Occupational stress has become a critical issue for many organisations and individuals in terms of costs to productivity and health. Effective rehabilitation intervention can markedly reduce these costs, yet a successful return to work is often fraught with difficulty due to the plethora of issues contained under the heading of occupational stress. An approach to case analysis and individual assessment has been developed in New South Wales, Australia to assist case managers employed by the Commonwealth Rehabilitation Service in the provision of efficacious rehabilitation programs, with the focus on return to work, for individuals with occupational stress.