2. Ergonomic Worksheet for Container Design GC27 2 CTIS #18641 (Stand-alone course) Module 14 (as part of CTIS #3049)

3. Ergonomics Worksheet for Container Design: Use and Limitations USE: Design and buy-off of new containers utilized in the Plant Manufacturing Process. NOT to be used to evaluate existing containers or containers proposed for re-use with same or similar commodities (i.e. containers currently in use in the plant/facility) unless: –The existing containers have a history of injuries associated with the container or application –There is a significant change in the part or the processing requirements of the part (i.e. automated unload changed to manual unload) USE: To identify areas of potential concern during the container design process.

4. Ergonomics Worksheet for Container Design  Container design proposals should support the Plant Manufacturing Process. Thus, the manufacturing processes specific to the container point of use must be considered when assessing a container.  Assessment score does not constitute a definite outcome – secondary analysis methods may be needed.  Force conditions must be measured with the container fully loaded with parts.  The worksheet, instruction manual, and this training material can be found at www.gmcontainers.com www.gmcontainers.com

5. Worksheet Format The worksheet is divided into nine areas as follows: Bulk Section PARTS (P1-P3) - Rates hand and finger clearances, part placement, rotation or flipping and part lifting moment. DUNNAGE (D1-D3) - Rates dunnage force and lift moment (for removable dunnage), frequency and handholds. LATCHES/LOCKS (L1) - Scores latches/locks, etc. used on body shop panel racks. RACK ENTRY (R1) - Rates obstructions and walking surfaces if rack entry is necessary. WORK ENVELOPE (WE1) – Work envelope matrix for parts and dunnage handling. Small Lot Section SIZE (S1) - Scores the dimensional characteristics of a tote or manually handled container. LIFTING MOMENT (M1) - Scores the lifting moment for the tote or container and whether or not a NIOSH Lifting calculation should be performed based on the lifting moment. FINGER CLEARANCE (P1) – Scores clearance for finger depth HANDHOLDS (H1) - Scores the dimensional characteristics and properties of handholds on manually handled containers.

6. Worksheet Format (Tabs)  Ergonomics Evaluation (GC27) – Bulk Evaluated for large, bulk dunnage.Evaluated for large, bulk dunnage.  Ergonomics Evaluation (GC27) – Small Lot Evaluated for totes and manually handled containers.Evaluated for totes and manually handled containers.  Input Sheets Created to allow for easier/more efficient input with drop-down lists.Created to allow for easier/more efficient input with drop-down lists. Copies/pastes information into appropriate cells in worksheet.Copies/pastes information into appropriate cells in worksheet. – GC27 Timing The worksheet should be completed by the container engineer prior to the sample/prototype meeting and sent out with the buy-off documentation prior to the meeting. Any issues that come up should be addressed.The worksheet should be completed by the container engineer prior to the sample/prototype meeting and sent out with the buy-off documentation prior to the meeting. Any issues that come up should be addressed.

7. Bulk Dunnage Input Sheet

8. Bulk Dunnage Worksheet

9. Small Lot Input Sheet

10. Small Lot Worksheet

11. Scoring Process – Loading / Unloading Consider both the loading and the unloading conditions. For most of the questions choose loading or unloading as the “worst case” and score the worksheet accordingly. There are 5 questions on the worksheet that require you to score both a loading and unloading condition. –Loading condition is represented by an (L) –Unloading condition is represented by a (U) Score all questions based on the “worst case” scenario. –For example: if a part must pass over a corner post to be inserted to or extracted from a rack, the part must be handled above the height of the corner post, which will be higher than when the part is actually positioned in the container for transportation, therefore question P2 needs to be scored accordingly.

12. Parts – Questions P1-P3 P1A –Opening for Hand for Loading/Unloading Part P1B –Finger Clearance for Loading/Unloading Part P2 –Part Rotation, Flipping or Obstructions P3 –Part Lifting Moment

13. Dunnage – Questions D1-D3 D1A –Dunnage Force (Contained Dunnage) D1B –Dunnage Lifting Moment (Removable Dunnage) D2 –Frequency of Dunnage Handling D3 –Cutout Handhold (Removable Dunnage)

14. Latches/Locks – Questions L1-L2 L1 –Hand Forces for Pull Cable Release L2 –Finger/Thumb Forces – Latches, Locks and/or Pull Rings

15. Rack Entry and Work Envelope – Questions R1 and WE1 R1 –Rack Entry WE1 –Work Envelope

16. Small Lot – Tote & Kit Section SIZE: S1A –Tote Size Requirements for Totes <30” (<760mm) Long S1B –Tote Size Requirements for Totes >30” (>760mm) Long LIFTING: M1 –Lifting Moment for Loaded Container PARTS: P1 –Finger Clearance for Loading/Unloading Part HANDHOLDS: H1A –Cutout Handhold H1B –Drawer-Pull

17. Small Lot – Tote & Kit Section The Small Lot tab within the Ergo Container Worksheet contains questions related to Totes, Kits and other Manually Handled Containers utilized in the Plant Manufacturing Process. All Small Lot containers are scored separately from bulk dunnage containers. The engineer should examine the container that is being evaluated and determine which "Size" and "Handhold" questions apply to the container and complete them. –Only one question from each section should apply.