Case Study

From Pain to Purpose: A Warehouse Worker's Return to Work Journey

Meet Ali...

After 7 months off with sciatica, Ali was ready to return – but pain, fear, and his slow progress held him back. The physically demanding nature of his warehouse role worried him and the emotional strain of not being able to provide for his family was taking its toll.

His employer, equally invested in supporting Ali return-to-work – needed clarity on what his was physically capable of, what adjustments might be needed and how long it might take for him to fully return.

Here’s how I worked with Ali and his employer to build a phased, practical return-to-work plan that made a safe, sustainable return-to-work possible.

assessment

I conducted Functional Capacity Assessment (FCE) during which we looked at what Ali could physically manage. We focused on his key job tasks – standing, lifting and bending which enabled me to determine his current physical tolerance.

The assessment also helped us explore:

The history of his condition and treatment to date
Progress made through GP support and physiotherapy
His current symptoms and functional limitations
The demands of his specific job role
The psychosocial barriers affecting his confidence to return.

Together, this gave me a well-rounded picture of where Ali was at and what support he’d need for a safe, successful return-to-work.

Our Approach:

The outcome of the FCE was that Ali was capable of returning to work with adjustments. Together with Ali and his Manager, I devised a return-to-work plan tailored to Ali’s need’s, with he aim of building his strength and confidence gradually. This included:

Reduced hours: Starting part-time and increasing gradually over an 8 week period.
Modified duties: In the first 4 weeks, we limited lifting and carrying. Ali was unable to handle 20kg loads but could manage 10kg safely. This was reviewed regularly and increased gradually through weeks 5-8.
Temporary restrictions: Specifically on on twisting and heavier lifting. Initially, he was unable to drive the forklift to prevent symptom flare up due to his position when getting in and out of the drivers seat.
Frequent movement breaks: To avoid staying in one position too long, reducing stress on soft tissues and helping manage pain.
Reassurance and education: I helped Ali understand the difference between pain linked to rebuilding strength and tolerance, and pain that signals harm — which played a key role in restoring his confidence and reducing fear.

This plan, which we reviewed every two weeks, gave both Ali and his manager clear direction. It reduced uncertainty, created a shared understanding of progress, and allowed us to spot and address any issues early.

The Outcome:

Over 8 weeks, Ali steadily progressed through the phased plan. Each step built his confidence and tolerance:

By week 6 he had resumed most of his duties with no major setbacks.
By week 8, he was back to full time hours.
His symptoms remained manageable, and his fear of re-injury significantly reduced.
His home life improved, with the return to routine easing both financial and emotional strain.
The employer retained a key team member with further delays or recruitment costs.

This case highlights the power of practical, compassionate occupational health input – empowering individuals to return to work safely, and giving businesses the clarity and support they need to take confident action.

Occupational health isn’t a one-size-fits all. Neither is the return-to-work process. That’s why it’s so important to have the right support in place – tailored advice, clear planning, and collaborative communication. When done well, it doesn’t just get someone back to work – it helps them stay there, healthier, more confident, and ready to contribute.

If you’re supporting someone back into work and want to get it right – we’re here to help

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