2. Ergonomics Design Requirements and Assessments for CETC
Replaces the DEW

3. 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.

4. 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)

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

6. GM Global Ergonomics revised February 2013

7. Ergonomics Design Requirements
GM Global Ergonomics revised February 2013

8. GM Global Ergonomics revised February 2013
Continued
GM Global Ergonomics revised February 2013

9. 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

10. Ergonomics Design Assessment (EDA) - Example

11. CETC Ergonomic Machine Run-off Checklist

12. Chart 4 - Powertrain Systems - Future Program Ergonomics ProcessKO 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)

13. 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.

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

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

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

18. 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.

19. Example of Use of Machine Run-Off Checklist
Toe Clearance

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

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

22. 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

23. 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

24. 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

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

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

27. Questions?

28. 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?