Ergonomics Design Requirements and Assessments for CETC Replaces the DEW

Ergonomics Design Requirements & Assessments Design Ergonomics Worksheets (DEWs) was used across all centers to analyze product designs and manufacturing processes. Manufacturing Engineers completed the DEW. Design Ergo Worksheet was developed in early 1990’s. Issues are now tracked and worked simultaneous to completing a worksheet. Info is more easily visible and comprehensive for program ME team members.

GM Ergonomics Requirements Vehicle Product Engineering uses these as internal checks for vehicle manufacturing system pre IV. Starting at IV issues are tracked in TED CETC uses as a tracking list because of the type of manufacturing processes tied to equipment Issues are tracked in Ergonomics Design Assessment (EDA)

OLD - Design Ergonomics Worksheet (1 of 2 pages) GM Global Ergonomics revised February 2013

GM Global Ergonomics revised February 2013

Ergonomics Design Requirements GM Global Ergonomics revised February 2013

GM Global Ergonomics revised February 2013 Continued GM Global Ergonomics revised February 2013

Ergonomics Design Assessment (EDA) Additional tracking list is used for N&M Powertrain (CET Center) programs Utilized as a screening tool to assess operator interaction with equipment, processes and parts Utilizes the same questions from the Ergonomic Requirements Includes component to adjust force levels for high repetition tasks

Ergonomics Design Assessment (EDA) - Example

CETC Ergonomic Machine Run-off Checklist

Chart 4 - Powertrain Systems - Future Program Ergonomics Process KO DC Mule CI Mnfg. Site Dec CS AR Approved Beta CC Gamma FA PA PT SORP Product Design • Participate in Reviews of New Product Designs during Mock-Ups and Slow Build Events Manufacturing Engineering Design • Review Ergonomic Design Requirements and Assessments (EDRA) • Review Machine Run-Off (MRO) Documentation Container Design • Review container worksheets & Attend Reviews / Buy-offs • Review and Track issues in TED • Transition open issues to Plant JETT 6 month clock* Based on GPDP September 2013 *Between Start of Regular Production (SORP) and 50% End of Acceleration (EOA)

Machine & Equipment Run-Off Checklist (MRO) To ensure all ergonomic requirements are incorporated & functionality is met on all manual operations Defined by Global Machinery & Equipment Ergonomics Specification G3.0 Owned by Mfg. Engineering & Mfg. Operations Ergonomics MRO may be completed by any Launch Team member after attending “Ergonomics Training for Launch Team” Highly recommend that at least one person from Ergonomics attend the run-off of MANUAL assembly stations/lines. The MRO checklist is the primary tool USED by the Launch Team to indicate ergonomic issues during the Run Off process. It is important to recognize that “Any” member of the Launch Team can fill out the ergonomics portion of the MRO Checklist as all members of the Launch Team are required to have Ergonomics Training.

Machine & Equipment Run-Off Checklist (MRO) Spec reference numbers Global Ergonomics revised August 2012

Machine & Equipment Run-Off Checklist (MRO) Global Ergonomics revised August 2012

Machine & Equipment Run-Off Checklist (MRO) Global Ergonomics revised August 2012

Example of Use of Machine Run-Off Checklist What would you be looking For???? Take a few minutes, look at a copy of the MRO checklist and give some examples.

Example of Use of Machine Run-Off Checklist Toe Clearance

Example of Use of Machine Run-Off Checklist Cycle Start Button Height Toe Clearance

Example of Use of Machine Run-Off Checklist Vertical Height and Horizontal Reach for Working areas Cycle Start Button Height Toe Clearance

Example of Use of Machine Run-Off Checklist Vertical Height to Centre of HMI Vertical Height and Horizontal Reach for Working areas Cycle Start Button Height Toe Clearance

Example of Use of Machine Run-Off Checklist Machine Access Door Width Height to Centre of HMI Vertical Height and Horizontal Reach for Working areas Cycle Start Button Height Toe Clearance

Example of Use of Machine Run-Off Checklist Overhead Clearance on Machine Machine Access Door Width Height to Centre of HMI Vertical Height and Horizontal Reach for Working areas Cycle Start Button Height Toe Clearance

Example of Use of Machine Run-Off Checklist Finger/Hand Clearances

Example of Use of Machine Run-Off Checklist Don’t Forget!!! Handles Removable Panels/Doors Weights of Covers/Guards Don’t forget maintenance tasks

Questions?

ERGONOMICS REQUIREMENTS Reference SP-S-Ergonomics G3.0 WORKSTATION & EQUIPMENT WORK ENVELOPES Revised Work Envelope Primary: Preferred zone for the majority of tasks. Secondary: For Cyclic work: if the weight/force exceeds 5 lb/2.3 kg/ 22 N or if the duration of the reach exceeds 10 seconds or if the frequency of the reach exceeds 2/minute, consult the Program Ergonomist. Undesirable: Not recommended. Consult the Program Ergonomist (> 25”/640 mm requires a one hand supported reach) Over-head: Consult the Program Ergonomist. Manual Operator Workstations - Is the majority of the work within the primary work zone? If yes, state Okay. If no, state Not Okay and provide dimensions and comments that pertain to the criteria listed under the secondary wo zone. Tool Change/Common Maintenance Operations - Is the work within the primary or secondary work zones?