3. Ergonomics Design Process – 21 Review
Overview of Changes for Vehicle/GPS
New book being published
Last revision was 2013
Collaboration during product development and start of regular production

4. Overview of Changes for Vehicle/GPS
Major changes in 2013, Minor changes in 2016
Changes for clarification
Changes to better align with revised GVDP/GPDP
CETC to Global Propulsion Systems (GPS)

5. Roles and Responsibilities
Page 7

6. Administrative and Training Elements
Page 9

7. Revised CETC to Global Propulsion System throughout the document

8. GM Vehicle Systems, Body Systems and GPS
Page 13

9. GM Vehicle Systems, Body Systems and GPS
Page 14
Body Systems
Stamping and Body-In-White (BIW Operations)

10. Changes based on GPDP definition shanges
Page 15

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

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

13. 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
2013 Version
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)

14. Chart 4 – Global Propulsion Systems (PT) - Future Program Ergonomics Process
Ergonomics Process Overview Meeting
Product Design
• Participate in Reviews of New Product Designs during Mock-Ups and Slow Build Events
Revised 2016 Change to align with new gate deliverables
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 and rev. June 2016
*Between Start of Regular Production (SORP) and 50% through Ramp

15. Other Changes made to EDP-21 Document
Operator Work Envelope
Table of Contents
Appendix
Acronyms
Revisions

16. Correction to Operator Work Envelope
In some documents the operator work envelope secondary limit had previously been defined as a 25”/640mm reach.
25” is actually 635mm. All charts using 640mm are updated to reflect this change to 635mm.
Documents updated include:
Assist and Specialized Tool Worksheet
BIW Worksheet
GPS Machining and Equipment Run-off Document

17. Appendix

18. Acronyms The following were deleted: The following were added:
CETC Casting, Engine and Transmission Center
DEW Design Ergonomics Worksheet
T-Event Try-out event
The following were added:
GPS Global Propulsion Systems (Formerly CETC/Powertrain)
The following were corrected:
MVBNS Manufacturing Validation Build Non-Saleable
MVBS Manufacturing Validation Build Saleable

19. Collaboration Between JETT and Future Program Ergonomist
Collaboration between the future program ergonomist and the JETT is key to launching a product with no ergo issues
Plant JETT has knowledge of how plant operates, what has worked, what has not worked
Future Program Ergonomist has knowledge of the product, early
Will learn the plant issues once Plant is identified. Lessons learned form the plant.

20. Collaboration Between JETT and Future Program Ergonomist
Once plant is identified (and throughout IV):
Meeting with JETT at site or on conference calls
Review of product working file and open issues
Attendance/review of containers, lift assists and tools
Timing may vary based on program

21. Collaboration Between JETT and Future Program Ergonomist
During IV JETT should be interfacing with plant core team members to be aware of product differences and changes from the current product. The JETT need to emphasize the importance of discovering ergo issues before the plant builds begin
JETT should visit PPO during a build at least once
JETT will be on distribution of Ergo Scorecard that is presented at the weekly quality wall

22. Collaboration Between JETT and Future Program Ergonomist
During the MVBns and MVBs builds the future program ergonomist and the JETT should be collaborating on issues
JETT can assist in measure parts, assess and verify BP’s when the FPE cannot be present
JETT will attend plant quality walls as ergo rep when FPE cannot be present

23. Collaboration Between JETT and Future Program Ergonomist
To facilitate the transfer of the program to the plant:
Before SORP, JETT and FPE determine a mutually agreed upon plan for program hand off from the FPE to the JETT
For issues not resolved prior to SORP, the 6 month clock will start between SORP and Launch Team release, on a date mutually agreed upon with the Division Ergonomics and JETT and/or Industrial Engineering Manager