📌 OCRA Index – Upper Limb Risk Analysis and Ergonomics Solutions in Repetitive Motion

Workers in assembly lines, packaging stations, and mass production environments are exposed to high-frequency, repetitive hand and arm movements. Over time, this leads to upper limb musculoskeletal disorders (MSD), loss of workforce, and decreased production efficiency.

The OCRA Index (Occupational Repetitive Actions Index) is one of the most detailed and quantitative analysis methods in the field of repetitive motion ergonomics. At Tokgöz Ergonomics, we combine the OCRA methodology with field data, making risks measurable and transforming them into implementable improvement plans.

Because sustainable productivity begins with healthy workers.

🔎 What is the OCRA Index?

The OCRA Index is a scientific ergonomics assessment tool that analyzes the loading on the upper limbs (shoulder, arm, elbow, wrist, hand) using objective metrics.

The method evaluates the following parameters together:

Number of repetitions (frequency)

Applied force level

Position (joint angle and strain level)

Working time

Rest intervals

Additional risk factors (vibration, cold environment, etc.)

Thanks to this multi-parameter approach, risks are revealed not only through observation but also through numerical scores.

🧭 1. Metric and Exposure Analysis in Repetitive Movements

In high-frequency assembly work, the risk is often invisible. OCRA mathematically calculates this invisible load.

✔ The Role of OCRA

The duty cycle at the workstation is analyzed, each movement is classified, and the total exposure score is calculated.

Result:

Low risk

Medium risk

High risk

Unacceptable risk

is categorized as follows.

✔ Complementarity with ART Tool

ART Tool; It assesses upper limb exposure in repetitive tasks through frequency, posture, and force. When used in conjunction with OCRA, it forms a powerful combination for detecting early upper extremity disorders (ULDs).

✔ Rapid Screening with RULA

RULA quickly classifies shoulder, arm, and wrist risks.

Especially if the RULA score is in the 6-7 range, an urgent need for improvement arises.

The OCRA + RULA combination provides both rapid screening and detailed metric analysis.

🔍 2. Process and Psychosocial Risk Assessment

Repetitive motion ergonomics is not just about physical posture analysis. Work organization and psychosocial burden also play an important role.

✔ KIM-MHO

It evaluates manual work processes with key indicators and quickly screens the level of strain.

✔ Job Strain Index

It measures the psychosocial impact of repetitive tasks by analyzing workload, control level, and stress factors.

✔ CMDQ & NOVA NORDIC

Pain and symptom profiles are created using employee feedback. Thus, subjective data is integrated with objective analysis.

Thanks to this holistic approach, both physical and psychosocial risks are managed.

🏢 3. Strategic Advantages with the OCRA Index

✅ Prevention of MSDs

Risky tasks are identified before clinical symptoms appear.

✅ Production Efficiency

Less fatigue → Fewer errors → Higher quality

✅ Legal and Standard Compliance

OCRA applications:

ISO 11228

ISO 11226

Law No. 6331 on Occupational Health and Safety

Provides a risk assessment infrastructure compliant with these laws.

✅ Sustainable Improvement Plans

Analysis results are transformed into the following areas:

Workstation redesign

Cycle time optimization

Job rotation plan

Integration of auxiliary equipment

Training and administrative controls

🏭 How to Apply OCRA Analysis?

Tokgöz Ergonomics application process:

1️⃣ Task Analysis

The work cycle is examined in seconds.

2️⃣ Movement Coding

Each repetition and force level is classified.

3️⃣ Exposure Calculation

A total risk index is created.

4️⃣ Identification of Critical Points

The riskiest task components are identified.

5️⃣ Ergonomic Improvement Design

Engineering and organizational solutions are planned.

6️⃣ Management Report

Numerical scores, graphs, and action plan are presented.

🎯 Target Users

Occupational safety specialists

Ergonomists

Assembly and production line managers

Industrial engineers

Human resources and operations managers

📈 Adding Value to Your Business with the OCRA Index

✔ Objective measurement of upper limb risks
✔ Optimization of repetitive motion ergonomics
✔ Reduction of workforce loss
✔ Auditable and reportable system
✔ Employee health-focused production design

🚀 Why Tokgöz Ergonomics?

We don't just calculate risk scores.

Integration of multiple methodologies

Field observation and data analysis

Cost-impact assessment

Management presentations

Training and consulting

We offer end-to-end solutions.

📞 Take Action

✔ Request an OCRA Index Analysis Demo
✔ Download the Repetitive Motion Risk Score Form
✔ Schedule a Free Appointment for Ergonomics Training and Consulting

Measure upper limb risks with the OCRA Index, protect employee health, and sustainably increase your production efficiency.

Supported by scientific metrics, ergonomics is the foundation of operational excellence.