BHP weighs in on worker safety

BHP has rolled out more than 400 safety initiatives across its Australian minerals operations as part of a maintenance redesign program aimed at reducing musculoskeletal injuries, one of the most common health risks in the mining workforce.

The initiatives stem from the Operations Services Maintenance Redesign Team (MRDT), established in 2020 to address the physical strain faced by maintenance crews handling heavy equipment. Using BHP’s Operating System principles, the team applied a structured problem-solving approach to develop practical solutions that could be replicated across sites.

This has resulted in the delivery of over 400 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.

One of the most visible outcomes has been the introduction of lightweight sling and shackle sets, developed after a maintenance worker was injured lifting a 30-kilogram shackle overhead. The incident prompted a redesign led by frontline teams, with the MRDT partnering with Mackay-based supplier Soft Rigging Solutions to produce equipment made from lightweight materials.

The new sling and shackle sets reduced the lifting requirement from 30 kilograms to just three kilograms, significantly lowering musculoskeletal risk and expanding the number of workers able to safely perform the task. Following a successful trial at the Goonyella mine, the equipment was deployed across multiple Queensland sites including Peak Downs, Caval Ridge and Saraji, as well as Newman in Western Australia.

BHP said the initiative demonstrates how thoughtful design can safeguard workers and strengthen operational excellence across its operations.

The OS Maintenance Redesign Team’s work was also recognised with the Health and Hygiene award at BHP’s 2025 Health, Safety, Environment and Community Awards.