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人机工程学 Ergo 101 Part 4.pdf

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人机 工程学 ERGO 101 PART
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Ergo 101 Part 4 Issue Identification & Tracking MODULE IV 2 Issue Identification & Tracking ? Ergonomics Risk Factors ?Stressful Postures ?Force ?Frequency ? FORD Ergonomic Process: ?So what has been done so far? 3 Module IV How Are Ergo Concerns Found? TT / PP V i r t u a lS e r i e sUNV1 / UPV1 Design ProposalErgonomic Direction to Engineering Facility and Tooling PDL High Hurts Physical Builds Rack Buy- Offs APT Tooling Buy- Offs Cycle Line Layout Program Status: AIMS / Ergo PAT Workstation Readiness Workstation Status: R/Y/G Complete HCAR ECAR eFDVS Program Status e2KS and/or AIMS / Integrator MDQOS BPR Metric DPA-5 VME 1,2, & 3 Ergo Checks / Virtual Build Event M1 Physical Builds - Validation of UN Content Program Status: CR's from Ergo AIMS BPR Metric Block / PMT / CLL Meetings / Communication from VOME's & PD Pre FDJ Virtual Analyses Y N 1 Ergonomic Evaluation of Product or Process (Ergo Toolbox: FEDS, ErgoWeb Toolbox, Handpak, Jack, MOCAP, etc) Pass? Document pass in appropriate system (i.e. e2KS, AIMS, ECAR / HCAR matrix) Standard Analysis Report Template (insert link) Program Status: e2KS/AIMS Integrator MDQOS / BPR Metric For UN: enter issues in e2KS until M1 Builds, at which point all issues are entered into AIMS. For UP: enter issues in e2KS until Builds, at which point all issues are entered into AIMS. Standard report template / email (Integrator / BPR Metric Work with program and drive resolution1 ? Ergonomist will evaluate Product and/or Process via these systems utilizing various ergonomic tools: ? FEDS ? Jack ? HandPak High Hurt Process ? Current ergonomic issues are collected from destination plant(s) and comparator vehicle locations for resolution on New Model Program. ? Product related / non- plant controllable issues will be driven for design resolution. Module IV All RED Ergo ISSUES Virtual Manufacturing Process ? Manufacturing & Ergonomic Engineers are triggered to review every part. ? All parts assessed on reach, hand clearance, and strength. ? Our vision: to utilize a system within the virtual world that would prevent assembly ergonomic issues from reaching the production lines of tomorrow. Module IV Virtual Manufacturing Process ? Example of a DPA Check: Module IV Virtual Manufacturing Process ? Evaluating reach to C-Pillar, part falls within reach envelope and is considered acceptable: Module IV Virtual Manufacturing Process ? Evaluate reach and hand clearance to mate the centre console electrical connector: ? Fails preliminary filter for clearance and reach ? Next steps: ergonomic deep dive. Module IV Virtual Manufacturing Process ? Ergonomic Deep Dive: ? Reach is acceptable ? Clearance is unacceptable: recommendations provided for design change. Module IV Ergonomic Risk Factor: Force ? How is it measured? ?Force Gauge ?Instrom ? What does it feel like? ?Hands on activity 11 Module IV Ergonomic Risk Factors ? How do you identify ergonomic issues during Physical Builds / What should you look for? ?Hands on activity / examples at Buck (or videos from Genk) ?Typical issues identified during Physical Builds: ? Pushpins ? Shipping caps ? Clips ? Hand clearance 12 Module IV Physical Build Process ? Program Ergonomist supports Physical Builds from to ?, , , ?Review issues identified during builds, as well as any identified for follow-up from Virtual Process. Module IV Physical Build Process ? Most issues (force, reach/posture, clearance, repetition) are identified by Product Specialists ? You are our eyes and ears! ? These issues get added to the Whiteboard – by Product Specialists and/or Supervisor ? Ergonomist will then conduct ergo analysis, provide ergo specification/target and work towards resolution with Engineers and Product Specialists ? Issues are entered into AIMS for issue tracking and resolution Module IV Physical Build Process ? What can you do to assist? ?Be aware of ergonomic risk factors: force, posture, clearance, repetition ?Ask yourself if you or your fellow operator could do this job safely all day long? ?Get your issues up on the Whiteboard ? The earlier the better, don’t wait! ?Let the Ergonomist know your issues and suggestions Module IV Issue Tracking & Resolution ? AIMS ? Detail on the issue is important, especially when there are multiple variants and the issue may only apply to certain variants and not all. Module IV Assembly Ergonomics Matrix Physical Build Issue – Hand Clearance S197 2011 Air Cleaner to Throttle Body Concern: Operator hits fingers on stud when installing Air Cleaner to Throttle Body. Design Resolution: Changed an engine stud to a bolt to improve hand clearance Physical Build Issue – Force C346 2012 Headliner Clips Concern: High insertion efforts to install the headliner Design Resolution: Design change to the clip. New clip reduced insertion efforts to approximately half (7lbsf/31N) of the old clip (17lbsf/75N). Old New Physical Build Issue – Force S197 2011 Vent Hose Concern: Insertion effort of the Vent Hose. Design Resolution: It was determined that the ID of the hose was not dimensionally controlled. The drawing was changed to add ID control process (mandrel at supplier). Tooling Reviews ? Process Flow: Module IV Tooling Reviews ? Tooling Design Checklist for Final & Body Module IV Workstation Design Checklist Module IV Rack Design ? MP&L follows Ergonomic Racking Design Guidelines ? Ergonomists may receive CAD on BCE Racks and assess rack design. ? Design changes provided to MP&L Module IV Rack Design Module IV Rack Design ? Process Flow & Virtual Review ?Assumptions: 8lbs, slide part to front of rack, 13” dolly to rack base, 5 thpercentile female ?Results: 21lbs is acceptable, 33” to last part. Module IV Rack Design Checklist Module IV ? Ergonomist, along with Product Specialists / Launch Team attend prototype rack reviews ? Design changes provided to MP&L Workstation Readiness Module IV ? There is a checklist with Ergonomic questions as part of the Workstation Readiness Process ? Currently on hold
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