiative, it’s become a movement.

Impact Beyond Training

First Move warm-ups have evolved into more than just injury prevention. Teams now use them as quick energy boosts before or during meetings, adding fun, connection, and a shared sense of purpose. These moments often spark wider wellbeing conversations – about hydration, movement, and mental health, creating a ripple effect that re-energises staff and strengthens team bonds. Stretch Champions have emerged across sites, leading with enthusiasm and inspiring others to join in. The programme has helped us shift from reactive safety to proactive wellbeing, and that impact continues to grow every day.

The Challenge

Before implementing the First Move programme, NZ Safety Blackwoods was grappling with several persistent and complex challenges across its Distribution Centres and Trade Centres:

• Rising Musculoskeletal Injuries: A steady increase in back, shoulder, and joint strain injuries, particularly from repetitive manual handling tasks involving unpredictable loads and awkward postures.
• Early Pain and Discomfort: Many team members were experiencing discomfort early in their shifts, often pushing through pain due to lack of awareness or support.
• Limited Awareness of Safe Movement: There was no structured education around body mechanics, stretching, or injury prevention exercises, leaving staff without the tools to protect themselves.
• Language Barriers: With many staff members speaking English as a second language, communication around safety practices was inconsistent and sometimes ineffective.
• Unpredictable Work Environments: The dynamic nature of DCs and Trade Centres made it difficult to apply one-size-fits-all solutions, requiring a more tailored and flexible approach.
• Low Engagement with Traditional Safety Messaging: Safety communications were often seen as compliance-driven rather than empowering, resulting in low uptake and minimal behaviour change.

NZ Safety Blackwoods Approach

NZ Safety Blackwoods partnered with Provention to embed safe movement principles across every part of the business; through a multi-delivery style approach, strongly championed by leadership at all levels.

1. On-site observations:  Provention assessed Distribution Centres (DCs) and Trade Centres to understand physical demands and tailor sessions to real tasks.

2. Train-the-trainer:  A broad group, including the Head of People, Safety & Sustainability, H&S team members, and elected reps from DCs and Trade Centres, became certified First Move trainers. This empowered NZSB to deliver onboarding and refresher training in-house.

3. Champion training:  All H&S reps nationally attended Champion sessions, ensuring safe movement principles were reinforced consistently for long-term habit change.

4. Provention delivery & trainer coaching:  Every staff member in Auckland DCs completed a First Move session co-delivered by Provention and in-house trainers. These sessions doubled as live coaching, giving trainers confidence and credibility with their peers. Senior Management introduced each session, reinforcing NZSB’s commitment to staff wellbeing.

5. National rollout:   In-house trainers extended the programme to all Trade Centres across the country.

6. Warm-Up programme:  Selected Warm-Up Champions in both DCs and Trade Centres were trained to lead daily First Move Warm-Ups, embedding safe movement into everyday routines.

Support resources:

To sustain behaviour change and ensure long-term success, NZ Safety Blackwoods embedded a suite of branded support resources:

Habit Maker Toolkit:  A comprehensive package of reinforcement tools, including:

• Posters with QR codes linking to safe movement videos.
• Ready-to-use Team Talks for supervisors and leaders.
• Short reminder videos to boost knowledge and application.
• Monthly newsletters highlighting everyday applications of First Move principles.

Online Programme: Used for both inductions and refreshers, giving staff across the country consistent access to First Move training.

Next Steps:

Building on the success of the First Move programme, NZ Safety Blackwoods is committed to sustaining momentum and embedding safe movement principles as a long-term cultural shift across the business:

• First Move Office: Extending the programme to the office workforce to address the unique risks of sedentary roles, including poor posture, repetitive desk tasks, and prolonged sitting.
• New Distribution Centre: Integrating First Move principles into the opening of the new Auckland DC Drury, ensuring safe movement is part of the site’s foundation and daily operations from day one.
• Area-Focused Implementation: Each site and team has been supported to focus on specific movement risks relevant to their environment. This targeted approach has helped teams take ownership of their safety, build confidence, and embed habits that are practical and sustainable.
• Keeping the Programme Alive: Ongoing reinforcement through warm-ups, team talks, visual reminders, and leadership support ensures First Move remains active and visible. Trainers and champions continue to drive engagement, adapting delivery styles to suit evolving team needs.
• Leadership Integration: Embedding safe movement into leadership conversations and health, safety and wellbeing initiatives, encouraging leaders to model behaviours and support team participation.
• Continuous Improvement: Using feedback, injury data, and participation metrics to refine delivery, identify high-risk areas, and tailor interventions for maximum impact.

Contact Provention to start the process of creating a successful Manual Handling training programme for your team as well.