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Strains and sprains accounted for a significant portion of Koppers’ recordable injuries. Many operations required physical handling that couldn’t be automated or redesigned without major capital investment. Prior to TuMeke, the company relied on third-party ergonomic assessments that were expensive and slow, with limited actionable outcomes. Another software trial offered some promise but lacked flexibility and engagement. Koppers needed a scalable, intuitive tool to make ergonomics part of their day-to-day safety culture.
“Certain operations simply can’t be engineered to remove the human factor. We needed a way to identify and reduce risk where people are physically moving heavy materials every day.”
– Blayne Darnell, Corporate Safety & Health Manager, Koppers
Koppers launched a pilot with six sites—five in the U.S. and one in Australia—using TuMeke's Risk Suite platform and mobile application to conduct ergonomic assessments across operations that posed the highest risk of strains and sprains. One early success came from the Huntington, West Virginia site, where a local safety professional used TuMeke to identify and validate a safer way to roll and handle heavy drums. The solution reduced risk scores and allowed the task to be per formed by one worker instead of two. The modification was later shared company-wide through Koppers’ internal innovation platform.
Koppers has already seen a measurable downward trend in strain and sprain injuries, with more consistent risk analysis across facilities.
“People really like seeing the risk scores and where they can improve. It’s sparked healthy competition between sites and made ergonomics approachable.”
– Blayne Darnell, Corporate Safety & Health Manager
For Koppers, TuMeke has become a cornerstone of proactive injury prevention— empowering teams to identify risk, engage workers, and drive safer performance in environments where manual work will always be par t of the job. Koppers plans to continue expanding TuMeke’s use and explore integrations with their incident management system to track ergonomic activities as leading indicators. Darnell also sees future potential for AI-generated diagrams and stretch visuals to support task coaching and warm-up routines.
Download and read the full case study here.
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Strains and sprains accounted for a significant portion of Koppers’ recordable injuries. Many operations required physical handling that couldn’t be automated or redesigned without major capital investment. Prior to TuMeke, the company relied on third-party ergonomic assessments that were expensive and slow, with limited actionable outcomes. Another software trial offered some promise but lacked flexibility and engagement. Koppers needed a scalable, intuitive tool to make ergonomics part of their day-to-day safety culture.
“Certain operations simply can’t be engineered to remove the human factor. We needed a way to identify and reduce risk where people are physically moving heavy materials every day.”
– Blayne Darnell, Corporate Safety & Health Manager, Koppers
Koppers launched a pilot with six sites—five in the U.S. and one in Australia—using TuMeke's Risk Suite platform and mobile application to conduct ergonomic assessments across operations that posed the highest risk of strains and sprains. One early success came from the Huntington, West Virginia site, where a local safety professional used TuMeke to identify and validate a safer way to roll and handle heavy drums. The solution reduced risk scores and allowed the task to be per formed by one worker instead of two. The modification was later shared company-wide through Koppers’ internal innovation platform.
Koppers has already seen a measurable downward trend in strain and sprain injuries, with more consistent risk analysis across facilities.
“People really like seeing the risk scores and where they can improve. It’s sparked healthy competition between sites and made ergonomics approachable.”
– Blayne Darnell, Corporate Safety & Health Manager
For Koppers, TuMeke has become a cornerstone of proactive injury prevention— empowering teams to identify risk, engage workers, and drive safer performance in environments where manual work will always be par t of the job. Koppers plans to continue expanding TuMeke’s use and explore integrations with their incident management system to track ergonomic activities as leading indicators. Darnell also sees future potential for AI-generated diagrams and stretch visuals to support task coaching and warm-up routines.
Download and read the full case study here.
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