GM Ergonomic Container Worksheet: GC27/NA27

GM ERGONOMIC CONTAINER WORKSHEET
GC27/NA27
ERGONOMICS WORKSHEET FOR CONTAINER
DESIGN: USE AND LIMITATIONS
USE: Provide guidelines for the Container

Engineer in the Design and Buyoff of new
containers.
USE: To identify areas of potential concern
during the container design process prior to
Sample Buyoff.
2 GM Global Ergonomics
revised August 2014
ERGONOMICS WORKSHEET FOR
CONTAINER DESIGN: USE AND
LIMITATIONS
USE: Guidelines should be used as a reference throughout the
entire container design process (including Concept). The goal
should be to bring a container to Sample Buyoff that meets the
Ergonomic Guidelines.
 Examples of information that should be defined at Concept Buyoff …
1) Are the orientation requirements the same for both the supplier
and customer?
2) Will load/unload be robotic, lift assist or manual?
3) What presentation equipment will be used (lift & tilt, lift & spin,
lift only, dolly, riser, floor, point of use rack)?
 Having a good understanding of these items at the Concept Buyoff will
reduce/eliminate changes at Sample Buyoff.
revised August 2014
ERGONOMICS WORKSHEET FOR
CONTAINER DESIGN: USE AND
LIMITATIONS (CON’T).
NOT intended to identify every risk factor, but to direct the

user, where needed, into a detailed ergonomic analysis.
NOT to be used to evaluate existing containers or
containers proposed for re-use with same or similar
commodities (i.e. containers currently in use in the
plant/facility) unless:
 The existing containers have a history of injuries associated with the
container or application
 There is a significant change in the part or the processing requirements of
the part (i.e. automated unload changed to manual unload)
NOT intended to evaluate containers out of repair or in
need of repair.
revised August 2014
Ergonomics Worksheet for Container Design:
Use and Limitations (con’t).
USE: Guidelines are based on the assumption that the

container will be delivered to the operator on the line.
NOT required for dollies, minomis or in-process carts.
Ergonomic guidelines for …
• CMA storage areas (Vehicle)
• Sequencing and Kitting Areas (Vehicle)
• Storage (Powertrain)
• Kitting and Rack Areas (Powertrain),
including dollies and minomis are available on the

Ergonomics SharePoint site.
Be sure and consult with ME if dollies and minomis will be used.
https://gmweb.gm.com/manufacturing/me_ergonomics/gmergo/ADM001_Reference_Ergo%20Analy
sis%20Tools/LMS_GSC/Dec_2011_LMS_Small%20Lot_Dolly_Minomi%20Quick%20Reference.doc
x
GM Global Ergonomics
5
revised August 2014
Ergonomics Worksheet for Container Design:
Use and Limitations (con’t).
.
NOT required to be filled out for evaluation of kits
(although many of the guidelines will be the same).
Ergonomics guidelines kits are also available on the Ergonomics
SharePoint site.
https://gmweb.gm.com/manufacturing/me_ergonomics/gmergo/ADM001_Reference_Ergo%20Analy
sis%20Tools/LMS_GSC/Design%20Guidelines%20for%20Kit%20and%20Small%20Lot%20Contain
ers.pptx
6
revised August 2014
Ergonomics Worksheet for Container Design
• Container design proposals should support the Plant

Manufacturing Process. Thus, the manufacturing
processes specific to the container point of use must be
considered when assessing a container.
• Assessment does not constitute a definite outcome –
secondary analysis methods may be needed.
• Force conditions should be measured with the container
fully loaded with parts.
• The worksheet, instruction manual, and this training
material can be found at (see links at the bottom of the
middle column on the main page of the Ergo Website)
https://gmweb.gm.com/manufacturing/me_ergonomics/Pag
es/default.aspx
7
revised August 2014
GC27 TIMING & PROCESSING
 The worksheet should be completed by the container engineer prior to the

sample/prototype meeting.
 The ergonomist will provide a link to the folder on the Ergo Website where
the files will be stored.
 Program Ergonomist will add program specific folder and provide link to
Container Liaison
 When providing link ensure Container Liaison is aware of the following:
 Completed GC27s required at Sample Buy-off to receive ergo buy-in/signature
 When possible, GC27s should be uploaded (3) days prior to buy-off for ergo
review
 The container engineer can save the completed files there.

 File naming convention …
Program_Part Description_Cont ID #
Example: C1UG_Panel Hood Inner_MAC14256
 Any ergonomics issues that need to be addressed should be documented
NEW on the Sample Container Buyoff form.
 The worksheet should also be completed by the container engineer
for the PPO Container Pull Ahead Sample Reviews.
revised August 2014
WORKSHEET FORMAT
The worksheet is divided into three main sections as follows:
1.0 Program & Part Information
Data entry required by Container Engineer
2.0 Packaging Information
Data entry required by Container Engineer
3.0 Analysis
Ergonomic Container Guideline details are listed in this section
No data entry is required in this section
Results and suggestions are automatically generated based on
data input in sections 1.0 and 2.0.
Space has been provided to enter comment/notes
revised August 2014
1.0 PROGRAM & PART INFORMATION
Screen shot of section 1.0 Program and Part Information

• Enter information as required in yellow shaded boxes only.
• User can choose to enter information in English or Metric units by
selecting their choice using the drop down menu for ‘UNIT OF
MEASURE’.
revised August 2014
2.0 PACKAGING INFORMATION
1 2
Screen shot of section 2.0 Packaging information

• As user makes selections, the data fields that do not apply to that application
will be ‘grayed-out’.
• User must enter the information in sequential order (I through MM) for the cell
color coding to work properly.
• If you enter information into a cell that is ‘grayed-out’, the formulas in the
spreadsheet may not work properly.
• If you do not enter information in a ‘yellow’ cell, the formulas in the
spreadsheet may not work properly.
revised August 2014
2.0 PACKAGING INFORMATION (CONT’D)
Container Strategy (I)
User will select one of seven strategies from a drop down
menu:
Small Lot – Totes/tray packs and other Manually Handled
Containers
 Individual containers that are delivered to the operator
(i.e. presented to the operator on a point of use rack).
 Lift moment and work envelope will be calculated for
lifting the tote.
revised August 2014
Line Side Bulk - Operator picks parts directly from a
tote/tray pack
on a pallet
 Pallet of totes is delivered the operator. The
operator does not lift the full tote but picks parts
directly from the tote. The operator moves the tote
only after it is empty.
 Lift moment and work envelope will be calculated for
lifting the part, not the tote.
TECHM
revised August 2014

Parts in Dunnage
 Operator picks parts directly from dunnage
Ring Gear
revised August 2014

Bulk Basket
 Operator picks parts directly from bulk basket.
revised August 2014
Bulk Rack
 Walk In (Step In) – cutout in base of container
 Walk On (Step On) – operator walks on to container floor
 Cantilever – parts are ‘hung’ on cantilever arms and operator
slides parts on cantilevers to load/unload
 Barriers – part holding details on a rack that are usually required
to achieve separation between parts for quality purposes
Walk On with part supporting details (barriers)

17 Walk In with Cantilevers
revised August 2014
Knockdown
4 Poster Rack (Skid)
revised August 2014
Design Stage Phase (J) - Concept, Sample, Production (drop-down
menu)
Container # (K) - Enter the Container ID# from the Container Buyoff
Form
Robotic Application (L)- Select N/A, Load, Unload or Load & Unload
(drop-down menu)
Note: If both Load & Unload are Robotic, there would be no operator
interface with the container and the remainder of the worksheet will
not need to be filled out.
Lift Assist (M) - Select N/A, Load, Unload or Load & Unload (drop-down
menu)
Presentation Equipment (N) – User will select presentation equipment
from 1 of 8 choices (presentation equipment should be identified at
Concept review)
Unknown Lift & Spin Dolly Floor
Lift & Tilt Lift Only Riser Point of Use Rack
revised August 2014
Tote Code (O) -
For Small Lot, select a standard tote code or ‘Engineered Tote’ from the
drop-down menu. Use ‘Engineered Tote’ for tray packs.
For Line Side Bulk, do the same as above OR select N/A if parts are in
dunnage trays.
Std Tote Size (P) - L,W,H fields will be automatically populated if a

standard tote was selected
Non Std Tote/Tray Pack Size (Q) - L,W,H fields must be manually filled in
for an Engineered or non standard Tote
Total Loaded Mass (R) - Enter tote weight or total container weight.
Overall Container Footprint (S) – Required for all Container Strategies

except Small Lot (Top Level Container Footprint)
revised August 2014
Tote Handhold Width (T) Small Lot or Line Side Bulk Only -
Tote Finger Opening (U) Not required for Std Totes, only
Tote Finger Depth (V) for Engineering Totes
(Handholds for Std Totes are
‘grandfathered-in’)
Finger Clearance for Part Removal (W) – Mainly used for Small
Lot and small parts (leave blank if NA)
Hand Clearance for Part Removal (X) – Mainly used for Bulk
Containers and larger parts (leave blank if NA)
Does part orientation in container match both supplier and
customer needs? (Y) – Does the orientation in the container
match the orientation at the station, fixture, machine (i.e. no
flip/rotate required)? Verify that proposed orientation in
container will meet the needs for both the supplier (GM or
external) and customer (ie. Stamping and Body Shop, Hood
Asm and Body Shop). Select YES,NO, N/A (drop-down menu)
revised August 2014
Removable Dunnage or Layer Pad? (Z) – Select Yes or No from Drop

Down Menu
Does Dunnage or Layer Pad have handholds? (AA) - Select Yes or
No from Drop Down Menu Parts in Dunnage
Dunnage/Layer Pad Cutout Length (BB) OR Dunnage/Layer
Dunnage/Layer Pad Cutout Width (CC) Pad inside a
container
Dunnage/Layer Pad Cutout Finger Clearance (DD)
Empty Dunnage/Layer Pad Weight (EE) – Enter weight of empty

dunnage or layer pad
Dunnage/Layer Pad Size (FF) – Enter dimensions of dunnage or layer
pad
revised August 2014
Walk Path (GG) – Bulk Racks only. Select Walk On, Walk In or NA
(drop-down menu)
Walk Path or Distance Between Cantilevers (HH) – Bulk Racks
only
Drop Gate Opening Width (II) – Knockdown Containers only
revised August 2014
Maximum Horizontal Reach (JJ) – Use worst case scenario

(farthest reach)
Top Vertical Pick Height including presentation device (KK) –
Use worst case scenario (top layer)
 If height of presentation device is unknown use
 380 mm (15 in) Dolly
 203 mm (8 in) Lift Table OR
 305 mm (12 in) Riser
Depth of Cutout for Walk in Rack (LL) – Walk in Rack only
Bottom Vertical Pick Height including presentation device
(MM) – Use worst case scenario (bottom layer)
 See notes above for assumptions if height of presentation
device is unknown
revised August 2014
3.0 Analysis – Functionality
Specification details Automatically Enter your

listed here. Detail on generated notes and
each specification will results ( based comments here.
be covered in this on data input
training. from previous
sections).
revised August 2014
3.0 Analysis - Functionality
= meets specification
= does not apply to the container strategy
selected
= there are no formulas to evaluate this
specification
= does not meet specification
• Message with suggestions for correcting the issue will be generated.
• The user should attempt to make a positive change before contacting the
Program Ergonomist.
• If a feasible solution is unknown, the issue should be discussed with the
Program Ergonomist and the team.
revised August 2014
3.0 Analysis - Guidelines
Part Rotation, Flipping – One Handed Loading
• Maximum part weight for a one handed lift without Flip or Rotate is
4.5 kg (10 lb)
• A 900 flip/rotate for a part < 4.5 kg (< 10 lbs) may be acceptable and
should be discussed
• But, if the part is flipped or rotated > 1200 ,the maximum weight for a
one hand load becomes 3.2 kg (7 lb)
If the result flags as RED …
• Can the orientation in container be changed to
eliminate flip/rotate/regrasp ?
• If part/object with weight > 4.5 kg (10 lb) can it be
lifted with two hands?
27
revised August 2014
Part Rotation, Flipping – Two Handed Loading
• Maximum rotation < 90 0

• Maximum flip <120 0
• No regrasp
Note: Rotation and flipping of parts does not include the orientation changes that
result during the act of pulling the part into or towards the body during lifting, it refers
to maneuvers when the part weight is not supported by the container or container
structure.

• Design station/operation to flip/rotate the part
• Consider changing the part orientation in container to eliminate
flip/rotate/regrasp
• Design a lift assist to flip/rotate the part
28
revised August 2014
3.0 ANALYSIS - GUIDELINES
PART OR TOTE LIFTING MOMENT (TWO HANDED
LIFT ONLY)
 Scores the lifting moment for the tote/container/part.
 This is automatically calculated using the Part Weight or Tote Weight
and Maximum Horizontal Reach entered in section 2.0
 The use enters the distance from the edge of the job (belt buckle) to
the approximate location of the operator’s middle knuckles.
 The spreadsheet formulas calculate D by taking that value and
adding 0.2 m (8 in) for distance to the spine.
Maximum
.2 m (8 in) Horizontal
Reach
29
D revised August 2014
PART OR TOTE LIFTING MOMENT (TWO HANDED LIFT
ONLY)
Use the formula to
solve for max H
20.5 lbs x (12 in reach + 8 in constant) ~ 410 in-lbs
30
revised August 2014
PART OR TOTE LIFTING MOMENT (TWO HANDED
ONLY AT START OF LIFT)
If the result flags as RED > 46 Nm (410 in-lbs) …

 the Program Ergonomist will use a Secondary Analysis tool for
further evaluation (NIOSH, 3DSSPP).
 If the Secondary Analysis also fails, then a solution must be
developed to reduce the Lift Moment.
 For a Tote, reduce the Total Loaded Mass and/or the Maximum
Horizontal Reach entered in section 2.0.
 For a Part, reduce the Maximum Horizontal Reach entered in
section 2.0. or use a lift assist.
 The reach can also be reduced by providing access in the
layout/process to two opposing sides of the container.
revised August 2014
Part or Tote Lifting Moment (two handed lift only)
Measure/estimate
Horizontal Reach
from the edge of the
job (belt buckle, Provide toe
edge of container) clearance 100
mm (4 in)
underneath a
riser or dolly
to allow the
operator to
stand as close
as possible to
the container.
32
revised August 2014
Part or Tote Lifting Moment (two handed lift only)
Bulk Rack with Cantilevers – for lift moment calculations –
assume that operator will slide parts to end of cantilever
before lifting. Use 305-510 mm (12-15 in)as the maximum
horizontal reach for lifting purposes. The maximum
allowed reach for sliding parts will be covered in the rack
entry section.
Operator can
slide parts to a
point on the
cantilever
where the reach
is
< 305-510 mm
(12-15 in)
33
revised August 2014
FINGER CLEARANCE FOR LOADING/UNLOADING
PART
The clearance between parts, or between parts and rack structure
specific to areas where the operator’s fingers must be placed.
Finger Clearance for Part Removal

Halo > 30 mm (1.2 in)
Depth > 40 mm (1.5 in)
NOTE: Dimensions given are from finger tip to mid-knuckle. Above the mid-knuckle
area the clearance will need to increase to accommodate the whole hand.
Clearance required is based on a 95% male gloved hand.
34
revised August 2014
HAND CLEARANCE FOR PART REMOVAL
The clearance between parts, or between parts and rack structure
specific to areas where the operator’s hand(s) must be placed.
Hand Clearance for Part Removal
> 85 mm (3.35 in)
85 mm
85 mm
85 mm
revised August 2014
Hand Clearance for Sequential Parts
(Rings/Gears/Lams)
Note: Keep in mind that for sequential parts, hand clearance requirements may be
required for the first part
revised August 2014
HANDHOLDS – ENGINEERED TOTES/TRAY
PACKS
Only applies to new tote designs. Does not apply to Standard Totes.
Handhold Width Finger Depth

> 90 mm (3.5 in)
Finger Opening
> 20 mm (.75 in)
Finger Depth
> 32 mm (1.25 in) (underneath tray) Finger Opening
Handhold Thickness
> 6 mm (.25 in)
Handhold Width
Example 1 – Drawer Pull
revised August 2014
Handholds – Engineered Totes/Tray Packs (cont’d)
Only applies to new tote designs. Does not apply to Standard Totes.
Handhold Width
> 90 mm (3.5 in)
Finger Opening
> 20 mm (.75 in)
Finger Depth
> 32 mm (1.25 in) (underneath tray)
Handhold Thickness (reference only)
> 6 mm (.25 in)
Example 2 – Cutout Handle
revised August 2014
HANDHOLDS – DUNNAGE OR LAYER PAD
Finger
Cutout Width Clearance Cutout Length
Cutout Length
> 90 mm (3.5 in)
Cutout Width Max 761 mm
> 20 mm (.75 in) (30 in)
Finger Clearance
> 32 mm (1.25 in) (underneath tray)
Cutout Thickness (reference only)
> 6 mm (.25 in) and < 85 mm (3.35
in) Target - Reference Only
due to difficulty in
dunnage tray
39 processing
revised August 2014
HANDHOLDS – DUNNAGE OR LAYER PAD
(CONT’D)
Dunnage handhold position
and orientation should be
designed to anticipate
handler position and to avoid
awkward wrist posture and
excessive reach.
Math models of hands in NX
and TcVis that can be used to
assess clearance and
orientation are available on
the Ergonomics SharePoint
site main page, central *Available in all TcVis databases
column under Product Hand
Clearance Instructions
https://gmweb.gm.com/manufacturing/me_ergonomics/Pages/default.aspx
revised August 2014
DUNNAGE WEIGHT
< 9.5 kg (21 lbs)
• Dunnage trays weighing more >9.5 kg (21 lbs) are

not recommended.

• If the weight cannot be reduced the operator should slide/flip
the dunnage or use a lift assist to handle the dunnage trays.
Sliding/Flipping will require that the supplier is willing to accept
the dunnage to be returned upside down.
• Another alternative would be to redesign the dunnage to be
half trays.
revised August 2014
DUNNAGE SIZE
< 1219x1219 mm (48x48 in)

• Dunnage trays >1320x1320 mm (52x52 in) are not
recommended.

• If the size cannot be reduced the operator should slide/flip the
dunnage or use a lift assist to handle the dunnage trays.
Sliding/Flipping will require that the supplier is willing to accept
the dunnage to be returned upside down.
• Another alternative would be to redesign the dunnage to be
half trays.
revised August 2014
3.0 ANALYSIS – GUIDELINES LID
WEIGHT
< 93 N (21 lbs)

• Lids weighing >93 N (21 lbs) are not recommended

• If the weight cannot be reduced, the operator should
slide/flip the lid. This will require that the supplier is willing
to accept the dunnage to be returned upside down.
• Another alternative would be to use a lift assist to handle
the lid.
revised August 2014
RACK ENTRY WALK ON (STEP ON )
This chart defines the minimum walk path requirements based on the height
of the barrier(s). A barrier can be a part holding detail on the rack or the rack
support structure itself.
Barrier
Barrier
Barrier
Rail Asm
revised August 2014
RACK ENTRY WALK ON (STEP ON)
Barrier Below
the Waist Barrier Above the Waist
Note: Step up should not exceed 178 mm (7 in)

revised August 2014
RACK ENTRY CANTILEVER RACK
This chart defines the maximum acceptable reach based on the distance
between cantilevers. Note: The maximum the reach allowance assumes that the
operator is sliding the part on the cantilever to the end of the cantilever where they can
lift the part with two hands (effective reach for lifting part is 380 mm (15 in) or less).
Door Inner
Cantilevers
revised August 2014
• A cut-out can be added to the base of the container to reduce to

horizontal reach to an acceptable range.
• The presentation equipment must also be designed to have a
cutout to match the container.
• If the parts come directly from the Stamping Plant to Body
Shop, presentation equipment at the stamping press EOL
must also be evaluated for reach.
revised August 2014
Part Geometry and Distance

Center of Gravity between
dictate location of Cantilevers
cantilevers. If
guidelines cannot be Minimum
met, another width for
container strategy cutout is 445
may need to be mm (17.5 in)
considered.
Ideally cutout would
Door Inner line up with space
between cantilevers
revised August 2014
3.0 ANALYSIS – GUIDELINES
TRIANGLES, PULL CABLE, PULL STRAPS,
SWING ARMS AND CURTAINS
(REFERENCE ONLY)
Force for Triangles/Pull Cables/Pull Straps/Swing Arms < 90 N (20 lbs)
Hand Clearance for Triangles > 100 mm (4 in)
Curtain – hand loop > 100 mm ( 4 in); force to pull curtain < 90 N (20 lbs)
Force to
Pull
Curtain
Hand < 20 lb.
Clearance =
4 in
• All guidelines are One Hand Force Limits

• Forces/clearance measured at Sample Buyoff
revised August 2014
TRIANGLES, PULL CABLE, PULL
STRAPS, SWING ARMS AND CURTAINS
H Force for Triangles/Pull Cables/Pull Straps/Swing Arms
< 90 N (20 lbs)
(V)ertical Height (H)orizontal Reach

>635 mm (25 in) ,< 1830 mm (72 in) < 380 mm (15 in)
V
Notes:
1) If the reach is > 380 mm (15 in) for triangles, pull cable, pull
straps, swing arms or curtains, consult with the Program
Ergonomist for a maximum force limit.
2) Parts in rack must not interfere with operator’s ability to reach.
3) If the operator must step up onto the base of the rack to reach
the pull strap, the standing surface must meet safety guidelines.
revised August 2014
3.0 Analysis – Guidelines
Triangles, Pull Cable, Pull Straps, Swing
Arms and Curtains
Locate locking
latch and a
‘handle’ for
If the handle on the operator
the Pull Cable is to pull up on
below 635 mm (25 to get the
in) from the floor swing arm in
… motion at >
635 mm (25
in) . > 51 mm (2 in)
> 90 mm (3.5 in)
Handle Design Guidelines
revised August 2014
A Triangle is preferred but if a pull ring

is used,
Maximum acceptable force is 8 lbs
Minimum ring diameter > 25 mm ( 1
in) Hand Access – provide at least
51 mm (2 in) of clearance
from obstructions
revised August 2014
Using a Force Gauge on a Pull Cable Release

revised August 2014
KNOCKDOWN DROP DOWN GATE
OPENING WIDTH
Drop gate opening width > 710 mm (28 in)
If part weight > 4.5 kg (10 lbs) AND/OR part size dictates two
handed lift
Drop gate opening width > 445 mm (17.5 in)

If part weight < 4.5 Kg (10 lbs) OR the part
can be slid/pulled to the drop down gate
revised August 2014
4 POSTER SKID – MANUAL LOAD OR
UNLOAD
All Parts – If Operator must Roof/Sunroof ONLY –
lift part over Posts with 2 person Load/Unload
< 43”
> 18”
Lowest parts > 455 mm (18 in)

Top of Rack (posts) < 1092 mm
All other parts use 635 mm (25 in)
(43 in)
min
All measurements from operator standing surface (include presentation equipment
such as a rack)
revised August 2014
WORK ENVELOPE
The work envelope analysis has been grouped into 4 categories:
Parts in Dunnage OR Line Side Bulk

Operator unloads parts directly from dunnage or totes on a pallet
Parts in a Bulk Basket OR Knockdown Container
Parts in a Bulk Rack OR 4 Poster Rack (Skid)
Small Lot /Empty Layers/Lids (Reference Only)

A tote is loaded/delivered by a material handling operator to the line.
revised August 2014
WORK ENVELOPE
GENERAL INFORMATION/TERMINOLOGY
(H)orizontal
Barrier (V)ertical
Edge
The operators ability to bend at the waist to reach is limited by the

height of the barrier edge.
57
Two Hand LiftGMMoment
Global Ergonomics
must be < 46 Nm (410 in-lbs)
revised August 2014
WORK ENVELOPE
Bulk Baskets - The operators ability to bend at the Dunnage/Stacked Totes - The operators
waist to reach is limited by the height of the barrier ability to reach is limited by the height of
edge. the barrier edge.
Target BARRIER EDGE HEIGHT-> If not on lift/rotate table/dolly Target BARRIER EDGE HEIGHT->
Optimal 940 mm (37 in) Max 1220 mm (48 in)
Max 1015 mm (40 in)
revised August 2014
WORK ENVELOPE REMOVING PARTS FROM
DUNNAGE
(OPERATOR IS UNLOADING PARTS DIRECTLY FROM
DUNNAGE OR TOTES ON A PALLET)
Barrier
Edge
Operator unloads parts directly Operator unloads parts directly

from the dunnage from the tote on a pallet
revised August 2014
WORK ENVELOPE
REMOVING PARTS FROM DUNNAGE OR TOTES
ON A PALLET
Recommended
max height for
top layer is
1220 mm
(48 in)
Note: 1220 mm (48 in) refers to maximum height for the full tote or dunnage including the
presentation device. One layer for Lids or Empty Layers can exceed the 1220 mm (48 in).
revised August 2014
WORK ENVELOPE
PARTS IN BULK BASKET/KNOCKDOWN
revised August 2014
WORK ENVELOPE
H= 380 mm
(15 in)
For Bulk Baskets

and Knockdowns V= 635 mm
containers with a
barrier edge > (25 in)
940 mm (37 in)
revised August 2014
WORK ENVELOPE
380 For Bulk Baskets and
mm (15
Knockdowns containers with a
in)
H > 380 mm (15 in)
• container must be on a
Effective
rotate dolly or table OR
Reach
Zone • operator must have access
to at least two sides of the
container OR
940 mm
• a rake must be used to pull
(37 in) parts towards the operator
High (may not work for
Barrier stacked/nested parts)
Edge
revised August 2014
WORK ENVELOPE PARTS IN BULK RACK
Window Frame
Hood Asm Body Side Outer

revised August 2014
Maximum
(H)orizontal
Reach is based on
(V)ertical Height
and the Two Hand
Lift Moment < 46
Nm (410 in-lbs)
revised August 2014
Walk On Rack
• Typically delivered by fork truck with rack set on floor
• Ensure that vertical height and horizontal reach
(measured from the walking surface) are within the
work envelope
• Walk Path requirements must also be met as
previously discussed in the Rack Entry section
Body Side Outer

Hood Asm
revised August 2014
Walk On or Walk In
• Dolly Delivery Strategy is driving more containers to be Walk In
• These are examples of racks that will need a cutout in the base
if they are to be dolly delivery in order to meet the Ergo work
envelope requirements
• Cut-out depth will be critical in achieving optimum horizontal
reach
• Dolly height will be critical in achieving optimum vertical
height
Rear End Panel Asm Hood Inner Frt/End Upper Tie Bar Asm
revised August 2014
Walk In
• A cut-out can be added to the base of the container to reduce to horizontal reach
to an acceptable range.
• The presentation equipment must also be designed to have a cutout to
match the container.
• If the parts come directly from the Stamping Plant to Body Shop,
presentation equipment at the stamping press EOL must also be evaluated
for reach.
• Distance between cantilever/walk path requirements must also be met as
previously discussed in the Rack Entry section.
F/Cmpt SI Rail Asm Door Inner
revised August 2014
Fender
Rocke
r Examples of other
Bulk Racks that are
not Walk On, Walk
In, or Cantilever
Rear Comp Lid Lwr
Door Outer
revised August 2014
Parts handled with Lift Assist/Hoist

• Discussion should take place with the Engineer responsible for the
purchase of the Lift Assist/Hoist to ensure that the design will facilitate
operation of such within the Ergo Work Envelope.
• Distance between cantilevers/barriers/walk path requirements must also
be met as previously discussed in the Rack Entry section.
Rail Asm I/P Tie Bar

Asm
revised August 2014
WORK ENVELOPE SMALL LOT – STACK
HEIGHT, LIDS, EMPTY LAYERS
(REFERENCE ONLY)
Stack
Height
or # of
layers in
Standard
Pack
GC27 addresses the design of the tote only. The

handling of the totes in a storage or kitting area will be
evaluated separately. Stack Height will be addressed
by the Ergonomist based on the NOISH Lift Analysis
(tote weight, (H)orizontal Reach, lifting frequency).
revised August 2014
WORK ENVELOPE SMALL LOT – STACK
HEIGHT, LIDS, EMPTY LAYERS
Reference only (formulas are not used to analyze the stack height)
• Overall Stack Height should be considered for the Small Lot Strategy.
• Handling of Lids and Empty Layers should be considered when evaluating
Stack Height.
• Ensure that work envelope requirements are considered for the operator
who is unloading totes/containers/lids from the stack in the following areas:
• CMA storage areas (Vehicle)
• Sequencing and Kitting Areas (Vehicle)
• Storage (Powertrain)
• Kitting and Rack Areas (Powertrain)
• If height of presentation equipment in the these areas is unknown, assume
305 mm (12 in).
• If height of pallet/base is unknown assume 178 mm (7 in) (actual 127 -178
mm (5-7 inches).
• The work envelope for the presentation of small lot containers at the Point of
Use (POU) will be evaluated separate from the container analysis.
revised August 2014
3.0 Analysis – Guidelines Other Information
Hand Location Lateral

For all part grasps and placements, the hands 380
mm
380
mm
should be located in front of the body and within

380 mm (15 in) of the body centerline
Overhead Clearance
The minimum vertical overhead clearance per SP-S
Ergonomics G3.0 section 3.1.2.3 is 1955 mm
(77 in)
VCI Bag Weight Limit
ONLY APPLIES TO VCI BAGS - The one hand lift
weight limit is 8.16 kg (15 lbs )
Toe Clearance > 100 mm (4 in)
• Step Up onto Rack < 178 mm (7 in)
revised August 2014
QUESTIONS?
74
EXAMPLES
75
Barrier
Barrier
Barrier
Barrier
Barrier
Identify Barriers
revised August 2014
38” 21”
Measure Barrier Heights
revised August 2014
BSO is
typically If a lift
manual
load at
24” or 28” assist is
used for
press EOL loading or
and unloading,
either 28” may be
unloaded required
roboticall between
y or with 20” barriers
a lift depending
assist in on the
the Body height of
Shop the barriers
Use Measurements/Guideline to determine Walk Path Requirements
revised August 2014
RACK ENTRY EXAMPLE
Lift Gate Inner
If this rack is delivered by fork lift and set on floor it would be

considered to be a Walk On and walk path guidelines would apply.
revised August 2014
RACK ENTRY EXAMPLE
If this rack is delivered by dolly, there are two options for

achieving the desired reach based on the distance between the
cantilevers:
1) Back stops can be added to the cantilevers to reduce the
reach to an acceptable value AND/OR
2) A cut-out can be added to the base.
revised August 2014
RACK ENTRY EXAMPLE
Hood Hood
Inner Inner
Cut-out added to Back stops added to

base cantilevers to bring
parts forward to meet
reach requirements
revised August 2014
3.0 Analysis – Guidelines Bulk Basket Example
6 Stacks of 22
Container: Standard Basket #28847

36x32x26
Up in Device: Top of Vehicle

Facing Operator: Front of Vehicle
Standard Pack: 132
revised August 2014
Bulk Basket Example
16 in
• Top of barrier edge is at 39” with a 15” dolly

• Floor of basket is at 22” but part height of 3.2” brings
(V)ertical Height for the bottom layer to approximately 25”
• (H)orizontal Reach will be < 15 in
• Either need access to 2 sides of container on layout or
dolly with turn table top
revised August 2014
Bulk Basket Example
3 Stacks of
14
Container: Standard Basket #23051

96x48x36
Up in Device: Inside of Vehicle

Facing Operator: Front of Vehicle
Standard Pack: 42
revised August 2014
Bulk Basket Example
• Top of Barrier Edge = 40” with a 15” dolly

24 in • (H)orizontal Reach to center of basket is
24”
• Part Weight
Barrier Edge=Height
9.1 lbsis OK
• (H)orizontal reach at bottom layer is >
15” NOK -> request drop gate on short
side
• Part weight is OK for a one hand lift
revised August 2014
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GM Ergonomic Container Worksheet: GC27/NA27

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GM ERGONOMIC CONTAINER WORKSHEET

USE: Provide guidelines for the Container

NOT intended to identify every risk factor, but to direct the

USE: Guidelines are based on the assumption that the

including dollies and minomis are available on the

• Container design proposals should support the Plant

 The worksheet should be completed by the container engineer prior to the

 The container engineer can save the completed files there.

Screen shot of section 1.0 Program and Part Information

Screen shot of section 2.0 Packaging information

Container Strategy (I)

Container Strategy (I)

Walk On with part supporting details (barriers)

4 Poster Rack (Skid)

Std Tote Size (P) - L,W,H fields will be automatically populated if a

Overall Container Footprint (S) – Required for all Container Strategies

Removable Dunnage or Layer Pad? (Z) – Select Yes or No from Drop

Empty Dunnage/Layer Pad Weight (EE) – Enter weight of empty

Maximum Horizontal Reach (JJ) – Use worst case scenario

Specification details Automatically Enter your

• Maximum rotation < 90 0

If the result flags as RED …

20.5 lbs x (12 in reach + 8 in constant) ~ 410 in-lbs

17.8 lbs x (15 in reach + 8 in constant) ~ 410 in-lbs

14.6 lbs x (20 in reach + 8 in constant) ~ 410 in-lbs

12.4 lbs x (25 in reach + 8 in constant) ~ 410 in-lbs

If the result flags as RED > 46 Nm (410 in-lbs) …

Finger Clearance for Part Removal

Handhold Width Finger Depth

Example 1 – Drawer Pull

Example 2 – Cutout Handle

> 20 mm (.75 in) (30 in)

• Dunnage trays weighing more >9.5 kg (21 lbs) are

If the result flags as RED …

< 1219x1219 mm (48x48 in)

If the result flags as RED …

< 93 N (21 lbs)

If the result flags as RED …

Note: Step up should not exceed 178 mm (7 in)

• A cut-out can be added to the base of the container to reduce to

Part Geometry and Distance

• All guidelines are One Hand Force Limits

(V)ertical Height (H)orizontal Reach

> 90 mm (3.5 in)

Handle Design Guidelines

A Triangle is preferred but if a pull ring

Using a Force Gauge on a Pull Cable Release

Drop gate opening width > 445 mm (17.5 in)

Lowest parts > 455 mm (18 in)

The work envelope analysis has been grouped into 4 categories:

Parts in Dunnage OR Line Side Bulk

Parts in a Bulk Basket OR Knockdown Container

Parts in a Bulk Rack OR 4 Poster Rack (Skid)

Small Lot /Empty Layers/Lids (Reference Only)

The operators ability to bend at the waist to reach is limited by the

Operator unloads parts directly Operator unloads parts directly

For Bulk Baskets

Hood Asm Body Side Outer

Body Side Outer

F/Cmpt SI Rail Asm Door Inner

Rear Comp Lid Lwr

Parts handled with Lift Assist/Hoist