General Motors

Safety 21 Design-In Safety P

rocess

Adapted from the GMU course Engineering for Health and Safety Industrial Engineering & Training
Introduction to
Design-In Safety
 Design-In Safety
– History
– Concepts
 Overview and highlights of the GM Com
mon Design for Health and Safety Speci
fication - DHS
 Design-In Safety

...is a strategy which promotes the integra

tion of health and safety requirements in
product and process concept and desig
n stages.
 Design-In Safety
Key Philosophies

•Eliminate / Minimize Human Exposure

•Safeguards will not be followed (Human Nature)
unless:
1) Easy to Use
2) Easy to Recover
 Why Do We Need Design-In?
Traditional Future

Design
Involvement
Design
Involvement

Effort
Retrofit

Cost
Retrofit Effort
Cost
Resources Resources
 Design - In
Effective Planning

High
Influence Cost

Low
Phase 0 Phase 3
 Hierarchy of Controls Desig
n Preferences
Proactive Least Human
Most Effective Involvement
1) Elimination or Substitution
2) Engineering Controls

3) Warnings

4) Training and Procedures

5) Personal Protective Equipment

Reactive Most Human
Least Effective Involvement
Specification Overview
 Machinery and Equipment
Environment

 Safety 21 Process and Tools

 Task-Based Risk Assessment

Process
DHS 3 • Hierarchy of Health and
Safety Controls
• Validation Process

 Guidelines and Specifications

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
 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
 1. Workstation Design/Operator Interface
 Design should accommodate a
wide range of human in term of
reach,clearance,movement and
work repetition
 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
 Use control display that are
meaningful and easy to
understand
Assess proper work space  Adequate lighting shall be
dimension provide during de-energized
period
2. Workstation Design/Operator Interface:
Tool Design
 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
 The manufacturer’s rated speed
(RPM) shall be clearly marked on all
pneumatic power tool
 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
2. Workstation Design/Operator
Interface: Tool Design (Cont.)
 Electrical power operated tools
shall be grounded or be double
insulated
 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
Tool Rest the manufacture’s rated speed
for the grinder
 The power tool shall be
equipped with the appropriate
tool rest
3. Maintainability

 All primary energy-isolation devices

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

 Design hoist rail into the system

structure in areas where lifting
of heavy system components is
Hoist Rail
required and access by
motorized lift equipment is not
available
 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
 4. Fall and Working Surface
 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
 The shutoff valves,monitoring
& maintenance equipment
should be located at readily
Shut-offs at floor level
accessible floor or grade floor
 4. Fall and Working Surface (Cont.)
 For climbing
applications,are fixed stairs
used in preference over
alternating tread type stairs
or vertical ladder
 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
4. Fall and Working Surface (Cont.)
 All step, ladder rungs and
working surface have
a“non-slip” surface
 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
Cable Cover covered
 Holes in floors or platforms
shall be properly marked
and guarded
5. Industrial Hygiene
 A Material Safety Data Sheet
(MSDS) from supplier that
meet GM requirements
 All chemical materials
proposed for use in research
and production shall be
approve before purchase
 All machinery,power tools
been design noise level not to
exceed 80dBA
MSDS
 All machinery been design to
assure impluse sound
pressure level not exceed 130
dBA
 6. Fire Prevention Plan
 Fireproof cabinet shall be
provide to store flammable
substances and each
cabinet shall be properly
marked identifying it as a
MSDS flammable storage cabinet
 Equipment that contain a
flammable substance shall
be designed to prevent
accidental ignition
 Fire fighting equipment
shall be stationed in the
work area an shall be
properly marked to indicate
Flammable storage cabinet
its use
 7. Safeguarding device:Guard
 A guard needs to be
Pulley constructed to prevent
reaching over under,around or
Guarding through to a point of hazard
 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
Sprocket  Guard shall be free of sharp
Guarding edges and protections and
shall not themselves create a
hazard
7. Safeguarding device:Guard (Cont.)

 A guard shall be
constructed where required
to allow for visibility into the
hazard area to reduce the
need for access beyond the
guard
 A guard shall contain parts
and equipment within the
guarded area from being
ejected to outside of the
guard area
8. Safeguarding device:Interlocks
 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
Interlock door unintentional bypass
device
– Be used where hinged or
sliding door or guards
provide access to hazard
– Be appropriate for the
task and related hazard
9. Safeguarding device:
Presence Sensing Devices
 Presence sensing devices
shall be control reliable and
be installed in a control
reliable manner
 Be installed per the safe
distance requirement under
the OSHA
 Indicator light shall provide
to indicated the device is
function.If used for operator
protection the indicator
lights shall be observable by
the operator
9. Safeguarding device:
Presence Sensing Devices (Cont.)

 If there is a loss of power

the PSD shall initiate an
immediate stop command to
the equipment it is
controlling
Light Curtains  Awareness devices should
be added to prevent
inadvertent trip of the PSD
10. Safeguarding device: Two Hand
Control Device 
Be protected against
unintentional operation
 Be arrange by
design,construction or
separation to require the
concurrent use of both hand
within 500 ms to initiate cycle
 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
Two-hand  Issue stop signal if any
Control operator’s hand is removed
from the control during
hazardous portion of the cycle
11. Emergency Stop Function and
Device
 Be provide at each operator
station where hazardous
motion exists
 Be hardwired into the
emergency stop circuit
 Function independently from
the system programmable
electronic system
 Not be of the automatic
resetting type,but shall require
manual reset
 Not initiate,restart or create any
Emergency Stop hazardous motion when reset
11. Emergency Stop Function and
Device (Cont.)
 Be red in color
 Be palm type or mushroom-
shaped
 Have any existing
background for the device
actuator colored yellow
 Be distinguishable from all
other controls by size and
color
Emergency Stop
 Be unguarded and not
recessed
12. Awareness Barriers Device
 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
 Awareness device shall be
designed constructed and
located to provide a
recognized signal
(audible,visual or a
Awareness Device combination)
 13. Lockout Energy Control
 The control circuit and primary energy
Lockout/energy control placard
isolating device shall be design to
provide easy and safe system access
for service and maintenance task
 Lockout/energy control placard that
identify the store energy sources and
the safeguard against their release
shall be provided
 When dropping or drifting of
equipment /part present hazard ,device
shall be install to eliminate hazard
 Master Iockable electric disconnects
and shut-off valve (Pneumatic and
Hydraulic) shall be install on the
service side,outside of the cell
14. Monitored Power Systems
Application
 Fail to Safe
– Safety systems stop in a safe condition
 Independent
– Allow a comprehensive test sequence to be written
– Detects if the safety circuitry has been bypassed or removed
 Redundancy
– Paralled or Series Devices
 Monitoring
– Internal and/or External Feedback
 Safety Design Review (SDR)
 A SDR consists of the GM DHS 3 Design In
Specification in question format.

 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
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.
 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
What Is Task Based Risk Assessme
nt (TaBRA)?
 It is a systematic approach to identify all t
asks and the hazards associated with eac
h task.
 It provides a methodology to select the ap
propriate safeguard based on each task/ha
zard combination.
 It provides a methodology to verify that th
e safeguard has reduced the risk of injury
during the performance of the task.
 Risk Assessment Process
Gather group of
skilled trades,
supervisor, and
safety personnel
familiar with
equipment
Review decision tre
e decision tree questi
outputs and apply
Hierarchy of Contr
ols
For those solutions
that require further
investigation or
SOP’s, assign
appropriate
personnel. Enter
final solutions later
Step 1: Identify all Task Step 2: Identify
s required or expected t all hazards that
o be could be
performed, daily, encountered while
weekly, monthly, performing each
annually, etc. task.
Step 4: Answer all Step 3: Enter task
and hazards into
ons Excel spreadsheet
Use TaBRA spreadshee For similar equipment
t to review for additional
track corrective action tasks and/or hazards
and for final
buy-off of equipment.
Review for input into
design of new equipm
ent
 Design-In Risk Assessment Process

TaBRA’s from
all plants go into master
base.

Designer selects components for new cell an

d
pulls tasks and hazards associated with the
equipment from master data base.

Welding Robot Sealing Robot

Conveyor Tooling
Tip Dresser Pedestal Welder

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.
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”
 SAFETY 21 PROCESS REVIEW

Safety 21 Process tools provides:

• Influence SDR
• Continuity TaBRA
• Confidence Validation
...for safety designs in manufacturing equipment and
systems.
 M & E Design Elements & Safety 21 Process

MFG. Life Cycle M & E Design Elements

Design 1. Preliminary design
 Safety Design Analysis (SDA) Common Templates
 SDR 1
2. Pre-Award (Quote)
3. Award P.O.
4. Detailed design
Pipeline

 SDR 2 & “New Equipment” TaBRA

5. Supplier Builds Equipment or buy off-the-shelf
 SDR 3
6. Accept
7. Install / Debug
Plt. Floor

 Validation
8. Run Production

Copyright 2000 General Motors University

Questions?