UAW-GM Energy Control SOPs James Holton UAW International Representative General Motors Department Cora Coleman UAW Special Assigned Fred Jackson Program Manager General Motors Company

Safety Vignette

Presenters Justin Verba – Process and Technical Support Engineer Mark Vance – UAW Skilled Trades Jamie Chatel –Safety Design and Launch Engineer

Agenda Introductions EC-SOP Introduction UAW-GM Lockout Progression EC-SOP Overview Team Exercise Break Exercise Wrap-Up Rollout and Timing Final Discussion/Questions

Introductions Name Plant/Local Title/Classification Years of Seniority

EC-SOP Introduction

What is an EC-SOP? How is it different from a regular SOP? Safe Operating Procedure (SOP): Standardized work instructions for doing a job safely. Includes steps to be followed, potential hazards to be controlled, etc. Energy Control SOP (EC-SOP): A standardized form used for the creation of an SOP around energy control

Why do we need EC-SOPs? Complies with OSHA regulations Provides a standard form that is structured to allow for quick creation and easy understanding Enhances existing Inadequate LO procedure Coordinates existing forms Takes advantage of the knowledge of the Skilled Trades as they work on the equipment Allows for a deep dive with the proper personnel

UAW-GM Lockout Progression

UAW-GM Lockout Progression 1989 MPS/SCS Full Lockout 1996 MPS/SCS Full Lockout TIS / PTP / EC-SOP 2016 Full Lockout Lack of Standardized templates for creating Pre-Task Plans and SOPS for manufacturing equipment. Templates for working with “partial power on” if full lockout cannot be done to perform the task (Inadequate LO SOP) UAW-GM Lockout Progression

Safe Operating Procedures 1989 2016 2017 Full Lockout Full Lockout Full Lockout Safe Operating Procedures Energy Control Safe Operating Procedures Pre Task Plan Incorporates the Lockout Placards Incorporates Task Creep note and Safe Work Zone Add Engineering Input (TIS) TIS Template 1 Template 2 EC-SOP Level 0 Level 1 Minor, Routine, Repetitive, Integral to Production MPS/SCS

Full Lockout OSHA 1910.147

MPS/SCS OSHA 1910.212 & 1910.217

Truck Plants Janesville Wi. The CHR trust me to follow the rules to lockout (which is a procedure) – but you don’t trust me to follow the Tasks (rules) to use MPS as described on the MPS Placard. MPS Pilots Joint Program

PTP / EC-SOP

How Can we have this process work in dynamic complex production environments? In January 2016 we assessed all the forms around working equipment Pre Task Analysis Warnings EC-SOP Level 1 MPS Placard CAST CARD EC-SOP Level 0 TIS Temporary SOP Safe Work Zone Full Lockout Risk Analysis Task Creep Lockout Placards

Thinking Through Safety…The Total Picture 1. Staying Safe Getting to the Work …easy as 1, 2, 3 Work Area Enter / Exit Exit / Egress 2. Staying Safe At the Work 3. Staying Safe Leaving the Work This Is What We Want To Accomplish

EC-SOP Forms EC-SOP 0000 (Level 0) is for unplanned maintenance EC-SOP 000X (Level 1) for use with unplanned breakdowns and for quick and safe response those who will do the work.

TIS / EC-SOP Structure EC-SOP Level 0 EC-SOP Level 1 TIS

Level 0 – identified as - EC-SOP- 0000 – “Local Site” "shop/Area" This is a blank checklist form, it prompts workers doing a PTP to consider, at a minimum, the items within each of the sections on the first page of the form when they are evaluating how to perform the proposed work in safe way. At the bottom of page 1 is some additional items to protect the equipment being “worked on” At the top of page #2, are three common steps that will appear in every safe work procedure On the back side of the form are 9 blank lines to describe additional detailed steps of the SOP to perform the task safely. As referenced in OSHA 1910.147 C (4) step 3 of 8. The bottom of page 2 is a place for signatures and a debrief

Level 1 – identified as – (e.g. EC-SOP- 0005 – “FWA” “Bodyshop“) The blank checklist form, filled out by the work team as they were evaluating how to perform the proposed work safely. This Document is not larger than two pages (one sheet of paper). The team considers the work will be performed and hand writes copy. If this work will be performed again the hand written PTP is sent to plant safety for review. If approved the PTP will be typed up, given a number by the LJH&S Lockout Committee Refer to the process flow chart for details The Local Joint Health and Safety lockout committee approves, and then the document becomes an EC-SOP Level 1 document. The local safety lockout committee sends the file to the GWS Safety Design and Launch team is notified for addition to the EC-SOP Database.

EC-SOP Flowchart 1 Job assigned 7 6 LO Placards and SOPs are posted in each area for “ready reference” Job assigned 7 6 SOP Team creates a PTP using Level 0 form and agrees with all steps in the plan Input from the entire maintenance team is vital 2 Modifications ? Lockout Committee Approval Add box under step 3 that is for one time use only 5 4 3 Perform Work Post Review *Form is for one time use only

Team Exercise

EC-SOP Rollout and Timing

EC-SOP Rollout Currently in early pilot at: Full rollout in 2018 Fort Wayne Assembly Lordstown Assembly Full rollout in 2018

Questions?