Here's a very simple character that operates with only 2 switch layers.
1 x Switch Layer for the mouth and 1 x Boned Switch Layer for the body.

http://www.wienertoonz.com/DK2SWITCHBODY.swf
http://www.wienertoonz.com/DK2SWITCHBODY.anme
The main keyframes you need to adjust and keep in sinc on the timeline when dong head rotations are:
1. eyemover bone. Adjust it with the Scale Bone tool.
2.re-topr (eyelidbone) - controls eye blinks. Use the manipulate bone tool.
3. Mouth sets - there are two sets available to use in the one switch layer, one for front poses and one for head turning to the left.
The mouth layer is free floating so needs to be moved manually when the characters body bones are tweeked. (Vern?)
To add a new pose or expression, duplicate a layer, rename it, tweek it and add to the timeline. The character will intrerpolate into the new pose.
Drag keyframes around for timing. It's not a perfect rig yet only a proof of concept that I wanted to share with you all.
Cheers
D.K