This research proposes a mathematical model of the problem of job rotation considering ergonomic aspects in repetitive works, lifting tasks and awkward postures in manufacturing environments with high variability. The mathematical model is formulated as a multi-objective optimization problem integrating the ergonomic constraints and is solved using improved non-dominated sorting genetic algorithm. The proposed algorithm allows the generation of diversified results and a greater search convergence on the Pareto front. The algorithm avoids the loss of convergence in each border by means of change and replacement of similar solutions. In this strategy, a single similar result is preserved and the best solution of the previous generation is included. If the outcomes are similar, new randomly generated individuals are proposed to encourage diversity. The obtained results improve the conditions of 69% of the workers. The results show that if the worker rotates starting from a high risk, his variation in risk always decreases in his next assignment. Within the job rotation scheme, no worker is exposed simultaneously to high ergonomic risk thresholds. The model and the algorithm provide good results while considering ergonomic risks. The proposed algorithm shows the potentiality to generate a set of quality of response (Pareto Frontier) in a combinatorial optimization problem in an efficient computational time. © 2018, Springer-Verlag GmbH Germany, part of Springer Nature.