g-dhs-1

Manufacturing Engineering

Global - Design for Health and Safety Specification

G-DHS-1

Risk Management Process and

Documentation

Production

People Involvement

ContinuousImprovement

ShortLead Time

Standardization

Built-In-Quality

February 2, 2007

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Global Design for Health and Safety Specification G-DHS-1 General Motors Corporation

TABLE OF CONTENTS

Section Page

Section 1: Requirements and Key Concepts....................................................................................... 1 1.1 Introduction..................................................................................................................................... 1 1.2 Scope ............................................................................................................................................. 1 1.3 Purpose .......................................................................................................................................... 1 1.4 G-DHS and Outside Standards...................................................................................................... 1 1.5 GM Engineering Requirements...................................................................................................... 2

1.5.1 Supplier Engineering Requirements ................................................................................... 2 1.6 Machinery and Equipment Lifecycle .............................................................................................. 3

1.6.1 Transposing the M & E Lifecycle ........................................................................................ 3 1.7 Safety Balance ............................................................................................................................... 4 1.8 Risk Management .......................................................................................................................... 5 1.9 GM-GMS Foundation of G-DHS..................................................................................................... 6 1.10 Five Main Segments for Regional Implementation and Global Communication ........................... 7

1.10.1 Safety Engineering Design Value Stream Map (VSM) ....................................................... 8 Section 2: Global Safety 21 Process .................................................................................................... 9

2.1 Safety 21 Gates and Deliverables.................................................................................................. 9 2.2 Global Safety 21 Process Overview............................................................................................. 10 2.3 Resource Time Requirements ..................................................................................................... 11 2.4 Global Safety 21 Responsibilities................................................................................................. 12 2.5 Global Safety 21 Quick Reference............................................................................................... 13 2.6 Global Safety 21 g-Tool Gate Support Tools ............................................................................... 15 2.7 g-Tool Submittals.......................................................................................................................... 16

LIST OF FIGURES

Figure Page Figure 1-1: Machinery and Equipment (M & E) Lifecycle ............................................................................ 3 Figure 1-2: M & E lifecycle for Value Steam Mapping Applications............................................................. 3 Figure 1-3: Safety Balance Function............................................................................................................ 4 Figure 1-4: Risk Management for Machinery & Equipment......................................................................... 5 Figure 1-5: G-DHS Link to GM-GMS ........................................................................................................... 6 Figure 1-6: G-DHS Plant Involvement per GMS.......................................................................................... 6 Figure 1-7: G-DHS Value Stream Map with 5 Areas and Flow Paths ......................................................... 8 Figure 2-1: Global Rocket Chart and Gate Placement ................................................................................ 9 Figure 2-2: Global Safety 21 Process Steps.............................................................................................. 10 Figure 2-3: Determining Global Safety 21 Resource Requirement ........................................................... 11 Figure 2-4: Global Safety 21 Roles & Responsibilities Chart .................................................................... 12 Figure 2-5: Engineering Reference Gates 1 through 3 Design Focus ...................................................... 13 Figure 2-6: Plant Reference Daily “Take 2” Applications........................................................................... 13 Figure 2-7: Gated Process Added to the M & E Lifecycle (Three Stages per Phase) .............................. 14 Figure 2-8: Global Safety 21 Summary Chart............................................................................................ 14 Figure 2-9: Transition from e-Tools to the Next Generation g-Tools ......................................................... 15 Figure 2-10: g-Tools Gate Location and Purpose ..................................................................................... 15 Figure 2-11: g-Tool Direct Submit from the M & E Lifecycle Reference.................................................... 16

February 2, 2007 Page iii Copyright © 2007 All Rights Reserved


Origin and Development of G-DHS In 1992 General Motors’ Manufacturing Managers Council sanctioned a document to be produced that included correct safety principles for machinery and equipment. This document issued internally in 1993 was known as “Safety Guidelines for Machinery and Equipment.” In 1995 a similar document was produced for robotics known as “Robotics Safety Specification” and focused on common safety techniques for robots and related equipment. In 1997 all equipment types were merged into a single document that was issued as the “Design for Health and Safety DHS 1.0.” The major focus in the document was the creation of the “Task Based Risk Assessment Process.” In 2000 DHS 2.0 was issued which included an overall gated execution process known as “Safety 21 Process” that further supported the risk assessment process. In 2003 DHS 3.0 was released with included the “Machine and Equipment Lifecycle” and additional details of how to implement safety designs with a North America focus. In 2007 Global Design for Health and Safety (G-DHS) specification was created and subdivided into three parts (Part 1, Part 2, Part 3) to integrate safety into engineering and program execution using common global architecture and components as defined by the Global Engineering Centers. The main principle in this document is the “2-Stage 7-Step Approach” for risk elimination and reduction. This approach describes an iterative process for providing “Safety Balance” and optimizing regional business goals. G-DHS offers guidance and requirements during all stages of the machinery and equipment lifecycle. This lifecycle is common to all global regions. Due to perspectives being different at each stage within the lifecycle, correct actions are achieved by using common global processes, tools, architectures and components.

February 2, 2007 Page v Copyright © 2007 All Rights Reserved


Section 1: Requirements and Key Concepts

1.1 Introduction

This document is written to encompass the responsibilities of many disciplines with various levels of understanding about health and safety and how health and safety relates to the machinery and equipment life cycle. Since most readers do not have responsibility for the complete machinery and equipment life cycle, some areas of this document will be more meaningful than others based on the level of responsibility and knowledge of the reader. The continued use of this document in your area of responsibility, within the framework of the three phases and nine stages of the machinery and equipment life cycle, will enhance your understanding of health and safety integration and how other disciplines both upstream and downstream of your area are affected by your health and safety decisions.

1.2 Scope

This document describes GM’s top leadership direction, an internal controls process, a program/project execution tool kit, and documentation requirements for health and safety design during any stage of the machinery and equipment life cycle.

1.3 Purpose

This document describes risk management of health and safety during the three phases and nine stages of the machinery and equipment lifecycle, for both stand alone and multiple machinery and equipment systems and subsystems..

1.4 G-DHS and Outside Standards

G-DHS complies with the intent set forth in all regional regulations, directives, and local laws and codes for due diligence requirements in both risk assessment and implementation of appropriate health and safety control measures for the intended use and foreseeable misuse of the machinery and equipment under evaluation. All harmonized and or consensus standards have revision cycles set by the Standard Organization Developer (SOD). Currently all standards are in a revision timing cycle. Based on these multiple revision cycles many interpretations and conflicts exist between many standards. All harmonized and consensus standards have or are considering converging to an International Standards Organization (ISO) standard equivalent. G-DHS will focus on harmonizing with current and future ISO standard equivalents to avoid the inconsistencies that currently exist between harmonized and consensus standards, due to these different revision timing cycles of each outside standard. See Annex A for a regional cross-reference of standards.

February 2, 2007 Page 1 Copyright © 2007 All Rights Reserved


1.5 GM Engineering Requirements

1. Optimize GMS Regional Business Goals (GMS) Risk Assessment (RA) and Risk Reduction or Health & Safety Control Measures (HSCM) through the Safety Balance function of: G-DHS = GMS + RA + HSCM.

2. All Program and Project leaders must take GMU CTIS Course No. 33651.

3. Understand the 3 phases and 9 stages of “Machinery and Equipment Life Cycle” and appropriate

Regional Regulations, Directives, Standards, local laws and codes.

4. Complete all actions and documentation during the four internal control process gates for every GM

project or program for compliance with GM risk management. 5. All Program and Project leaders must appoint Designate(s) to facilitate Gate 3 “risk assessment”

documentation for each project and program. Each Designate must take GMU CTIS Course No. 33650.

6. Submit all defined deliverables to GM’s Global Health and Safety Website.

1.5.1 Supplier Engineering Requirements

1. Understand the “2-Stage 7-Step Approach” methodology and design concepts needed to optimize your interface, as a supplier, with the GM project or program teams.

2. Complete the g-Guide tutorial and document all risk reductions techniques through design in

the g-Guide tool.

3. Participate, through net meeting or physical attendance, if needed during Gate 2 and Gate 3 of the Global Gate Reviews. The GM contact will communicate with you and will guide your participation as required.

4. Perform risk elimination and risk reduction by using GM common architecture and global

common components supplied by Global Engineering Centers.

5. Deviation from common architecture and global common components requires approval from the Global Engineering Center with responsibility for that area.



1.6 Machinery and Equipment Lifecycle

The Machinery and Equipment (M & E) Lifecycle is common across all Global Regions. This concept of a lifecycle for M & E can be defined in three phases and nine stages. Figure 1-1 is a visual description of these 3 Phases and 9 Stages that occur during the lifecycle for any type of machinery and equipment or system under consideration.

Figure 1-1: Machinery and Equipment (M & E) Lifecycle

1 Concept & feasibility studies

2 Preliminary design

3 Award purchase order

4 Detailed design

5 Build equipment or buy off-shelf

6 Accept

7 Install / Debug

8 Production & associated activities

Design

Supplier

Plant Floor

M & E Lifecycle StagesM & E Lifecycle

Phases

9 Decommission

Phase 1

Phase 2

Phase 3

1.6.1 Transposing the M & E Lifecycle

Another way of visualizing this concept is shown in Figure 1-2 below. This is very important for describing how the Global Safety 21 Process communication links within the Global Design for Health and Safety Value Steam Map described later in Figure 1-7.

Figure 1-2: M & E lifecycle for Value Steam Mapping Applications

3

2

7

9

8

1

5

6

4

3

2

7

9

8

1

5

6

4

Machinery & Equipment Lifecycle

M & E 9 Stages

98

76

54

32

1Concept & feasibility

Preliminary DesignAward Purchase Order

Detail DesignBuild or Buy

AcceptInstall / Debug

Run ProductionDecommission

Design Supplier Plant FloorM & E 3 Phases

Gate 1

Gate 4

Gate 3

Gate 2

PRODUCTIO

N

or BuyBuild

M & E

START U

P

DesignDetailed

FeasibilityConcept &

Gate 1

Gate 4

Gate 3

Gate 2

PRODUCTIO

N

or BuyBuild

M & E

START U

P

DesignDetailed




1.7 Safety Balance

In the dynamic world of safety design and control measure implementation, safety solutions must be effective on machinery and equipment, which is designed, operated, maintained and decommissioned by diverse groups of people with many specialty skill sets, over varying frames of time. General Motor’s specific system applications are thoroughly risk assessed and appropriate health and safety control measures have been applied by using a safety hierarchy which is the common thread in all harmonized standards across the globe. These safety measures are balanced to meet the “Safety” principle within the regional business goals of General Motors - Global Manufacturing System (GM-GMS). G-DHS can be thought of as a Safety Balance Function (Figure 1-3), - consisting of one dependent variable, “safety balance,” and three independent variables: “regional business goals (GMS,)” “risk assessment analysis and documentation (RA),” and the proper “health and safety controls measures” (HSCM)” - applied to Machinery and Equipment systems and sub-systems during its lifecycle.

Figure 1-3: Safety Balance Function

G-DHS = GMS + RA + HSCMSafety

BalanceRegionalBusiness

Goals

Risk Assessment

Documentation

Health & Safety Control Measures

4.2. 3.1.G-DHS = GMS + RA + HSCM

SafetyBalance

RegionalBusiness

Goals

Risk Assessment

Documentation

Health & Safety Control Measures

4.2. 3.1.

1. Dependent variable G-DHS Safety Balance methodology is provided by executing the work instructions of the Global Safety 21 Gates 1 through 4.

2. Alignment of Health and Safety Control Measures actions with regional GMS

business goals of Safety, People, Quality, Responsiveness and Cost (SPQRC) and regional cultures.

3. Identification and Documentation of health and safety exposures and action plans

through a Risk Assessment (RA).

4. Application of Health and Safety Control Measures (HSCM), provided by Global Engineering Center guidance, which will lower the remaining risks to an acceptable level.



1.8 Risk Management

Global Design for Health and Safety is all about risk management. As stated in the GM University course titled “Risk Management Overview” CTIS # 31098, we can insert two key requirements of the G-DHS “Safety Balance Function” into the risk management. See Figure 1-4 below.

Figure 1-4: Risk Management for Machinery & Equipment

The standardized work shown above in Gates 1 through 4 of the Global Safety 21 Process achieves:

Influence - early input and modification avoids rework in the program or project

Continuity - provides correct focus and direction for resources throughout the project or program time frame

Confidence - verified results that all action items identified have been completed and work as intended

Credibility - globally retrievable documentation of the due diligent safety design effort created during the program or project.



1.9 GM-GMS Foundation of G-DHS

G-DHS is the second of nine health and safety core requirements. These requirements are enabled from element #3 under “People Involvement” within the overall GMS process as shown in Figures 1.5.

Figure 1-5: G-DHS Link to GM-GMS

PROCESS FULLY IMPLEMENTED (ACCEPTABLE)

PROCESS PARTIALLY IMPLEMENTED WITH SUFFICIENCY PLANS

LIMITED OR NO IMPLEMENTATION OF

PROCESS - NO SUFFICIENCY PLAN

Evaluation (O∆X)

1. Plant works with project or program engineering leads to follow a documented process to validate safety at the design stage.(GS-21 Gate 2)

1. Plant works with project or program engineering leads to validate safety at the design stage, but the process is not documented. (Gate 2 deliverables not submitted)

1. Plant does not work with project or program engineering leads to facilitate safety at the design stage.

2. Work area layouts and process layouts are analyzed in the risk assessment and actions are taken to apply health and safety control measures to reduce any remaining risk to an acceptable level. (GS-21 Gate 3)

2. The most recent revised facility layouts and process layouts were not obtainied for the risk assessment, or did not document (Gate 3 not submitted)

2. Work area layouts and process layouts are not analyzed in the risk assessment and actions are not taken to apply health and safety control measures to reduce any remaining risk to an acceptable level.

3. Plant follows a process to ensure or verifies that all open items or employee concerns were addressed in the final installation. (GS-21 Gate 4)

1. Plant works with project or program engineering leads to validate safety at the design stage, but the process is not documented. (Gate 4 deliverables not submitted)

3. Plant does not follow a process to ensure or verifies that all open items or employee concerns were addressed in the final installation.

Ο ∆ Χ

Global Design for Health & Safety - The organization has identified and documented appropriate groups of team members and skilled trades to participate in safety reviews for any modifications to equipment, tools, machinery and work processes related to new design, redeploy, retrofit, rearrangement, and decommission, of new or existing processes, tools, machinery and equipment.

Core Requirement#2 Global Design for Health & Safety - The organization has identified and documented appropriate groups of team members and skilled trades to participate in safety reviews for any modifications to equipment, tools, machinery and work processes related to new design, redeploy, retrofit, rearrangement, and decommission, of new or existing processes, tools, machinery and equipment.

Record Results:

Example Documents / Source Information for Global Design for Health & Safety:Documented process that includes equipment design validation, risk assessment and plant floor verification. - Observe equipment buy-off tags attached to new / relocated equipment until final buy-off from safety.- Equipment buy-off log sheets. (g- Comply, Hard copy or electronic copies)- Risk assessment for newly acquired equipment that was initiated by the plant. (g-Risk Assessment)

Expanded Comment Section: Reviewer can use this section to help the plant understand the scoring or identify ways to improve implementation and where applicable identify key areas that can be shared across the global regions.

1. Health and Safety Culture 2. Global Design for Health & Safety (G-DHS)

3. Risk Control Programs 4. Skilled Trades Focus

5. Ergonomics6. Environmental Culture and Management

7. Hazardous Material Control and Exposure Assessments

The plant GMS health and safety self-assessment to this core requirement is shown Figure 1.6 below:

Figure 1-6: G-DHS Plant Involvement per GMS

8. Chemicals and Resource Management9. Health and Safety Assessment

People Involvement1. Vision 5. Team Concept

2. Values 6. People Involvement3. Health & Safety Process 7. Open Communication 4. Qualified People 8. Shop Floor Management

Standardization9. Workplace Organization

10. Management by Takt Time11. Standardized Work

12. Visual Management

Built-in Quality13. Product Quality 17. Quality System Management

Standards 14. Manufacturing Process

Validation15. In-Process Control &

Verification16. Quality Feedback/feedforward

Short Lead Time18. Simple Process Flow 22. Scheduled Shipping/Receiving

19. Small Lot Packaging 23. Temporary Material Storage20. Fixed Period Ordering 24. Internal Pull/Delivery

System/Order Parts 25. Level Vehicle Orders Schedule 26. Supply Chain Management

21.Control External Trans.

Continuous Improvement27. Problem Solving 31. Early DFM/DFA28. Business Plan 32. Total Maintenance

Deployment System 33. Continuous Improvement

29. Andon Concept Process

30. Lean Design of Facilities, Equipment Tooling and Layout

GMS Principles & ElementsG-DHS “Balance” with

GMS business goalsSafety - 9 Core Requirements

GMS 5 Principles and 33 Elements

GM - Global Manufacturing System3. Health and Safety Process

G-DHS



1.10 Five Main Segments for Regional Implementation and Global Communication

The many variables encountered globally can be categorized or visualized in five main segments, and can be represented graphically by the following symbols shown below.

Segment 1 - GM’s Global Common Designs as defined by the appropriate Global Engineering Center. This area is depicted by the following symbol.

1

9 Box

CommonDesigns

CKD Hi Med Lo

Segment 2 - GM’s Global Common Components Lists Designs as defined by the appropriate Global Engineering Center. This area is depicted by the following symbol.

GlobalCommon

ComponentsList

GCCL

2

Segment 3 - G-DHS, a balanced approach to safety engineering for application on all GM programs and projects. This area is depicted by the following symbol.

Global Design for Health &

Safety

G-DHS 1.0

3

Segment 4 - Regional regulation, directives, local laws and codes as depicted by the following symbol.

Regional RegulationsDirective

& LawsRegional

RegulationsDirective

& LawsRegional


& LawsRegional


& Laws

GMNA

GMAP

GME

GMLAAM

4

Segment 5 - All Harmonized national and international standards (i.e., ISO, EN, ANSI, NFPA,

etc.). See Annex A. This area is depicted by the following symbol.

RIA15.06

Dynamic Consensus and Harmonized Standards (800+)

NIST

ISO

ENCENANSI

TR’sANSIB11

55



1.10.1 Safety Engineering Design Value Stream Map (VSM)

The five global symbols listed above with their respective communication paths can now be arranged in a “Value Stream Map” shown in Figure 1.7 below. This map includes all flow, pull and continuous improvement paths. All communication paths are represented by a line with an arrowhead indicating the direction of communication flow. There are 4,095 or (212-1) ways to communicate using this VSM.

Figure 1-7: G-DHS Value Stream Map with 5 Areas and Flow Paths

RIA15.06

Regional RegulationsDirective

& LawsRegional


& LawsRegional


& LawsRegional


& LawsDynamic Consensus and

Harmonized Standards (800+)Global

CommonComponents

ListGCCL

Influence

Continuity

Confidence

Confidence

GMNA

GMAP

GME

GMLAAM

NIST

ISO

ENCENANSI

TR’sANSIB11

Global Design for Health & Safety G-DHS Value Stream Map

Global Design for Health &

Safety

G-DHS 1.0

22

33

44

55

1

9 Box

CommonDesigns

CKD Hi Med Lo

Gate 1

Gate 4

Gate 3

Gate 2

PRODUCTIO

N

or BuyBuild

M & E

START U

P

DesignDetailed


Gate 1

Gate 4

Gate 3

Gate 2

PRODUCTIO

N

or BuyBuild

M & E

START U

P

DesignDetailed


5.1

4.1

4.3

2.1

1.1

3.2

3.1

3.31.35.2

4.2

1.2

Legend for Communication Paths Above:

1.1 Common Designs submitted with Purchasing Requirements 1.2 Common Designs used during detailed designs 1.3 Common Designs driving content of “Global Common Components List” 2.1 Common Components List as bill of material for Machinery & Equipment builds 3.1 G-DHS-2 used to provide influence early in the design phase to eliminate and reduce risks 3.2 G-DHS-2 common methods of reducing remaining risks to and acceptable level 3.3 Analyzing detailed designs with user to reduce risks based on tasks performed 4.1 Regional Directives efforts for creating harmonized standards to meet the intent of the directive 4.2 Regional, local requirements and emerging issues monitored 4.3 Regional or local inspections of plants or production facilities 5.1 Harmonized regional, local and global standards involvement 5.2 Design alignment with harmonized standards and alignment with GMS.



Section 2: Global Safety 21 Process This section describes the gated process and the deliverables for all programs and projects to meet the due diligent safety design part of the “Governance for Compliance with Health & Safety Laws and Regulations” under the direction General Motors Legal Staff. See Global Health and Safety Website for a copy of this Governance and Compliance document.

Under the direction General Motors Legal Staff, GM received a Patent No. 6,931,293 that includes a gated manufacturing process and all related software tools known as the Global Safety 21 Process and associated software tools.

2.1 Safety 21 Gates and Deliverables

The Global Safety 21 gates are integrated into each project and program based on the fundamental principle of all projects and programs. The fundamental principle is variables for programs and projects converge as time increases.

Figure 2-1: Global Rocket Chart and Gate Placement

Using this convergence principle allows the correct number of Global Safety 21 Gates to be placed at critical milestones in all project or program timing to ensure, through standardized work, the four key deliverables of Influence, Continuity, Confidence and Credibility are met.



2.2 Global Safety 21 Process Overview

Figure 2.2 describes the nine major deliverables for each gate and associated global support tool (g-Tool) for each project and program.

Figure 2-2: Global Safety 21 Process Steps

Global Safety 21 Process OverviewGate 1 Gate 2 Gate 3 Gate 4Gate 1 Gate 2 Gate 3 Gate 4

1. Define Scope and overview of G-DHS Specification

2. Establish how project or program will be segmented, set up gate timing on

e-Card.

3. Set up Program/Project Lead net ID for Direct Submit to H&S web site.

6. If using common design & components Risk Assessment documentation is complete, just review the in relation to the facility interface.

7. Bring together users, designers and suppliers as required to perform a risk assessment.

g-Risk Assessment

8. Plant review machinery and equipment for compliance using

9. Verify safety compliance of all identified exposures in the Risk Assessment and all Health & Safety Control Measures have been installed and are functioning correctly.

g-Comply.

g-Card Review g-Guide

g-Risk Assessment

g-Complyg-Card Review g-Guide

g-Risk Assessment

g-Comply

Project or ProgramTiming

Release to

Production

Design Iterations

g-Guide

GlobalSafety 21(GS-21)Process

(4 Gates)(4 g-tools)

5, Complete Detail design review using and focusing on HSCM

4. As engineers perform design iterations, use the identify & implement the health & safety

control measures (HSCM) recommended by GECs.g-Guide to

g-Guide



2.3 Resource Time Requirements

The number of deliverables for Gates 2 and 3 are project and program dependent based how the project or program Leaders divides the main systems and sub-systems.

Figure 2-3: Determining Global Safety 21 Resource Requirement

Note:1. Gates 2 & 3 can be a line item on an agenda,

during any standing project or program meeting.

2. When using common designs & components architectures, Gates 2 and 3 are minimized because evaluations are only looking at facility the interface.

Gate 1 Gate 2 Gate 3 Gate 4Gate 1 Gate 2 Gate 3 Gate 4 g-Card Review

g-Guideg-Risk

Assessmentg-Complyg-Card Review

g-Guideg-Risk

Assessmentg-Comply


Release to

Production

Design Iterations

g-Guide

GlobalSafety - 21

Process(4 Gates)(4 g-tools)

The amount of effort or time spent on Gates 2 and 3 is dependent on how close each project and program aligns with common designs and components. Alignment with common designs and components allows existing g-Guides and g-Risk Assessments to be used. Only the facility interfaces need to be considered which saves time and effort for the project or program team.



2.4 Global Safety 21 Responsibilities

Figure 2.4 below details who is responsible for each gate and g-Tool deliverable during each project and program.

Figure 2-4: Global Safety 21 Roles & Responsibilities Chart Global Safety 21 Responsibility

Gate 1 Gate 2 Gate 3 Gate 4Gate 1 Gate 2 Gate 3 Gate 4

MFG Engineering Leads Global Health & Safety

(Mike White)

Plants (Local Health & Safety)

Regional Safety Managers

Mike White Global Health & Safety

g-Gate Review g-Safety Guide

g-Risk Assessment

g-Complyg-Gate Review g-Safety Guide

g-Risk Assessment

g-Comply

Manufacturing Engineering Leads


Release to Production


Release to Production

Design Iterations

Fill out g-Safety Guide

Manufacturing Engineers

Global Safety 21 Process(4 Gates)(4 g-tools)

Manufacturing Engineering Leads

For a detailed and complete understanding of all deliverables, three GMU courses have been established and are listed with their target audience. M E Program//Project Leads need to take a 4 hour course, GMU CTIS Course No. 33651, explaining the scope and deliverables of the new Global Safety 21 Process. (Step 5 in Figure 2-2) M E Program/Project Leads should appoint designates to lead and deliver a 4 hour course, GMU CTIS Course No. 33650 on g-Risk Assessments to support the project or program (1 or 2 people), (Steps 6 and 7 in Figure 2-2) All designers (GM and suppliers) must take a downloadable tutorial on the g-Guide tool (describes the 2-Stage 7-Step Approach). (Step 4 in Figure 2-2)



2.5 Global Safety 21 Quick Reference

The Global Safety 21 Process can be summarized in two figures: Figure 2-5: “Engineering focus” leading to the risk assessment” and Figure 2-6: “Plant focus of ‘Take 2’ anchored in risk assessment.” These figures can be used as a quick reference pocket card. These two quick reference cards are available on the Global Safety website.

Figure 2-5: Engineering Reference Gates 1 through 3 Design Focus

Using the Safety Guide

Review Safety Guide as you create and design your systems

Apply the Health and Safety Control Measures in the “ 2 stage 7 step balanced approach” of eliminating or reducing the remaining risk from hazards to an acceptable level.

Successful Risk Assessment

Gate 1 (Kickoff Meeting)

Balance

Stage 1

Stage 2

1. Engineering Controls

2. Awareness (Warnings, signs & devices, Placards, etc…

3. Safe Operating Procedures

4. Personnel Protective Equipment

5. Training (operator, Maintenance, etc…

2. Substitution of Materials

1. Change Task, function, location etc...

Eliminate

(Continuous use through-out Design Process)

Gate 2 (Detail Design Review)

Gate 3 (Risk Assessment with User)

Figure 2-6: Plant Reference Daily “Take 2” Applications



Inserting Gate 1 through 4 into the M & E Lifecycle from Figure 1-1, we get Figure 2-7.

Figure 2-7: Gated Process Added to the M & E Lifecycle (Three Stages per Phase)

2. Preliminary design2. Preliminary design3. Award purchase order

4. Detailed design

5. Supplier builds equipment or buy off-the-shelf6. Accept

7. Install / Debug

8. Production & Related Activities

Design

Supplier

Gate 1

Gate 2

Gate 4

Plant Floor 9. Decommission

M & E Lifecycle StagesM & E Lifecycle Phases

Gate 3

1. Concept & Feasibility

Combining Figure 2-1, Figure 2-5, Figure 2-6, and Figure 2-7 creates the summary in Figure 2-8.

Figure 2-8: Global Safety 21 Summary Chart

TimeTime

PossibleVariables

To TargetGate 1

Gate 2Gate 3

Gate 4

Approval Global Safety 21 Gates

P r o d u c t i o nProject / Program Design Targets

1

5

3

9

4

6 7 8

2

3 Phase 9 Stage M & E Lifecycle

Daily applications of Safety

Risk Assessment

Health and Safety Control Measures

“ 2 stage 7 step approach”

Pre-task plans and SOPs

“Take 2”

Step 1

Step 3

Step 2

Ready for use in daily applications

Balance

Stage 1

Stage 2

1. Engineering Controls

2. Awareness (Warnings, signs & devices, Placardsetc…

3. Safe Operating Procedures


5. Tra ining (operator, Maintenance, etc…

2. Substitution of

1. Change Tlocation et

,

Ma terials

ask, function, c...

El imina te

Using the Safety GuideReview Safety Guide as you create and

design your systems

Apply the Health and Safety Control Measures in the “ 2 stage 7 step balanced approach” of eliminating or reducing the remaining risk from hazards to an acceptable level.

Successful Risk Assessment

Gate 1 (Kickoff Meeting)

Balance

Stage 1

Stage 2

1. Engineering Contro ls

2. Awareness (Warn ings, signs & devices, Placards, etc…

3. Safe OperatingProcedures


5. Train ing (operator, Maintenance, etc…

2. Substi tu tion o

1. Change Tasklocation etc...

f Materials

, function,

El iminate

(Continuous use through-out Design Process)

Gate 2 (Detail Design Review)

Gate 3 (Risk Assessment with User)



2.6 Global Safety 21 g-Tool Gate Support Tools

The global tools began life as e-tools in North America Safety 21 Process which developed over a three year period. Figure 2-9 shows this progression.

Figure 2-9: Transition from e-Tools to the Next Generation g-Tools

The Global Safety 21 Process has five g-Tools. Figure 2-10 shows each tool in relative sequence of use in the Global Safety 21 Process and the role each plays in the four major deliverables of Credibility, Influence, Continuity, and Confidence in the Global Safety 21 Process.

Figure 2-10: g-Tools Gate Location and Purpose

Gate 1

Gate 2

Gate 3

Gate 4

Gate 1

Gate 2

Gate 3

Gate 4

Credibility

Influence

Continuity

Confidence

Credibility

Influence

Continuity

Confidence



2.7 g-Tool Submittals

Building upon the M & E Lifecycle (wide arrow in Figure 1-2), all g-Tool deliverables as detailed in the GMU courses must be directly submitted to the Global Safety website. Figure 2-11 below summarizes the g-Tool relationship with the M & E Lifecycle. All completed g-Tools are submitted through the “Direct Submit” Global Health and Safety website. The g-Card tool serves as the dynamic scorecard for the Global Safety 21 Process status during program or project design through installation and as the permanent record of “due diligence” required by all Regions, local laws, and codes.

Figure 2-11: g-Tool Direct Submit from the M & E Lifecycle Reference


g-dhs-1

Documents

1general motors corporation

manufacturing engineering leads

regional business goals

safety control measures

global engineering center

global engineering centers

gated process added

equipment life cycle