Changes in Blue Overview of Changes  Roles & Responsibilities  Administrative & Training Elements  GM Vehicle Systems, Body Systems, and Powertrain.

Changes in Blue

Overview of Changes  Roles & Responsibilities  Administrative & Training Elements  GM Vehicle Systems, Body Systems, and Powertrain (CETC) – combined section –NEW SECTION: Replaces existing GM Assembly & Stamping and Powertrain Sections –Review of new content  Customer Care and Aftersales (CCA) – formerly known as Service Parts Operations (SPO) –Changes being reviewed with CCA personnel in a different session

Scope & Application  The Corporation recognizes the important contributions from the joint ergonomics process. EDP-21 includes new technology, new products, and new processes that are sourced for manufacturing in UAW- represented GM facilities.  It is understood that final design decisions are the responsibility of the Corporation. For this purpose, EDP-21 defines constructive opportunities for joint ergonomics involvement in existing GM Engineering Design Processes.  These engineering processes are complex and change to reflect continuous improvement, therefore EDP-21 will be updated accordingly.  For this reason the most recent copy will reside on the UAW- GM Center for Human Resource (CHR) Joint Activity System www.uawgmjas.org

Roles & Responsibilities Checklists are located in the appendices

Roles & Responsibilities

GM Vehicle Systems, Body Systems, and Powertrain (CETC) Introduction Introduction  The specific activities and meetings in which the JETT will be expected to attend and, at times, report out will be determined by the respective manufacturing sector’s program, project, and/or launch manager working collaboratively with the program ergonomist and the JETT. In the case of multiple location process or equipment, the specific activities and meetings in which the JETT are expected to attend and report out will be determined on a case-by-case basis.  The JETT will consult with the Plant Safety Administrator regarding the release of machinery or equipment to production (“Red Tag” process). NEW SECTION: Replaces existing GM Assembly & Stamping and Powertrain Sections

PLANDESIGNBUILDINSTALL Generic Ergonomics Timing Overview Common design safety and ergonomics specification Purchasing process Lesson learned/ feedback from JETTs Ergonomics analysis & reviews with JETTs Plant Run Off & Build Event Red Tag –review with safety & ergonomics

Vehicle Systems General Assembly Operations In General Assembly, design-in ergonomics activities for new/major programs (at headquarters) are divided into four main categories: 1.Product Design 2.Assist and Specialized Tools Design 3.Line Balance Design 4.Container Design Activities related to each category are depicted in Chart 2 – Vehicle Systems Ergonomics Timing Overview. The program ergonomist works collaboratively with the JETT to accomplish these tasks.

Review Assist Tooling Worksheets & Attend Reviews / Buy-offs Review Container Worksheets & Attend Reviews / Buy-offs Identify Issues during Virtual Engineering Phase (Pre-IVER) Attend Physical (Integration) Builds at Pre-Production Operations (PPO) Attend Physical (Integration) Builds at Pre-Production Operations (PPO) Attend Physical (Validation) Builds At Plants Attend Physical (Validation) Builds At Plants Product Design Assists and Specialized Tools Containers Review Assembly Process System (APS) ergonomics evaluations Line Balance Chart 2 - Vehicle Systems - Future Program Ergonomics Process Transition open issues to Plant JETT 6 month clock* VPI CSO CVER SORP SVER IVER MVB- NS MVB- S DSI Ergonomics Process Overview Meeting *Between Start of Regular Production (SORP) and Launch Team Release (LTR) Review and Track issues in TED Based on GVDP September 2013

Supplier completes assist tooling ergo worksheets Mfg. Engr. forwards worksheet to Future Program Ergo for review Any ergonomics concerns? Assist & Specialized Tool Ergonomics Worksheet Process Flowchart Supplier obtains assist tooling ergo worksheet from web and completes on-line training

Review Assist Tooling Worksheets & Attend Reviews / Buy-offs Review Container Worksheets & Attend Reviews / Buy-offs Identify Issues during Virtual Engineering Phase (Pre-IVER) Attend Physical (Integration) Builds at Pre-Production Operations (PPO) Attend Physical (Integration) Builds at Pre-Production Operations (PPO) Attend Physical (Validation) Builds At Plants Attend Physical (Validation) Builds At Plants Product Design Assists and Specialized Tools Containers Review Assembly Process System (APS) ergonomics evaluations Line Balance Chart 2 - Vehicle Systems - Future Program Ergonomics Process Transition open issues to Plant JETT 6 month clock* VPI CSO CVER SORP SVER IVER MVB- NS MVB- S DSI Ergonomics Process Overview Meeting *Between Start of Regular Production (SORP) and Launch Team Release (LTR) Review and Track issues in TED Based on GVDP September 2013

Body Systems Stamping and Body-In-White (BIW) Operations For Stamping and BIW operations, design-in ergonomics activities for new/major programs (at headquarters) are divided into four main categories: 1.Stamping - Part Handling Plan 2.BIW Tooling 3.Assist and Specialized Tooling 4.Container Design Activities related to each category are depicted in Chart 3 – Body Systems Ergonomics Timing Overview. The program ergonomists work collaboratively with the JETT to accomplish these tasks.

Review part handling data in the Part Handling Forum (PHF) database (approximately week -120 to -98) Stamping (Die Execution) - Part Handling Plan Review Assist and Specialized Tooling Worksheets & Attend Reviews / Buy-offs (approximately week -94 to -64) Assist and Specialized Tooling Review Container Worksheets & Attend Reviews / Buy-offs (approximately week -75 to -63) Containers Chart 3 - Body Systems - Future Program Ergonomics Process Transition open issues to Plant JETT 6 month clock* VPI CSO CVER SORP SVER IVER MVB- NS MVB- S DSI *Between Start of Regular Production (SORP) and Launch Team Release (LTR) Review BIW Worksheets & Attend Reviews / Buy-offs (approximately week -94 to -64) Body-in-White (BIW) Tooling T4 Review and Track issues in TED Based on GVDP September 2013

Supplier obtains body-in-white ergo worksheet from web and completes training Supplier completes body-in-white ergo worksheets Body in White Engineer forwards worksheet to Ergonomist for review Any ergonomics concerns? Body-In-White Ergonomics Process Flowchart

Supplier completes assist tooling ergo worksheets Mfg. Engr. forwards worksheet to Future Program Ergo for review Any ergonomics concerns? Assist & Specialized Tool Ergonomics Worksheet Process Flowchart Supplier obtains assist tooling ergo worksheet from web and completes on-line training

Powertrain / Casting Engines Transmissions Center (CETC*) In Powertrain (CETC), design-in ergonomics activities for new/major programs (at headquarters) are divided into three main categories: 1.Product Design 2.Manufacturing Engineering Design 3.Containers Activities related to each category are defined within the Global Powertrain Development Process (GPDP) and are depicted in Chart 4 – Powertrain (CETC) Ergonomics Timing Overview. The program ergonomist works collaboratively with the JETT to accomplish these tasks. *CETC - Castings, Engines, and Transmissions Center

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

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

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

Spec reference number

GVDP and GPDP Process Interfaces GPDP is aligned with, but somewhat decoupled from, GVDP: 1.GPDP begins 6 to 12 months prior to GVDP for a new Powertrain 2.Powertrains are designed to support multiple vehicle customers and multiple programs 3.Powertrains are developed to enable maximum reuse of long lead-time parts/subassemblies with minimum changes for new vehicle applications 4.The introduction of Existing Powertrains into New Vehicle programs may be staggered to avoid having to add time to vehicle program critical path for integration and calibration activities

Ergonomics New Program Scorecards

New Program Scorecard – Vehicle Assembly

New Program Scorecard – Powertrain

ColorDefinition Not enough data or design stability to identify as an issue. Items for further follow-up Confirmed issue without an approved plan or date Issue is not progressing, planned dates not achieved or solution was not effective and no back-up plan/containment in place. Confirmed issue with an approved plan* and viable dates (containment in place, if required) *Approved plan may include obtaining additional data. Issue that is resolved/closed

Additional Training  GC27 Container worksheet  Powertrain (CETC) Ergonomic Design Requirement Assessment (EDRA)  CETC Machine & Equipment Run Off (MRO) Checklist  BIW Ergonomics Worksheet  Assist & Tooling Worksheet

Supplier obtains assist tooling ergo worksheet from web and completes on-line training Supplier completes assist tooling ergo worksheets Any ergonomics concerns? Mfg. Engr. forwards worksheet to Future Program Ergo for review Assist & Specialized Tool Ergonomics Worksheet Process Flowchart

Body Systems Stamping and Body-In-White (BIW) Operations For Stamping and BIW operations, design-in ergonomics activities for new/major programs (at headquarters) are divided into four main categories: 1.Stamping - Part Handling Plan 2.BIW Tooling 3.Assist and Specialized Tooling 4.Container Design Activities related to each category are depicted in Chart 3 – Body Systems Ergonomics Timing Overview. The program ergonomists work collaboratively with the JETT to accomplish these tasks.

Supplier obtains body-in-white ergo worksheet from web and completes training Supplier completes body- in-white ergo worksheets Any ergonomics concerns? Body in White Engineer forwards worksheet to Ergonomist for review Body-In-White Ergonomics Process Flowchart

Supplier obtains assist tooling ergo worksheet from web and completes on-line training Supplier completes assist tooling ergo worksheets Any ergonomics concerns? Mfg. Engr. forwards worksheet to Future Program Ergo for review Assist & Specialized Tool Ergonomics Worksheet Process Flowchart

Powertrain / Casting Engines Transmissions Center (CETC*) In Powertrain (CETC), design-in ergonomics activities for new/major programs (at headquarters) are divided into three main categories: 1.Product Design 2.Manufacturing Engineering Design 3.Containers Activities related to each category are defined within the Global Powertrain Development Process (GPDP) and are depicted in Chart 4 – Powertrain (CETC) Ergonomics Timing Overview. The program ergonomist works collaboratively with the JETT to accomplish these tasks. *CETC - Castings, Engines, and Transmissions Center

GVDP and GPDP Process Interfaces GPDP is aligned with, but somewhat decoupled from, GVDP: 1.GPDP begins 6 to 12 months prior to GVDP for a new Powertrain 2.Powertrains are designed to support multiple vehicle customers and multiple programs 3.Powertrains are developed to enable maximum reuse of long lead-time parts/subassemblies with minimum changes for new vehicle applications 4. The introduction of Existing Powertrains into New Vehicle programs may be staggered to avoid having to add time to vehicle program critical path for integration and calibration activities

Ergonomics New Program Scorecards

New Program Scorecard – Vehicle Assembly

New Program Scorecard - Powertrain

Additional training GC27 Container worksheet Powertrain (CETC) Ergonomic Design Requirement Assessment (EDRA) CETC Machine & Equipment Run Off (MRO) Checklist BIW Ergonomics Worksheet Assist & Tooling Worksheet

Changes in Blue Overview of Changes  Roles & Responsibilities  Administrative & Training Elements  GM Vehicle Systems, Body Systems, and Powertrain.

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Changes in Blue Overview of Changes  Roles & Responsibilities  Administrative & Training Elements  GM Vehicle Systems, Body Systems, and Powertrain.

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