1. General Motors Safety 21 Design-In Safety Process Adapted from the GMU course Engineering for Health and Safety Industrial Engineering & Training

2. Introduction to Design-In Safety l Design-In Safety – History – Concepts l Overview and highlights of the GM Common Design for Health and Safety Specification - DHS

3. Design-In Safety...is a strategy which promotes the integration of health and safety requirements in product and process concept and design stages.

4. Eliminate / Minimize Human Exposure Safeguards will not be followed (Human Nature) unless: 1) Easy to Use 2) Easy to Recover Design-In Safety Key Philosophies

5. Why Do We Need Design-In? Design Involvement Retrofit Design Involvement Retrofit Future Effort Cost Resources Effort Cost Resources Traditional

6. Design - In Effective Planning High Influence Cost Phase 3 Phase 0 Low

7. Hierarchy of Controls Design Preferences 1) Elimination or Substitution 2) Engineering Controls 3) Warnings 4) Training and Procedures 5) Personal Protective Equipment Proactive Most Effective Reactive Least Effective Least Human Involvement Most Human Involvement

8.  Machinery and Equipment Environment  Safety 21 Process and Tools  Task-Based Risk Assessment Process Hierarchy of Health and Safety Controls Validation Process  Guidelines and Specifications Specification Overview DHS 3

9. Guidelines and Specifications 1. Workstation Design/Operator Interface 2. Workstation Design/Operator Interface:Tool Design 3. Maintainability 4. Fall and Working Surface 5. Industrial Hygiene 6. Fire Prevention Plan 7. Safeguarding Device : Guarding 8. Safeguarding Device : Interlock

10. Guidelines and Specifications 9. Safeguarding : Presence Sensing Device 10. Safeguarding : Two-Hand Control Device 11. Emergency Stop Function and Device 12. Awareness Barrier Devices 13. Lockout Energy Control 14. Monitoring Power Systems Application

11. 1. Workstation Design/Operator Interface l Design should accommodate a wide range of human in term of reach,clearance,movement and work repetition l Design and position operator control,displays,labels,Machine component and tool where operator has clear,unobstructed manual and visual access and to provide a clear view of the entire cell l Use control display that are meaningful and easy to understand l Adequate lighting shall be provide during de-energized period Assess proper work space dimension

12. 2. Workstation Design/Operator Interface: Tool Design l Power tools shall be equipped with a constant pressure switch to ensure that power is shut off when pressure is released from the power switch l The manufacturer’s rated speed (RPM) shall be clearly marked on all pneumatic power tool l Power tools that shoot nails,rivets or staples shall be equipped with a special device to keep fasteners from being ejected unless the working end is pressed against the work surface

13. l Electrical power operated tools shall be grounded or be double insulated l The manufacture’s rated speed shall be clearly marked on portable grinders and grinding wheels.The maximum RPM of the grinding wheel must be rated equal to or higher than the manufacture’s rated speed for the grinder l The power tool shall be equipped with the appropriate tool rest Tool Rest 2. Workstation Design/Operator Interface: Tool Design (Cont.)

14. 3. Maintainability l All primary energy-isolation devices should be located near cell entrance points to minimize the time required for lockout and system restart l Design for safe access, working space,and clear cell visibility within and around all control panel l Design and install direct task lighting as part of a system to provide greater visibility during routine maintenance and service Isolation Device

15. l Design hoist rail into the system structure in areas where lifting of heavy system components is required and access by motorized lift equipment is not available l The manufacturer shall provide information on rigging and lift system. The follow as Center of gravity/Total weight of the system/Designated lift points/Specifying the require working load limit Hoist Rail 3. Maintainability (Cont.)

16. 4. Fall and Working Surface l Whenever performance of any task would allow a worker to fall a distance where the likelihood of a serious or fatal injury exist the hazard of falling must be identified,evaluated and control l The shutoff valves,monitoring & maintenance equipment should be located at readily accessible floor or grade floor Shut-offs at floor level

17. 4. Fall and Working Surface (Cont.) l For climbing applications,are fixed stairs used in preference over alternating tread type stairs or vertical ladder l If fixed stairs can not be used due to limited space application are alternating tread-type stair will be use.In the event neither of the above can be use,vertical ladder should be use only for infrequent accessed maintenance location Fixed stairs

18. 4. Fall and Working Surface (Cont.) l All step, ladder rungs and working surface have a“non-slip” surface l Consideration shall be given to elevating cable,pipe,hose and conduits should minimize tripping hazards,If elevation of cable,pipes,hoses is not possible,they shall be covered l Holes in floors or platforms shall be properly marked and guarded Cable Cover

19. 5. Industrial Hygiene l A Material Safety Data Sheet (MSDS) from supplier that meet GM requirements l All chemical materials proposed for use in research and production shall be approve before purchase l All machinery,power tools been design noise level not to exceed 80dBA l All machinery been design to assure impluse sound pressure level not exceed 130 dBA MSDS

20. 6. Fire Prevention Plan l Fireproof cabinet shall be provide to store flammable substances and each cabinet shall be properly marked identifying it as a flammable storage cabinet l Equipment that contain a flammable substance shall be designed to prevent accidental ignition l Fire fighting equipment shall be stationed in the work area an shall be properly marked to indicate its use Flammable storage cabinet MSDS

21. 7. Safeguarding device:Guard l A guard needs to be constructed to prevent reaching over under,around or through to a point of hazard l A guard needs to be designed and install with an understanding of what tasks need to be per formed on the equipment it is design to protect l Guard shall be free of sharp edges and protections and shall not themselves create a hazard

22. 7. Safeguarding device:Guard (Cont.) l A guard shall be constructed where required to allow for visibility into the hazard area to reduce the need for access beyond the guard l A guard shall contain parts and equipment within the guarded area from being ejected to outside of the guard area

23. 8. Safeguarding device:Interlocks l Safety Interlock system for gate and guard shall: –Be control reliable device and installed in a control reliable manner –Prevent the use of unauthorized and or unintentional bypass device –Be used where hinged or sliding door or guards provide access to hazard –Be appropriate for the task and related hazard Interlock door

24. 9. Safeguarding device: Presence Sensing Devices l Presence sensing devices shall be control reliable and be installed in a control reliable manner l Be installed per the safe distance requirement under the OSHA l Indicator light shall provide to indicated the device is function.If used for operator protection the indicator lights shall be observable by the operator

25. 9. Safeguarding device: Presence Sensing Devices (Cont.) l If there is a loss of power the PSD shall initiate an immediate stop command to the equipment it is controlling l Awareness devices should be added to prevent inadvertent trip of the PSD Light Curtains

26. 10. Safeguarding device: Two Hand Control Device l Be protected against unintentional operation l Be arrange by design,construction or separation to require the concurrent use of both hand within 500 ms to initiate cycle l Be designed to require the release of all operator’s hand control and the re-activation of all operator’s hand control before a cycle can be initiated l Issue stop signal if any operator’s hand is removed from the control during hazardous portion of the cycle

27. 11. Emergency Stop Function and Device l Be provide at each operator station where hazardous motion exists l Be hardwired into the emergency stop circuit l Function independently from the system programmable electronic system l Not be of the automatic resetting type,but shall require manual reset l Not initiate,restart or create any hazardous motion when reset Emergency Stop

28. 11. Emergency Stop Function and Device (Cont.) l Be red in color l Be palm type or mushroom- shaped l Have any existing background for the device actuator colored yellow l Be distinguishable from all other controls by size and color l Be unguarded and not recessed Emergency Stop

29. 12. Awareness Barriers Device l Awareness barriers (e.g guardrails and chains on post) Provide a point of physical contact before entering the hazardous area and warn personnel of a present or approaching hazard l Awareness device shall be designed constructed and located to provide a recognized signal (audible,visual or a combination) Awareness Device

30. 13. Lockout Energy Control l The control circuit and primary energy isolating device shall be design to provide easy and safe system access for service and maintenance task l Lockout/energy control placard that identify the store energy sources and the safeguard against their release shall be provided l When dropping or drifting of equipment /part present hazard,device shall be install to eliminate hazard l Master Iockable electric disconnects and shut-off valve (Pneumatic and Hydraulic) shall be install on the service side,outside of the cell Lockout/energy control placard

31. 14. Monitored Power Systems Application l Fail to Safe –Safety systems stop in a safe condition l Independent –Allow a comprehensive test sequence to be written –Detects if the safety circuitry has been bypassed or removed l Redundancy –Paralled or Series Devices l Monitoring –Internal and/or External Feedback

32. Safety Design Review (SDR) l A SDR consists of the GM DHS 3 Design In Specification in question format. l A SDR is conducted at the pre-quote, final design, final build stage and then reviewed prior to turn over of the equipment to production. –Pre-quote ensures all applicable sections are included in the quote

33. Safety Design Review (SDR) –Final Design ensures that our specifications are part of the equipment design, safety controls, etc. –Final build ensures that all of the specifications we asked for are included and functioning. Can also be no argument on who is responsible if the specification requirement is not included or fuinctioning.

34. SDR Benefits to: 1. Operators and Skilled Trades  Reduces potential for personal injury  Reduces the amount of human involvement to work safely  Improves employee moral 2.Engineers and Purchasing  Reduces re-engineering when not necessary  Reduces complaints from end-users  Reduces potential modification costs later (retrofit) 3.Company  Increases compliance with all known safety regulations  Reduces initial equipment build costs  Reduces initial program start-up costs  Supports common global initiatives

35. What Is Task Based Risk Assessment (TaBRA)? l It is a systematic approach to identify all tasks and the hazards associated with each task. l It provides a methodology to select the appropriate safeguard based on each task/hazard combination. l It provides a methodology to verify that the safeguard has reduced the risk of injury during the performance of the task.

36. Risk Assessment Process Gather group of skilled trades, supervisor, and safety personnel familiar with equipment Step 1: Identify all Tasks required or expected to be performed, daily, weekly, monthly, annually, etc. Step 2: Identify all hazards that could be encountered while performing each task. Review decision tree outputs and apply Hierarchy of Controls For similar equipment review for additional tasks and/or hazards Step 4: Answer all decision tree questions Step 3: Enter task and hazards into Excel spreadsheet Use TaBRA spreadsheet to track corrective action and for final buy-off of equipment. For those solutions that require further investigation or SOP’s, assign appropriate personnel. Enter final solutions later Review for input into design of new equipment

37. Welding RobotSealing Robot Conveyor Tooling Tip Dresser TaBRA’s from all plants go into master base. Designer selects components for new cell and pulls tasks and hazards associated with the equipment from master data base. Designer places components within the new cell to eliminate/reduce the hazards associated with existing equipment. Divisional Safety, LJHSC, skilled trades from plant location and designer review layout and complied risk assessment. All parties input recommendations to eliminate/reduce risk and verify complied TaBRA. Pedestal Welder Design-In Risk Assessment Process

38. TaBRA Benefits to: 1. Operators and Skilled Trades  “Hands On” involvement in equipment safety process  Seeks their input, suggestions and solutions  Improves employee moral 2.Engineers and Purchasing  Ensures its done right the first time  Eliminates re-engineering of safety equipment  Reduces complaints from end-users  Reduces potential modification costs later (retrofit) 3.Company  Improves initial equipment build schedule  Reduces initial program start-up costs  Supports common global initiatives  Results captured to eliminate “reinventing the wheel”

39. Safety 21 Process tools provides:...for safety designs in manufacturing equipment and systems. SAFETY 21 PROCESS REVIEW Influence SDR Continuity TaBRA Confidence Validation

40. Copyright 2000 General Motors University

41. Questions?