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Job rotation is one method that is sometimes used to reduce exposure to strenuous materials handling; however, developing effective rotation schedules can be complex in even moderate sized facilities. The purpose of this research is to develop methods of incorporating safety criteria into scheduling algorithms to produce job rotation schedules that reduce the potential for injury. Integer programming and a genetic algorithm were used to construct job rotation schedules. Schedules were comprised of lifting tasks whose potential for causing injury was assessed with the Job Severity Index. Each method was used to design four job rotation schedules that met specified safety criteria in a working environment where the object weight, horizontal distance and repetition rate varied over time. Each rotation was assigned to a specific gender/lifting capacity group. Five versions of the integer programming search method were applied to this problem. Each version generated one job rotation schedule. The genetic algorithm model was able to create a population of 437 feasible solutions to the rotation problem. Utilizing cluster analysis, a rule set was derived from the genetic algorithm generated solutions. These rules provided guidelines for designing safe job rotation schedules without the use of a computer. The advantages and limitations of these approaches in developing administrative controls for the prevention of back injury are discussed.

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This research developed worker schedules by using administrative controls and a computer programming model to reduce the likelihood of worker hearing loss. By rotating the workers through different jobs during the day it was possible to reduce their exposure to hazardous noise levels. Computer simulations were made based on data collected in a real setting. Worker schedules currently used at the site are compared with proposed worker schedules from the computer simulations. For the worker assignment plans found by the computer model, the authors calculate a significant decrease in time-weighted average (TWA) sound level exposure. The maximum daily dose that any worker is exposed to is reduced by 58.8%, and the maximum TWA value for the workers is reduced by 3.8 dB from the current schedule.