Equipment Safety Buy-off g-Comply Tool

Presentation on theme: "Equipment Safety Buy-off g-Comply Tool"— Presentation transcript:

1

2 Equipment Safety Buy-off g-Comply Tool
October 2016 Update

3 Equipment Safety Buy-off Process (Red Tag Process) g-Comply
Ian Givens UAW Intl Rep Tracy Walker/Cora Coleman UAW Special Assigned Mike Rumley GM Program Manager

4 Introductions – UAW/GM g-Comply working group
UAW/GM CHR Ian Givens – UAW Mike Rumley – GM Tracy Walker – UAW Cora Coleman – UAW GM Safety Design & Launch Graham Parr – GM Steve Kapuscinski – GM Wentzville Assembly Marsha Steele – UAW Romulus Engine Ralf Hiebl – GM Ernie Bruton – UAW Lifetime Members Enju Liang – GM Mike Douglas – GM

5 Session Outline g-Comply rollout g-Comply early experience
May 2013 rollout, g-Comply original features overview g-Comply early experience Major Launches, revisions prior to 2016 g-Comply 6.1 – what has changed? Procedure Revised Red tag visual control modified Specific checklists added – Single Spindle Tools Where to get the latest version Management of Change (MOC) and g-Comply g-Comply 6.1 demonstration

6 g-Comply Rollout

7 History and Timeline

8 g-Comply History May 2012 through May 2013 A Joint Team was organized
Three sites involved in product launches were visited Buy-Off Questions were collected, consolidated & new ones developed Procedure and Buy-Off Checklists were drafted Draft Procedure & Tool were introduced at the 2012 Black Lake Training Procedure & Tool were piloted at three sites Procedure & Tool were refined based on Black Lake feedback & pilot experience New g-Comply Process was released at Annual Joint Training in May 2013

9 g-Comply Rollout Prior to rollout May 2013 Annual Joint Training
Review of Technology Audit Module Many plant processes for Red Tag Desire for a consistent process May 2013 Annual Joint Training New consistent g-Comply process to replace former plant Red-Tags

10 May 2013 Annual Joint Training New consistent g-Comply process to replace former plant Red-Tags
Before May 2013 Variety of Tags & Procedures After May 2013 Common Tags & Procedure

11 g-Comply Official Materials
After May Annual Joint Training: UAW/GM rollout letter was sent g-Comply uploaded to the JAS website g-DHS website also updated with tool and tutorial (covered later)

12 Joint Letter to Plants

13 g-Comply Features

14 A look at the g-Comply 4.0 Initial Tool as rolled out in May 2013

15 Equipment Safety Buy-Off Procedure g-Comply 4.0
Commissionig Ready In Full Production Mode Red Power On System complexity determines number of Checklist items Green 3.0 Deliver and set in place Turnover to Production Initial Test Try-Out Without & With part(s) 1.0 Check Point A Check Point B Check Point C 2.0 4.0

16 Red/Yellow/Green Tags
g-Comply 4.0 Master Listing Foot Print Checklist Red/Yellow/Green Tags Schedule Rate Chart

17 Highlights of 4.0 Full Feature Mode
Master Listing Sheet Print Red, Yellow, Green Tags Buy-Off Checklists Red Tag Items Yellow Tag Items Green Tag Items Schedule Safety Resources Foot Print (Visual Status) Rate Chart (Visual Status)

18 g-Comply 4.0 Master Listing
Allows Program/Project engineers to enter or update their System/Equipment Details Provides 2-way Link to the Schedule Provides Password Protection for Status Updates Coordinates Red / Yellow / Green Tagging (Commissioning) Activities Creates Leadership Status Reports (Foot Print & Rate Chart)

19 g-Comply Checklist Questions by Category – g-Comply 4.0

20 How the Checklist Questions were Distributed in g-Comply 4.0
Total Checklist Questions = 188

21 Equipment Safety Buy-Off Procedure v 4.0
Commissioning Ready In Full Production Mode Red Power On System complexity determines number of Checklist items Green Deliver and set in place Turnover to Production Initial Test Try-Out Without & With part(s) Check Point A Check Point B Check Point C Deliver and set in place Turnover to Production Power On Time Ready Usage Mode Red Green X X

22 Equipment Safety Buy-Off Overview v 4.0
Print Red, Yellow, Green Tags and Buy-Off Checklists Begin Buy-Off (Do-Not Use) Equipment Power-On & Initial Test Try-Out (with & without parts) Prepare for Production Buy-Off Checklists

23 g-Comply Scheduling Allows Plant Safety to Plan & Agree to a Schedule
Provides Weekly (7-Day) Calendar for Buy-Off Scheduling, Provides Black-out dates for health & safety resources Allows Commissioning Activities to be scheduled in Hourly Segments (from 7 am to 5 pm)

24 g-Comply Foot Print LA103R01; LA103 SCA Unit #2 Provides Status at a Glance for Review with Plant and Launch Leadership Tracks number of Attempts made per cell (min. 3, typ. 5) Displays System Complexity

25

26 g-Comply Early Experience

27 g-Comply Launch Use – Some Notable Launches Soon After Rollout
Spring Hill – Equinox Flex Assembly and LGE Engine were in g-Comply transition period, LGE had 714 tags not including Jib Cranes Bowling Green - New Corvette Wentzville – Brand new lines for Chevy Colorado, GMC Canyon - van production continues, production increase 2016 Fort Wayne – K2XX Body Shop upgrade Detroit / Hamtramck – Flexible lines for Malibu, then Impala added to Volt & ELR – 2 shifts one Salaried one UAW safety Saginaw – Brand new casting lines – HFV6 block & head Romulus – Up from no production – HFV6 machining and assembly, then GRX transmission machining and assembly

28 g-Comply Lessons Learned Since Roll-Out
System overall does provide a consistent approach for review of equipment Red and Yellow allowable actions were question marks for many sites Each plant has to give clear answers (from LJHSC) to the launch team about what is allowed E-stop testing – plants have to develop their process Plant Process Integration Checklist questions for chemicals, noise, air sampling, ventilation, confined space, pedestrian/vehicle, falls, ergo have to be integrated into existing joint processes g-Comply process efficiency A major launch can require multiple visits to each piece of equipment, cell, etc. (at least 4; on avg. 6) Many N/A items have to be duplicated multiple times by engineers and checked by safety

29 g-Comply Lessons Learned Since Roll-Out
Responsibilities – Installers / launch team / maintenance / production / safety Some checklist questions require input from other resources, e.g. fire, maintenance, production - assign clear responsibilities for answers and fixes The process seems to work best when the project leader or installer drafts responses to all checklist questions, and safety verifies Administration – Identifying who provides the packets and who schedules a day’s tag reviews is critical Carry-Over Items – If something needs to be done but doesn’t impact safety immediately, must develop a consistent tracking method

30 g-Comply 5.0 Question revisions were approved for the g-Comply tool
Improvements to tool functionality were also made g-Comply 5 uploaded to g-DHS website Updated tutorial in place

31 g-Comply Version 5 (First Revision)

32 g-Comply Changes made in version 5 (Last revision before current)
New Mobile Equipment Category Checklist Items Touch-Safe Modification New Functions Print multiple tags Store checklist comment data by Tag # Reset data

33 g-Comply Changes - Version 5
New Mobile Equipment Category Checklist Items

34 g-Comply Changes - Version 5
New Mobile Equipment Category Checklist Items

35 g-Comply Changes - Version 5
New Mobile Equipment Category Checklist Items

36 g-Comply Changes - Version 5
New Mobile Equipment Category Checklist Items

37 g-Comply Changes - Version 5
New Mobile Equipment Category Checklist Items

38 g-Comply Changes - Version 5
Touch-Safe Modification

39 g-Comply Changes - Version 5
New Functions Print multiple tags

40 g-Comply Changes - Version 5
New Functions Print multiple tags

41 g-Comply Changes - Version 5
New Functions Print multiple tags

42 g-Comply Changes - Version 5
New Functions Print multiple tags

43 g-Comply Changes - Version 5
New Functions

44 g-Comply Changes - Version 5
New Functions Print multiple tags

45 g-Comply Changes - Version 5
New Functions Store checklist comment data by Tag #

46 g-Comply Changes - Version 5
New Functions Reset button to clean up checklist data

47 g-Comply 6.1 Current Latest Version
Revised Procedure Specific Checklist Questions

48 g-Comply Revisions in 6.1 Joint working group convened to address lessons-learned in launches and buyoff after version 5.0 Two modifications made Written procedure revision Specific Equipment questions Single Spindle Electric Tools Single Spindle Pneumatic Tools Possible future work (e.g. lift tables, lift-assist)

49 g-Comply Procedure Update – version 6.1
Safety Buyoff Procedure Button on Main Screen

50 Procedure (See Handouts)

51 Revised Procedure Flowchart
Added example - typical employees involved (for launch work) at each stage After Red Tag signed – Initial Test, Debug, Program After Yellow Signed – Production/Operation Readiness (Tryout) Allow loading non-production parts for Initial Test, Debug, Program

52 Purpose Define a procedure and identify the common global compliance tool (g-Comply) for evaluating machinery/equipment and processes to determine compliance with regulatory and company safety requirements. This procedure is a multi- stage process for reviewing machinery/equipment to ensure these requirements are followed. Each stage contains specific criteria for achieving compliance.

53 Scope This procedure shall be applied to all New, Off-The-Shelf, Retrofitted, Refurbished, Re-commissioned, Relocated machinery/equipment and/or installation projects at General Motors locations.

54 Scope Examples Examples of New and Off-The-Shelf machinery/equipment installation projects that require use of this procedure include: Installation of New Robotic Cells Installation of New Ergonomic Hoists and Rail Systems Installation of New Machining Cells Installation of New Technologies

55 Scope Examples Continued
Examples of Refurbished, Retrofitted, Re-commissioned or Relocated machinery/equipment that requires use of this procedure include: Addition of Robots to existing cells Addition of Tooling or Machinery/equipment to existing robotic cells Start of idled machinery equipment Movement of machinery/equipment within a facility Installation of machinery/equipment from another facility Modification of existing machinery/equipment Note: The above examples are not all inclusive of projects requiring this procedure.

56 Requirements

57 Create Contact List for Plant Safety Processes
The Responsible Project Leader must work with the facility to initiate several procedural items. Examples include: Review of chemicals at Hazardous Material Control Committees (HMCC); coordination of noise data review with plant noise committee; ergonomic assessments; review of fall hazard control methods; air sampling plan updates; confined space evaluations; review of fire protection methods. Local personnel are responsible for the existing processes that manage these safety items supporting the Local Joint Health & Safety Committee (LJHSC) and reporting to the Plant Safety Review Board. The checklist items for these questions are milestones that verify that the plant processes are working towards the agreed-upon safety reviews. The above examples are not all inclusive of all procedural items that may require pre-work.

58 Plant Contact List (example - not in official procedure or tool)

59 1.0 Red Tag (Initial Install)

60 1.0 Red Tag (Initial Install) (cont.)

61 2.0 Red Tag (Power on and Debug)

62 2.0 Red Tag (Power on and Debug) (After red signed; before yellow)

63 2.0 Red Tag (Power on and Debug) (After red signed; before yellow)
At this stage the Original Equipment Manufacturer (OEM), programmers, contractors or trades (installers) may: Power on Check safety circuits e-stops/safety devices Debug Check communication i/o (input/output) Program Verify motor rotation and all Manual functions (Major & Minor) Place trial parts in fixtures Check alignments/clearances Verify Dual Check Safety (DCS) envelopes Check limit switches This list may not be all inclusive of tasks required to establish basic functions of the machinery/equipment.

64 Red Tag Revision Yellow Box around “APPROVED FOR POWER ON & DEBUG”
DO NOT USE EQUIPMENT –ADDED LANGUAGE “Until Tag is Signed”

65 3.0 Yellow Tag (Tryout)

66 3.0 Yellow Tag (Tryout)

67 Yellow Tag

68 4.0 Green Tag (Production)

69 4.0 Green Tag (Production)

70 Green Tag

71 Documentation Retention

72 Specific Equipment Questions
Previous versions of g-Comply had a minimum set of questions for every piece of equipment (>100) Many N/A answers for simple equipment Committee worked to create smaller more specific checklists for frequently needed tag reviews

73 Specific Equipment Questions
During a launch with new tools some sites perform a high volume of Single Spindle Electric/Pneumatic tool tags Plants may now group multiple tools in one red tag (see procedure) For cells, all equipment can be reviewed at once (see procedure) Management of Change process addresses identical tool swap (see later slide) For plants using a tag that only includes tool reviews, the new checklists are shorter and more specific

74 Specific Equipment Future Work
The working group currently plans to address pneumatic lift tables and lift assist hoists as future specific equipment, possibly others Let us know if the approach is useful and should be continued

75 Previous Equipment Selection Minimum for Power Tools
Select Red, Yellow and Green questions, and Power Tools 113 Questions Selected

76 New Specific Checklist Fewer Questions – SS Electric Tool
12 13 14 39 Select Single Spindle Electric Tool Only 39 Questions Selected (Concept shown – Not final tool)

77 New Specific Checklist Fewer Questions – SS Pneumatic Tool
6 14 34 Select Single Spindle Pneumatic Tool Only 34 Questions Selected (Concept shown – Not final tool)

78 Where to get the latest versions Excel File Scheduler Tutorial
g-Comply Files Where to get the latest versions Excel File Scheduler Tutorial

79 Logon and select Health & Safety

80 JAS Common Login Joint Letter sent July 15, 2016
This new common login and password will allow all members of our Local Health and Safety teams to access the JAS website information…

81 Go to Online Documents

82 And Equipment Safety Buy-off Procedure

83 https://gmweb.gm.com/manufacturing/mfg_ghs/Pages/g-DHS
Or go to the g-DHS web page And Download the g-Comply Gate 4 files and tutorial

84 And Download the g-Comply
Gate 4 files and tutorial

85 g-Comply and MOC (Management of Change)

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87 Change Validation Example – Equipment Move

88 Change Validation Example – Equipment Move
Results of Example Validation – Use Red Tag Buyoff Process

89 g-Comply Demonstration

90 Equipment Safety Buy-off g-Comply Tool
Questions?

91 Equipment Safety Buy-off g-Comply Tool
Thank you

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