AZ Tooling Standards Check-Off sheet ver 1.4
	Refer to www. azautomotive             .com	AZ Representative(s):	Compiled by D. Bacon Weld&AssyMgr 586 880 2050
		Date of first evaluation:
		Tool description:
	Tooling Standards Reference		OK	Variance allowed
		15.0 Design for Manufacturing Ergonomic Guidelines:		NG	N/A	x
	15.1.1.	Are the followings maximums within specifications?
	15.1.1.1.	Two handed lift max = 20 lbs
	15.1.1.2.	Two handed push/pull max = 44 lbs (24 lbs sustained)
	15.1.1.3.	Two handed carry max = 30 lbs
	15.1.1.5.	Lateral force at arm full extension max = 15 lbs
	15.1.2.	Are the following tasks within guidelines?
	15.1.2.1.	Horizontal carry distance max = 20 ft
	15.1.2.2.	Horizontal reach max = 20 in
	15.1.2.4	Horizontal reach is minimized at lift or lower point?
	15.1.2.5.	Vertical hand travel is minimized at the lift or lower point?
	15.1.2.6.	Frequency of lifts are minimized?
	15.1.2.7.	Holding the weight overhead is minimized in weight and duration?
	15.1.2.8.	The need to push or pull is minimized?
	15.1.2.9.	Is gravity used wherever possible to move material?
	15.1.2.10.	Can a lift/lower operation be converted to a carry/push operation with a conveyor?
	15.1.2.11.	Can a carry operation be replaced with a push/pull with a slide?
	15.1.2.12.	Can a pull be replaced with a push operation?
	15.1.3.	Concerning Dunnage:
	15.1.3.1.	Material easy to grasp with one hand?
	15.1.3.2.	Operator does not have to step up or down with parts?
	15.1.3.3.	Material handling racks have lightweight returnable dunnage and/or counter weighted dunnage bars, each weighing a maximum of 14 kg (30 lbs.).? The material is oriented in assembly position.?
	15.1.3.4.	Returnable dunnage has interchangeable cap and base. ?
	15.1.3.5.	Dunnage layer separators that require rotation for high-density stacking returns are not recommended.
	15.1.3.6.	Does dunnage have a pick up point near the center of gravity?
	15.1.4.	Material Handling Devices:
	15.1.4.1.	Manual handling of materials is minimized?
	15.1.4.2.	Articulating arm and lift device designs include consideration of the product, dunnage, production rate, shop floor layout, Ergonomic Guidelines, Tooling Do’s and Don’t’s, MTI and SMI Safety Standards, and test trials of actual plant conditions?
	15.1.4.3.	Pushcart have max caster diameters? Can 10" be considered? Push handles are 36 to 44" above the floor?
	Tooling Standards Reference		OK	Variance allowed
		15.0 Design for Manufacturing Ergonomic Guidelines:		NG	N/A	x
	15.1.5.	Handles:
	15.1.5.1.	One-handed cut-out handles have a min 5" in width with a 2.5" hand clearance?
	15.1.5.2.	two-handed cut-out handles have a min 10" in width with a 2.5" hand clearance?
	15.1.5.3.	If the hand must fully encircle the handle, its diameter must be 1.5" or less.
	15.1.5.4.	For loads up to 5 lbs., the minimum handle diameter is 0.25" For loads between 15-20 lbs minimum is 0.75" For loads over 20 lbs., minimum is 0.5" Are handle diameters as close as possible to 1.5"?
	15.1.5.5.	Are handles at or above the center of gravity?
	15.1.5.6.	Do loads over 10 lbs have good "hand coupling"? (see 15.2.2.4.)
	15.1.5.7.	Unstable loads weighing more than 40 lbs. have a good hand coupling for multiple person lifting?
	15.1.5.8.	Handles don't slip out of hands?
	15.2.1.	Are manual forces required within the following?
	15.2.1.1	Maximum pinch force is 2 lbs.
	15.2.1.2.	Max push button force is 3 lbs.
	15.2.1.3.	Eliminate palm buttons where possible.  When necessary, select REES low force 8.5 N (1.9 lb.) palm buttons # 04957-012, for palm buttons cycle initiation applications.  The spacing between the palm button should not exceed 61 cm (24").  Static force application to palm buttons must not exceed 4 seconds in duration per cycle.
	15.2.1.4.	Maximum hand crank control forces are 5 lbs.
	15.2.1.5.	Eliminate hand tool feed force. (Consider using weld nuts and the use of hex or torx head rather than slotted or Phillips head screws.)
	15.2.1.6.	Make levers as long as practical to maximize mechanical advantage. The maximum manual lever force requirement is 29 lbs.
	15.2.2.1.	The sealer or paint gun trigger grip force is 5 - 25 N (1 - 6 lbs.).  Two finger activation triggers are preferred over one finger triggers. Thumb trigger activation devices are not recommended for repetitive operations. Articulating surfaces such as cycle buttons, levers or triggers shall be designed to minimize contact stress on the skin surfaces while providing positive off -- on differentiation sensory feedback.
	15.2.2.2.	Maximum grip strength is achieved with a hand tool grip span between 7.5 - 8 cm (2.9" to 3.1").  The maximum grip force is 45 N (10 lbs.).
	15.2.2.3.	Manual hand tooling with hinged design such as pliers must be equipped with appropriate spring loaded return assist mechanisms, when assigned to be used on a frequent cyclic basis
	15.2.2.4.	Make the tool handle diameters as close as possible to  4 cm (1.5") with a minimum of 11.5 cm (4.5") in length. Surface materials must have a high coefficient of friction to minimize the required grip force. The holding and controlling surface of the tools should be designed without deep grooves, sharp edges or fluted finger surfaces.  For a tool used with a power grip, the tool must be designed, whenever possible, with an oval shaped handle 3 cm by 4.5 cm (1.25" by 1.75") in diameter. If an oval shaped handle cannot be used, select a circular handle of at least 4 cm (1.5") in diameter.  Tool handles should be equipped with a flange to prevent the tool from slipping out of the hand. Tools in which an axial force is applied such as punches should be equipped with a 15 mm (0.6") flanges to prevent the hand from slipping off the handle and to guard the hand from hammer contact and collision with a rigid surface.
	15.2.2.5.	Tool handles extend beyond the palm of the hand with a minimum length of 4.5"?
	15.2.2.6.	Hand tools have padded and rounded surfaces?
	15.2.2.7.	Use four-finger throttle on right-angled, crow foot and tube nut runner power tools. Locate the power tool throttle opposite the torque reaction force for non-reversing tools or opposite the work task on reversing tools. For example if a reversing tool is used overhead the throttle should be facing downward. Consult your corporate power tool specialist for further assistance.
	Tooling Standards Reference		OK	Variance allowed
		15.0 Design for Manufacturing Ergonomic Guidelines:		NG	N/A	x
	15.2.3.1	Are power tools AZ Approved?
	15.2.3.2	Manually handled tools have minimum weight and ballanced in the "in use" position?
	15.2.3.3	Hand tool have minimal vibration? (Ref ISO 5349.2)
	15.2.3.4	Are "pulse tools" used in preference ove others?
	15.2.3.5	Are swivel couplings used where needed for multiple positioning?
	15.2.3.6	Air tool exhaust is directed away from user?
	15.2.3.7	Maintenance areas easily accessed?
	15.2.4.1	Pneumatic nut runners shut off when torque is reached?
	15.2.4.2	Reaction bar used when right angled tool's torque exceeds 50 Nm (37 ft lbs)?
	15.2.4.3	Aluminum reaction bar on pistol grip tools exceeding 30 Nm (26 ft lbs)?
	15.2.4.4	Aluminum reaction bar or articulating arm on in-line tools exceeding 16 Nm (14 ft lbs)?
	15.2.5.1	Tools over 25 lbs (or 7 lbs, used frequently) have a lift assist?
	15.2.6.1	Operator controls are minimized?
		Located between 36 and 48" above the surface?
		Can operate with gloves on?
		Used as in chart in AZ Tooling Standards?
	15.2.6.2	Controls located in order of importance, frequency and sequence of use?
		Digital displays for precise values?
		Analog for monitoring rate of change and range?
		Color coded dials indicate operating conditions?
	15.3.1.1	Job designed to use a variety of muscles and positions?
	15.3.1.2	Can both hands be used?
	15.3.1.3	Whole body vibration minimized?
	15.3.1.4	Can worker avoid being inside vehicle?
	15.3.1.5	Worker does not have to twist?
	15.3.1.6	Worker does not have to walk backwards?
	15.3.1.7	Max downward two handed pull is 24 lbs?
	15.3.1.8	Can worker keep wrists straight?
	15.3.1.9	Can worker's palms keep facing each other (not up or down)?
	15.3.1.10	Workers upper arms stay against the body, in vertical position?
	15.3.1.11	Are highly repetitive tasks automated?
	15.3.1.12	If there is an articulated arm seating device, does it meet the referenced guideline?
	15.3.2.1	Tools kept on front of the workers?
	15.3.2.2	Eliminated any reaching behind the worker?
	15.3.2.3	Frequently used objects near the worker?
	15.3.2.4	Heavier objects close to the worker?
	15.3.2.5	Operator does not have to step up and down?
	15.3.2.6	Display screens between 48" and 60"?
	15.3.3.1	Is task close to optimal working height of 41"?
	15.3.3.2	Can the worker stay within the recommended work envelope of 36" to 48" above the floor?
	15.3.3.3	Are there fixtures to support items being worked on?
	15.3.3.4	Platforms provided where the work area cannot be lowered?
	15.3.4.1	Are the reach areas suitable for the smallest users?
	15.3.4.2	Is horizontal reach distance less than 20"?
	15.3.4.3	Are frequently used parts within 15" of worker?
	15.3.5.1	Do the clearances work for the largest user of this station?
	15.3.5.2	Minimum of 18" between moving and fixed surfaces?
	15.3.5.3	Is there 80" of clearance above the floor?
	Tooling Standards Reference		OK	Variance allowed
		15.0 Design for Manufacturing Ergonomic Guidelines:		NG	N/A	x
	15.3.5.4	Is there foot clearance of 6" depth, 4" height for the worker?
	15.3.5.5	Are walkways at least 28" wide?
	15.3.5.6	Does worker handling material have a cylindrical workspace of 48" diameter?
	15.3.5.7	Is the minimum workspace at least 27" in diameter?
	15.3.6.1	Are auditory signals used when a quick response is necessary?
	15.3.6.2	Are auditory signals at least 15 dba above background level (in the plant)?
	15.3.7.1	Are vision systems considered for complex repetitive inspection tasks?
	15.3.7.2	Ias artifical light provided?
	15.3.7.3	Is normal vewing distance between 13' and 28" (ideally 18")?
	15.3.7.4	Are there minimal blind or hidden assembly areas?
	15.4.1.	Does the digital simulation accomodate 95% of the manufacturing population?
	15.4.2.	Is the max metabolic energy consumption less than 4.5 Kcal/minute?
	15.4.3.	Are material handling tasks acceptable to 75% of the female population?
	15.5.1.	Did the supplier conform to the requirements and responsibilities in this paragraph, by making every effort to comply with all of the above guidelines?