Respirators are widely used for protection against inhaled toxins. The emph
asis of research and implementation effort has evolved through several stag
es: the respirator device itself, use situation respirator program factors
under employer control, individual worker factors not under employer contro
l, and occupational health systems. For this study, a computer-simulation d
ecision assistance model was developed to assess the impact of various fact
ors on the number of workers receiving adequate protection. Factors include
the respirator protection factor identification of sites needing respirato
r protection, selection of proper device, availability when needed, frequen
cy of ever use, regularity of use among users, and variability in personal
susceptibility or other factors. This analysis demonstrates that for both m
oderate-risk and high-risk (ie, IDLH, immediately dangerous to life and hea
lth) exposures under current circumstances, the actual protection afforded
depends upon the optimization of program factors and detection of atypical
outlier persons and worksites. Therefore, programs and research must focus
an these areas. Occupational medicine specialists should help optimize thes
e areas and in addition, use each case of respiratory protection failure as
an index case to improve the overall programs.