the challenge

Stocking a warehouse involves intense, repetitive movement. Without proper training, this movement can degrade a worker’s ability to get the job done safely and effectively.

The Story

Warehouse workers face severe physical demands, lifting thousands of pounds per day during long shifts lasting 12 to 14 hours. At one U.S. food wholesaler, warehouse workers complained of chronic pain and fatigue due to the physical nature of their job.

Physical pain and fatigue, plus unpredictable hours and environments, contributed to work-related injuries and early employee burnout. High turnover rates pushed the grocer to update the exercise portion of their new-hire training program. EXOS stepped in to help.

Did You

According to this company’s research, reducing warehouse injuries could save them $2.3 million per year in injury claims.

the solution

After evaluating the workers’ needs, EXOS designed a 12-week program to decrease the number of on-the-job injuries while boosting productivity and morale.

The program aimed to enhance performance and improve outcomes for workers and the company. Warehouse workers learned to improve lifting postures through proper movement patterns during specially designed movement sessions before and after shifts. Participants also received nutrition counseling and healthy habit education to help them boost energy levels and quality of life at work and at home.

“I’ve increased my productivity by 15 to 20 percent and am now one of the top selectors. I’m able to spend more time with my family instead of sleeping,” says Marquese, a program participant.

During movement sessions, employees practiced proper movement patterns that translated directly to their daily occupational responsibilities.
Proper movement training helped employees prepare to lift thousands of pounds of boxes during long shifts.
Movement sessions and one-on-one nutritional coaching introduced participants to healthy strategies.


  • Percent increase in worker productivity at the end of the program 0
  • Percent of new hires retained after the 12-week program, compared to 30-percent benchmark 0
  • Number of injuries during day and night shifts at the end of the program

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