Background
6Prior to his injury in 2005 the applicant was employed as a machine operator at the respondent's Warwick Farm plant operating the "Texo 3" machine. He was subsequently taken off the "Texo 3" machine and returned as a stacker for that machine, but was paid as an operator. He was working as a stacker but paid as an operator at the time of his injury. He was off work for three months and then returned to work.
7In about February 2006, the applicant again injured his back. His treating doctor sent him for physiotherapy and he was subsequently certified fit for suitable duties. The respondent had no duties and directed him to stay home. On 4 May 2006, the applicant returned to normal duties.
8In July 2007, the applicant aggravated his back injury and developed right leg pain. He was off work for a further 3 months. In November 2007, the applicant aggravated his back injury. He was referred to physiotherapy, prescribed painkillers and advised to return to work on light duties. The respondent declined to provide light duties and the applicant was off work for about six weeks. When he returned to work he was placed back on normal stacking duties.
9In May 2008, the applicant again reported severe back pain and the respondent's workers compensation insurer sent him to a Dr Silva for assessment. In
about November 2008, the applicant was summoned to a meeting with management representatives of the respondent and advised that he did not have to do stacking anymore because they had received Dr Silva's report.
10In mid January 2009, the applicant was made the operator on the "Ward 2" machine, which involved the following duties: putting ink into the machine which involved lifting a bucket of ink of about 30kg onto the machine about 100mm off the ground five times a day; assisting the stackers to lift the "form and stereos" which weigh from 20kg to 80kg; and operating the machine which involved "pushing buttons". The "Ward 2" machine was decommissioned in June 2011.
11On 5 August 2009, Dr Greg McGroder, an approved medical specialist appointed by the Workers' Compensation Commission, issued a Medical Assessment Certificate that certified the applicant suffered from 6 per cent "Whole Person Impairment" apportioned equally between the applicant's 19 April 2005 and 21 November 2007 injuries.
12In December 2009, the applicant sustained an injury to his lower back and was off work until February 2010. In February 2010, the applicant again injured his back and received a medical certificate for light duties. The applicant continued to see his treating doctor and was provided with medical certificates for light duties. However, he was told the respondent had no such duties and was directed to stay at home.
13On 6 July 2010, the respondent received a letter from Dr Greg Etherington, a spine surgeon who examined the applicant at the request of CGU, the respondent's workers' compensation insurer. The letter stated:
[The Applicant] described the lumbar pain now as being fairly constant. It is made worse with activities, particularly bending and lifting, but it is also made worse with prolonged sitting and standing.
14On 21 January 2011, Recovre, a workplace rehabilitation provider appointed by CGU, carried out a Workplace Assessment. The Assessment report, dated 17 February 2011, recommended that the applicant graduate towards returning to his pre-injury duties once medically endorsed and the applicant work in the least physically demanding line being the "string wrap" line. However, the applicant was directed to stay at home.
15On 18 March 2011, the respondent received a report following a Case Conference attended by the applicant and Dr Tran (the applicant's nominated treating doctor). The report stated that during the Case Conference, Dr Tran indicated it was not possible to predict when the applicant would return to pre-injury duties. The report further stated that the applicant was not undertaking any treatment for his lower back or hip injury.
16On 4 May 2011, the respondent received a copy of a Functional Assessment undertaken by Saskia Van Der Lely of MP Safety Management. The Functional Assessment was sent to Dr Tran to provide comment on the applicant's ability to return to work. On 19 May 2011, the respondent received a copy of Dr Tran's responses to the Functional Assessment. The responses stated that the applicant was unable to perform a number of the tasks assessed. It should be noted that the Functional Assessment was carried out in relation to the "Ward 2" machine, which was no longer in operation after June 2011.
17On 9 June 2011, Dr Tran sent a letter confirming that the applicant was fully fit for pre-injury duties. Given the short period of time between when Dr Tran had indicated the applicant was unable to perform a number of the tasks assessed in the Functional Assessment and when he certified the applicant was fully fit, the respondent sought answers from Dr Tran in relation to a number of questions.
18Question 7 asked:
As you are aware, a Functional Assessment was undertaken by MP Safety Management on 2 May 2011. The findings were sent to you by MP Safety Management and you responded on 19 May 2011. In your response you stated that Mr Chau was unable to undertake a majority of tasks assessed. Based on your clinical assessment of Mr Chau, do your responses remain current? YES/NO
19Dr Tran responded to the question as follows:
YES/NO. Employer had been unable to provide suitable duties. Patient is afraid about his job termination. He is keen to get back to pre-injury duties but will review accordingly to monitor his progress.
20The respondent sought an independent medical assessment of the applicant. Dr Peter Aldridge, an injury management consultant, subsequently assessed the applicant on 28 June 2011. Dr Aldridge, in correspondence to the respondent, assessed that the applicant was fit for pre injury duties with warm up exercises and continuing home spinal strengthening program also noting "mild degenerative changes with no significant pathology". Dr Aldridge stated:
Given that the underlying condition does not "go away" but the aggravation settles, it is important to realise that any duties that involve manual handling have the potential to aggravate again. The chances of aggravation are less with the lightest of manual handling but almost guaranteed with heaviest manual handling. He should be able to minimise risk by excellent manual handling procedures, warm-up and home exercises and avoiding the heavier manual handling components...
He is at pre-injury duty status now. He has a risk of aggravating his underlying degenerative condition. He should probably avoid heavy manual handling. Light to moderate manual handling is appropriate as long as he continues to perform his home exercise program and his warm-up exercises at work. He may benefit from some one-on-one manual handling training as this will certainly reduce risk of aggravations if he takes it seriously. The Applicant would avoid lifting more than 20Kg in static or 16Kg in dynamic lift. Repetitive and awkward lifting should be avoided. Jerking movements are unsafe. Manual handling in confined spaces axe a risk. Unrestricted pre-injury duties do have a risk of aggravation. His degenerative spinal condition will gradually worsen over the years.
21Evidence was received from Mr Gerard Schouten, the respondent's General Manager Operations, New South Wales. Mr Schouten explained the steps taken after receipt of Dr Aldridge's report:
On 7 July 2011, I met with Adam Covington, Manufacturing Manager to discuss the Applicant's employment. Following a long discussion regarding the medical evidence, the Functional Assessment of 4 May 2010, we made the decision to terminate the Applicant's employment.
We agreed that, due to the manual nature of the work which required physical exertion for extended periods, the Applicant was unsuitable for the inherent requirements of the position. This was partly based on the fact that on 5 August 2009 the Applicant was assessed as having 6% Whole Person Impairment following injuries to his back sustained on 19 April 2005 and 21 November 2007. I also considered the Applicant's history of recurrent back injuries, and the advice of numerous medical reports that he stood a significant chance of further aggravating his back injury if he performed repetitive movements or lifted weights in the range of duties he was required to perform.
We also gave consideration to the fact that it is in Visy's best interests to assist workers to return to work. We balanced this with the duty of care obligations owed by Visy and its officers to eliminate or reduce risk to employees' health and safety. We decided that we were not prepared to make a decision which would increase the risk of injury to the Applicant.
Further, I remain concerned that the Applicant has not returned to pre-injury status given that the WorkCover Medical Certificates issued by Dr Tran and other doctors and provided to Visy have only been "progress certificates". Visy is yet to receive any "final" WorkCover Medical Certificate which confirms that the Applicant has returned to full pre-injury status. Further, no explanation has been provided regarding the Applicant's condition suddenly and unexpectedly improving to the extent that he was fit for full pre-injury duties according to Dr Tran's correspondence of 9 June 2011 ...
When making the decision to terminate the Applicant's employment, we considered the possibility of alternative positions either within Visy Board or other entities associated with Visy.
Visy operates a number of separate and distinct operating entities. The Applicant was employed in the Fibre Packaging Division which operates over the Warwick Farm and Smithfield sites. Each entity's operations and the products that they manufacture involve diverse machinery and specialised processes that are generally not interchangeable. It is very uncommon for an employee to work at both sites concurrently or to switch sites due to the re-training and induction processes, which can be 18 months in duration and are specific to each site. Despite this, we considered the suitable duties register at various times during the Applicant's periods of injury to assess if suitable duties were available.
Amongst the roles deemed unsuitable were forklift driving, driving the sweeper, stacking and separately working as a corrugator, control panel operator or dry end operator. All of these roles involved bending, lifting, manual handling, stacking, pushing or pulling, twisting or repetitive movements involving a combination of those movements. There are very few jobs at Visy that do not require these manual activities.
Additionally, Visy's workers are generally longstanding employees who are engaged to work with machinery they have operated for many years. Much of the workforce is unionised and, as a result, any disruption to the way in which Visy employs its staff in order to accommodate the Applicant's condition is likely to result in an industrial dispute. Further, the creation of a position to accommodate the Applicant is not possible and would disrupt Visy's production processes.
22On 8 July 2011, the decision was made to terminate the applicant's employment on the basis that the applicant was unsuitable for the inherent physical requirements of his former role.
23The applicant continued to consult Dr Tran. On 29 July 2011, Dr Tran saw the applicant and noted his work capability was "8 hrs/day - 5 day week - need assistance for heavy lifting (avoid lifting > 15-20 kg in weight)". Dr Tran again saw the applicant on 15 August 2011. The applicant complained of lower back pain. Dr Tran prescribed "Analgesia, physiotherapy, Active range of motion exercise, Strengthening exercise, Stretching exercise".
24A further consultation occurred on 2 September 2011 at which time the applicant complained of chest wall pain. Dr Tran proposed an X-ray. On 28 September 2011 the applicant was treated for chest wall pain. It was noted the applicant was "attending gym/swimming regularly". On 4 October 2011 the applicant reported he was not suffering back or hip pain. On 4 November 2011 the applicant reported he was suffering "Persistent dull aching pain over his lower back which has been improving since he has been training at the gym and swimming".
25The applicant ceased receiving workers' compensation payments on 25 January 2012.
26On 11 April 2012, at the request of the applicant's lawyers, Dr Roger Pillemer, an orthopaedic surgeon, undertook a medical examination of the applicant and provided a report. The report stated, inter alia:
On direct questioning Mr Chau informs me he has obtained a clearance from his general practitioner to go back to his pre-injury duties but Visy Board are reluctant to take him back....
... Mr Chau has had intermittent ongoing problems with his low back and referred pain down his right lower limb but he is very much better at the present time and in fact he has not had any back pain for a year and he has not had any leg pain for a couple of years.
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Mr Chau was a strongly built adult male almost certainly from his regular gym work...
He had an excellent range of back movement being easily able to touch his toes with his fingertips and other movements were also full.
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I note that he had an MRI of his lumbar spine carried out on 6 April 2011 which was reported as being normal and I would agree with this assessment.
From Mr Chau's history it would seem that he has had a mechanical low back problem in the past with discomfort in the lower lumbar region and at one stage referred pain into his right lower limb. As noted, symptoms have long since settled down and he has not had any problems for over a year at this stage. He is also doing regular gym work with an excellent physique and does a lot of weight lifting in the gym...
Noting his history, in my opinion the nature and conditions of his work would have been a substantial contributing factor to his development and recurrent back problem.
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In my opinion Mr Chau is fit for unrestricted duties at the present time and I would suggest fit for his pre-injury duties. One can certainly understand his employers being reluctant to take him back in view of his previous history, and my only advice to Mr Chau would be to be very careful with heavy lifting and repeated or prolonged bending and twisting activities and at the first sign of any symptoms, it would be sensible to cut back on strenuous activities.
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Noting his history, it is certainly possible that he will have intermittent ongoing problems with his lower back in future.
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In my opinion condition (sic) can now be regarded as having stabilised/reached maximal improvement.
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Mr Chau fits into DRE Category 1 of his lumbar spine at the present time with 0% whole person impairment.
In answer to your very specific question then, in my opinion Mr Chau is fit to return to work on a fulltime basis as either a stacker or machine operator, with the simple precaution that he avoid excessively stressful lifting activities.