2. Assist and Specialized Tool Ergonomics Worksheet Training & Instructions

3. Assist and Specialized Tool Ergonomics Worksheet  Overview –Participants will receive an overview of the Assist and Specialized Tool Ergonomics Worksheet. Each question on the worksheet will be discussed in detail, with examples. –This worksheet is a proactive SCREENING TOOL and was developed to identify potential ergonomic issues early in the design of an assist tool or other specialized tooling for use in general assembly that requires manual interface.  Objectives –After completing this module, the participants will be able to: Complete an electronic version of the Assist and Specialized Tool Ergonomics Worksheet.Complete an electronic version of the Assist and Specialized Tool Ergonomics Worksheet. Know how to interpret results from the Worksheet.Know how to interpret results from the Worksheet. Know what action to take for “No” responses.Know what action to take for “No” responses.

5. Worksheet Scope  This Worksheet is applicable to any assist tool, or other specialized tooling used in General Assembly that requires manual (human) interface. –Note: A similar worksheet is also available as an attachment to the Body in White Ergonomics Worksheet, where it is used as part of the body in white (BIW) ergonomics process.  This Worksheet does not apply to general portable power tools or hand tools such as screwdrivers, pliers, hammers, etc. –For these types of tools, refer to the ‘Global Machinery and Equipment Guidelines’, which has a section on portable power tools and manual hand tools. ‘Global Machinery and Equipment Guidelines’ can be downloaded from two locations: Suppliers can go to www.gmsupplypower.com. Choose ‘Manufacturing’ from the document center, then choose the folder named ‘Standards, Machinery & Equip, Facilities’, then choose ‘Ergonomics’. Note that you must be registered with GM SupplyPower and logged-in first to view the Ergonomics content.Suppliers can go to www.gmsupplypower.com. Choose ‘Manufacturing’ from the document center, then choose the folder named ‘Standards, Machinery & Equip, Facilities’, then choose ‘Ergonomics’. Note that you must be registered with GM SupplyPower and logged-in first to view the Ergonomics content. GM employees can use GM SupplyPower as explained above, or go through the ME Ergonomics Website on Socrates (look under ‘E’ for Ergonomics in the A-Z list). In the ME Ergonomics site, choose the section ‘Specifications’.GM employees can use GM SupplyPower as explained above, or go through the ME Ergonomics Website on Socrates (look under ‘E’ for Ergonomics in the A-Z list). In the ME Ergonomics site, choose the section ‘Specifications’.

6. Assist and Specialized Tool Ergonomics Worksheet Process  The Assist and Specialized Tool Ergonomics Worksheet (or a reference to its location on GM Supply Power) is to be included with each Tooling and Equipment Statement Of Requirements (SOR) for the supplier to use when evaluating their tools (a Vendor Guideline that lists the requirements is also available, and should also be included with the SOR)  The GM Engineer is to ensure completion of the Worksheet at two intervals - during Tool Design Buy-off and Tool Buy-off at the Vendor. –If any issues are raised (indicated by any ‘No’ response on the Worksheet), the tool design must be adjusted to eliminate the issue. –If the problem cannot be eliminated, the Worksheet must be forwarded to the ergonomist for review, per the Assist and Specialized Tool Ergonomics Process Flowchart.

7. Factors  Common Corporate Handle –Grip Length –Handling Grip Diameter –Handling Grip Surface –Hand Location on Handle –Trigger/Button/Paddle Force –Pushbutton Control  Handle Span  Grip Span  Compression Force  Clearance for Hand  Hand/Wrist Twist/Turn  Wrist Posture  Work Envelope  Visual Access and Locating Method  Tool Push/Pull Force - Whole Body  Unassisted Tool Movement  Control Complexity  Control Design Orientation

8. Common Corporate Handle  If not using Common Corporate Handle, answer questions 1a-f. If using Common Corporate Handle, skip to question 2.

9. 8. Work Envelope - Global If the operator’s hands remain in the Primary or Secondary regions of the work envelope and within 380mm (15”) lateral distance while loading/unloading parts, place an “X” in the ‘Yes’ box and continue with worksheet. Barrier Edge H V Vertical Height (V) is measured from the surface the operator stands on to where the hands will perform the work. Horizontal Reach (H) is measured from the barrier/surface edge to the location where the hands will perform the work. In the absence of a horizontal barrier, physical measurements should be taken from the belt buckle. 380 mm

10. 8. Work Envelope – Global cont. Barrier Edge H V Hard Point (Top of Barrier Edge) Primary: Preferred zone for the majority of tasks. Secondary: 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. Note: For reaching > 20”/510mm, the top of a barrier edge (hard point) must not exceed 40”/1015 mm in height.

11. Questions?  This completes the instructions for filling out the Assist and Specialized Tool Ergonomics Worksheet. If you have any questions about the meaning of a question or its applicability while completing a Worksheet, do not hesitate to contact your ergonomist for assistance or clarification. Your ergonomist can also assist you in obtaining force gauges, should you need them for your evaluation.