This paper illustrates the process of developing and configuring the prototype Computer Analysis System for Controlling Occupational WORKload (CAS-COWORK). The software interface between the database and expert system was attempted. The database is used for storing and retrieving series of data entered by general users and the expert system is used for identifying and solving occupational problem areas. Two theories were applied in developing the algorithm base of CAS-COWORK that were used to calculate overall workload stress level. The fuzzy set theory was introduced to capture the subject‘s workload stress perception. The Analytic Hierarchy Process (AHP) was introduced to estimate the importance of the task and workplace variables. The purpose of the system development is for future prediction and problem solving which would be highly valuable to the industrial engineer.