This study was performed to develop and evaluate a scheme for matching the strength of workers to the strength demands of their jobs. Biomechanical analyses were performed on production jobs in an aluminum reduction plant to identify and quantify strength demands. These data were used to design a set of nine strength tests which simulated job activities with the greatest strength requirements. A cross section of plant employees assigned to these jobs was strength tested and monitored for medical incidents for a period of over two years. Significant relationships were found among job strength requirements, worker strengths, and medical incidents. Workers with strength abilities (as determined by the tests) less than job strength requirements suffered a higher rate of medical incidents than workers whose strength abilities matched or exceeded job demands. It was concluded that strength testing can be used to identify workers who would be at increased risk of suffering medical incidents if placed on jobs which exceeded their strength abilities.