Download - Manual Machines Equipments
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Date: June30, 2009Revision No.: 00Resp.: Joo MendonaFile : EM_08.docPage 2 of 32
EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
NBR NM 272 Machines Safety Protections General requirements for fixed and movable
protections project and construction.
NBR NM 273 Machines Safety Interlocking associated to protection devices Project and
selection principles. NBR 5410 Low Voltage electric installations.
NBR 13536 Plastic and elastomers injection machines Safety technical requirements.
NBR 13759 Machines Safety Emergency Stop Equipments Operational features Projects
Principles.
NBRNM-ISO 13852 Machines Safety Safety distance for dangerous zones access impeding to
upper limb components.
NBRNM-ISO 13853 Machines Safety Safety distance for dangerous zones access impeding to
lower limb components.
NBRNM-ISO 13854 Machines Safety Minimum clearances to human bodys parts smashing.
NBR ISO 13855 Bodys parts approaching speed Safety distances. NBR 13930 Mechanical presses Safety requirements.
NBR 14009 Machines Safety Risks evaluation principles.
NBR 14152 Machines Safety Both hands operated devices Working features and project
principles.
NBR 14153 Machines Safety Safety related control systems parts General project principles.
NBR 14154 Machines Safety Unexpected start prevention.
NBR 15417 Pressure vessels In-service safety inspection.
7. DOCUMENTATION
A Machine or Equipment manufacturing, assembling, installation and delivery time-schedule shall be
supplied within 10 (ten) days counted from the purchase order placement.
All manual (operation, programming, maintenance, mechanical, electrical, etc.) shall be in the
Portuguese Language.
Machines or Equipments foundations drawings, transportation standards, leveling, as well as
templates (models, 1:50 scale) shall be forwarded to TRW, at least 30 (thirty) days before machine or
equipment deliver. Should such deeds do not exist, a TRW shall not answer for occasional caused
damages.
Equipments accessories templates, (tank, filters, hydraulic unit, control boards, etc.). shall be
supplied in *.DWG (AUTOCAD) format.
All Machine or Equipment shall be accompanied by its respective geometric control, which shall bere-done after its installation at TRW.
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
OBS.: Reports are suppliers responsibility, under TRW supervision. Clearances shall be informed TRW
together with the purchase order.
When delivering the Machine or the Equipment, its suppliers shall also deliver a replacement list of
those parts considered as being critical and of greater wear, with the technical description of the listed parts
as well their Brazilian suppliers contact particulars, as well as MTBF and MTTR analysis.
Predictable as well as Preventive Plans Spreadsheets shall be supplied within 2 (two) weeks before
Machine or Equipment deliver, contemplating mechanical and electrical items periodicity, Machines status
for such plan performing and each plans activity respective execution time.
A Lubrication Plan Spreadsheet shall be supplied within two (2) weeks before Machine or Equipment
deliver, with a manual lubrication points lay-out, lubrication periodicity, Machines status for such plan
performing and each plans activity respective execution time.
Software as well as communication cable (clp, ihm, pc, etc...) shall be supplied together with the
Machine or Equipment.
Together with the Machine or Equipment shall also be supplied:
Pneumatic, hydraulic drawings as well as Electric Diagrams (Monofilar Diagram NR 10).
General Manuals
Cycles Diagram
Software Commented List
Specific mechanisms and devices drawings.
CD copy of all software and programs related with the Machine and its equipments/accessories.
Should it possess any type of pressure vessel, deeds related with NR 13 and NBR 15417 shall be
supplied.
ART (Anotao de Responsabilidade Tcnica Technical Responsibility Register) together with
collection (payment) receipt.
All outlines, manuals, lists, drawings and diagrams shall be supplied in a reproducible CD together
with two printed copies.
In the specific case of Assembly Lines, the supplier shall deliver the operating descriptive flow-
chart of each lines working place for any failure point evaluation aiming further maintenance
intervention.
OBS: All supplied mechanical drawings shall be separated by places/operations for items research
facilitating.
EX: Place No. 1 Assembly Bench
Place No. 1, Op. 20 Riveting device,
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
and so on.
8. ELECTRIC,ELECTRONIC SYSTEM
Inlet required voltage for Assembly Benches shall be 220 Vac / 60 Hz (Three-phased or Bi-phase).
Inlet required voltage for Machines shall be 440 Vac / 60 Hz (Three-phase).
Control voltage shall be 24 Vac or 24 VCC.
One sq. meter or greater surface boards shall enclose fluorescent lamps with door switch and
protection fuses, provided with a connection independent from the general control.
Boards shall be made with dust-proof gasket, heavy-duty, as well as with 165 degrees frontal doors
minimum opening.
Board funds shall be removable and shall have 85% maximum use rate.
Control circuits shall be made in order to, in voltage return cases, machines and installations may not
spontaneously restart, unless clearly required by the general switch operation.All control and motor circuits shall possess a three-phase circuit breaker, for 600V, external handle
operation, placed at the frontal door of the electric board, sized for operation under load and provided with
padlock hobble.
All electric boards shall have a 110 / 220 Vac - 6 A outlet, for instruments connecting, with general
switch dependant feeding and a voltage gauge.
All components shall be clearly identified, as showed in the electric diagram (conductors ringing).
Electronic equipments shall be able to work with:
Net voltage oscillation 10 %
Room temperature + 5 C to + 45 C; an air conditioning appliance shal l be installed if needed.
Electronic controls must be able to be installed near to cables bearing appreciable current loads or to
welding machines or to other electric controls in general, with no interference suffering.
Possibility of inserting electronic control boards in a wrong groove shall be avoided through
appropriated safety measures.
All Machine or Equipment electric/electronic equipments shall be grounded.
Cables shall be flexible, thermoplastic 600 V insulation, obeying to the following color code:
a) Phases Black
b) Grounded neutral Yellow/Green
c) Control 110 Vac Red
d) Control 24 Vcc Blue
e) Control 24 Vac Gray
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Date: June30, 2009Revision No.: 00Resp.: Joo MendonaFile : EM_08.docPage 5 of 32
EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
All electric conductors shall be clearly identified with numbers and engraving as well as with same
denomination used in electric diagrams, which encloses terminals where they shall be connected.
Components Options: 1 / 2 / 3 /
General Circuit Breaker Moeller / ABB / Siemens / Cutler-Hammer
Fuse Siemens / Legrand / Weg
Circuit breakers Moeller / Siemens / Cutler-Hammer / FAE
Contactors Siemens / Telemecaniq / Moeller
Control buttons ACE / Blindex / Moeller / Cutler-Hammer / Banner
Signalization ACE / Blindex / Moeller / Cutler-Hammer
Digital Indicators Coel / Digimec / Euro-Control / Gefran / Transtec
Sensors Balluf / Sense / Festo / Sick / Banner / Turk
CLP / IHM Moeller / Rexroht / Allen Bradley / Altus
OBS.: For all cases, the software source shall be saved in the memory card.
CLP with Redundancy Pilz
CNC Control Fanuc / Siemens / Mazatrol
Inverter/Servomotor Rexroht / Parker / Wrg
End-of-track switch Euchner / Sick / Banner / Siemens / Telemecaniq
(all with positive rupture)
Safety Relay (Class 4) Pilz / Banner / Sick
Simultaneity Control (Class 4) Pilz / Banner / Sick Safety switches (Class 4) Pilz / Banner / Sick
Optical actuating buttons Pilz / Banner / Sick
Electronic screw-driver CP / Bosch/Rexroht / Atlas Copco
Vision system Vision & Control / DVT/Cognex
Optical barrier Leuze / Banner / Sick
(all Class 4 and 14 mm resolution)
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Date: June30, 2009Revision No.: 00Resp.: Joo MendonaFile : EM_08.docPage 7 of 32
EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
Emergency control buttons
Class 4, positive rupture action and feedback, additional safety, should the contact block be not
positioned, the machine does not start.
For EMERGENCY STOP, it shall be red colored, mushroom shape, blockage equipped, yellow
indication ring and letters in red (emergency) heavy duty and ease of access, placed in the control board as
well as in the main service points.
For ON/TOUCHES function, it shall be green, heavy duty and ease of access.
For CYCLE function, it shall be black, heavy duty and ease of access.
Motors
They shall all be high efficiency motors.
They shall all be fully sealed, with outside ventilation.
Motors start shall be: up to 7,5 CV - direct. Over 7,5 CV as needed (star/delta, compensation control,
etc.).
Electric cables with inlet voltage shall be directly connected to the General Switch Breaker, at its
upper part, and shall not pass through connection terminals.
Actuation buttons shall be optical type (equal/similar to SOFT SWITCH of Banner), provided with
simultaneity control, upper part protection and obliging the operator to stay with his hands on actuation
buttons until the device/machine shall have ended its advancement. Redundant class 4 control and
ergonomic actuations (when removing hands from buttons the resources shall block in current position
should the work cycle have not started yet).
All electric boards shall have an informative panel showing working voltage and general switch;
according to board size, following size standard shall be used: 17 X 24 cm or 08 X 12 cm, also applied to
remaining actuation controls of size compatible with the board.
Presses or similar shall be provided with all controls of both hands actuating, light curtain,
emergency buttons, safety switches, maximum redundant safety (class 4) valve vas well as ball-rollers on
table base for stamping dies change.
OBS: Relays class 4 (curtain, emergency, safety switches, etc.) shall also be load monitoring, i.e., of
two positive rupture contactors.
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Date: June30, 2009Revision No.: 00Resp.: Joo MendonaFile : EM_08.docPage 8 of 32
EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
9. HYDRAULIC SYSTEMComponents: Options: 1 / 2 / 3 /
Pumps REXROTH / VICKERS / EATON
Filters HDA / BARRA
Gates REXROTH / VICKERS / EATON
Hoses/ Connections GATES / AEROQUIP
Thread standards GAS / NPT / BSP
OBS: Presses and similar shall possess monitored hydraulic safety gates (class 4) as well as no-return
gates.
Hydraulic oil temperature shall not exceed 50 C in a 24 hours shift. Should this not be assured by
the supplier, this shall install an oil cooling system to attend such aforementioned specification.
In order to facilitate the working pressures control, as well as to defects find, either pressure gauges
in main circuits or a sole pressure gauge with circuit selecting switch shall be installed. The pressure
gauges shall possess circuit insulator gate.
All equipments shall be identified as shown in the pneumatic diagram.
Automatic systems shall inform feedback need, as well as possess an interlocking to avoid machine
cycling, in hydraulic missing case, pump failure, etc., i.e., in any system abnormality that may jeopardize
the machine operation due to hydraulic oil missing.
Refrigeration requiring equipment shall possess individual refrigerating units.
Flow control gate that automatically closes or disconnects after a piping/hosing rupture.
The noise generated by the hydraulic unit/pump cannot exceed 75 dB.
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
10. PNEUMATIC SYSTEMComponents Options: 1 / 2 / 3 / ..............
Gates SMC / Festo / Ross (Redundancy safety system)
Filters SMC / Festo
Conservation Unit SMC / Festo
Pneumatic screw-driver Deprag / Bosch / Atlas Copco / Desoutter
Vacuum Governors SMC / Schmalz
Piping SMC / Festo
Connections SMC / Festo
Pressure Transducers Smar / Gefran / Wika
Vacuum Pump PIAB
Flow and Pressure Drop Gauges Uson / Ateq / Cincinnatti
OBS: Presses and similar shall possess a safety valve class 4 with dynamic monitoring and pressure
switch for minimum and maximum pressure control as well as a no-return gate to keep the devices raised
even when a pneumatic system pressure drop would occur.
Aiming to make working pressure control easier as well as to defects find, either pressure gauges in
main circuits indicating the working range (appropriated for the kind of machine or equipment) or one only
pressure gauge with circuit selection switch shall be installed.
The pressure gauge(s) shall possess a circuit separating gate as well as a system for the machine or
equipment net depressurizing (with a padlock blocking mechanism).
The pressure gauge shall possess a colored scale to identify the working pressures range.
OBS: The pressure dropping control shall be near to the operator for easy accessing.
All equipments shall be identified as shown in the diagram.
Should negative pressure (vacuum) be needed, the Machine/Equipment shall self-generate it.
The Machine/Equipment shall be designed for 6 bar maximum compressed air using, save special
conditions requested by TRW.
The pneumatic circuit inlet shall possess a governor plus filter unit for the line proceeding
compressed air.
The pneumatic system general valve shall automatically decrease equipment pressure after being
closed, shall possess a blockage option (padlock) in the closed position and shall be installed in an
operator ease of access place as well.
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Date: June30, 2009Revision No.: 00Resp.: Joo MendonaFile : EM_08.docPage 10 of 32
EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
Should there be a need for a lung in the pneumatic system, it shall obey all NR 13 (Boilers and
Pressure Vessels) requirements, which encloses test certificate and REFERENCE BOOK.
Advancement, return and vacuum circuits shall be color distinguished as follows:
Advancement circuit: blue hose
Return circuit: black hose
Vacuum circuit: white hose
All double solenoid valves shall be memory type. Use of cylinders and actuating and/or spring
operated return valves is not allowed.
Should there be cylinders/actuators movements that may put the operator in an electric failure,
power dropping and/or pneumatic line depressurization accident risky situation, only either automatic pilot
valves or solenoid operated no-return and crossed flow valves shall be used in order to avoid undesired
cylinder/device actuation as below shown (crossed flow installation referred).
CONSERVATIONUNIT INTERMEDIARYSTOPPAGEFilter Cylinder 1Lubricator No-return valve with flow governor 2Closing valve Valve 5/3 Open center 3Progression valve
Gauge with colored scale
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
11. LUBRICATION SYSTEM
The lubrication system shall be centralized and automated, with line obstruction indicator, for all
points lubrication requiring within 200 h.
The lubricants tank shall be over 200 hours capacity, before re-feeding.
The automatic systems shall inform the re-feeding need, as well as they shall posses and
interlocking to avoid machine recycling, in case of lubrication failure, pump failure, etc., i.e., any system
abnormality that may place in a risky situation the machine operation due to lack of lubricant.
The element cascade system may be used provided item 6.3 safety conditions be satisfied.
Lubricants containers, lubrication devices as well as Machine or Equipment lubrication instructions
shall be in accordance with TRW specification.
Components Options: 1 / 2 / 3 /
Centralized lubrication system Eximport / Soned / Sehi
Grease dosing devices Dopag
12. MACHINES VISUAL CONTROLS
All Machine/Equipment identifications (Buttons, locations, risks, procedures, etc.) shall be in the
Portuguese Language, which encloses plates and signalization adhesives.
Control components (pressure gauges, pressure switches, thermometers) shall possess working
range visual control as well as be located at operators ease of access/sight place.
Liquid, grease and others tanks shall possess working level visual control (maximum and minimum).
Piping shall show content identification (colors) and flow direction.
Refrigeration units shall possess a cooling fluid flow checking component.
Hand operate\d valves and gates shall possess open and close positions identification as well aspadlock blocking option only in the closed position.
Belts protections shall be made out from a belt conservation status sight allowing raw material, with
no need of belts removal.
Gyratory components (motors, pulleys) shall show rotation direction.
Nuts/bolts the maker knows may lose during operation shall be visually identified by a marking liner.
Machines shall possess Status identification (machine in cycle, machine stopped).
Mechanical risks (movable parts) shall be provided with mechanical and or electronic protections,
operators protecting from existing risks. Should there be any movable mechanical protection, there shall
also be an electronic protection, i.e., in open position, the machine/equipment shall immediately enter into
emergency situation (it shall not start).
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
13. NOISE LEVEL
The Machines allowed noise level shall be 85 DB (A), slow answer, measured with the measuring
device placed 1 meter far from the machines ground projection, with the microphone at a height of 1,5
meters from the ground. The greatest values shall be considered in accordance with the Machine emitted
sound direction. The maker shall submit to TRW appreciation, for approval, the noise control planning,
should the equipment emit noise levels exceeding the specified ones.
Allowable noise emission level for Assembly/Test Benches shall be 75 DB (A) -, slow answer,
measured with the measuring device placed at 1 meter far from the machine ground projection, with the
microphone at a height of 1,5 meter from the ground. The greatest values shall be considered in
accordance with the Machine emitted sound direction. The maker shall submit to TRW appreciation, for
approval, the noise control planning, should the equipment emit noise levels exceeding the specified ones.
14. MACHINES,EQUIPMENTS AND INSTALLATION PAINTINGUsed colors shall be in accordance with NB 54 and NR 26 Safety Signalization.
For piping, movable equipments, ducts, chimneys, stairs, protections, fences, fire fighting materials,
civil installations, Signalization Safety/ SMA 040 Procedure shall be used.
For Machines painting, following standard shall be used:
Boards: GRAY RAL 9002
Structure: BLUE RAL 5015
Movable and Protuberant Parts (movements): LARANJA RAL 2011
Protections / Steel plates works: GRAY RAL 9002
Chip drag: BLUE RAL 5015
Refrigerating and Hydraulic Units: BLUE RAL 5015
Test and Assembly Benches shall be treated in a specific item in this Manual (Item No. 12).
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
15. TRAINING
Training shall be operational type ministered. Book of such training shall be issued with all
information needed for a Machine or Equipment appropriated operation and shall point out risks and
respective due cares to be adopted during preparation and operation.
Mechanical as well as Electronic Maintenance Training shall be ministered. Book of such training
shall be issued with all information needed for TRWs maintenance technicians to have full conditions for a
Machine/Equipment intervening.
The number of persons to be trained shall be indicated by the maker, taking into consideration the
Machine/Equipment complexity as well as the operation difficulty degree, considering, however, a minimum
of 3 maintenance workers per area (electric/mechanic).
The operational training shall be made together with the TRW plant operation START and shall be
up-dated in case of alteration in equipments release.
The Mechanical and Electro-electronic training may be made either at TRW or at the maker. It shall
be made at the place that may offer the best learning conditions.Operational/Maintenance training Cost shall be enclosed in the Machine/Equipment acquisition.
16. TRY-OUT
A try-out shall be made with the TRW inspection team at the maker plant for the Machine or
Equipment releasing. 100 parts shall be produced and tested.
The supplier shall be prepared for such try-out two weeks before the Machine or Equipment delivery
date.
Two weeks before the delivery date, an audit of this manual items shall be performed.
A second try-out shall be made with the TRW inspection team at TRWs plant after installation and
START. 150 parts shall be produced and tested.After approval, maxim period of time for productivity reaching (parts per hour) as per Purpose shall
be 30 days.
The at-makers plant try-out may possibly not be made should TRW judge it unnecessary through
purchase order responsible opinion.
OBS: During the try-out removal or inhibition of the machine installed safety resources shall not be allowed.
Should they not attend the process requirements, such resources shall be adjusted before starting. Only
after such adjustment and work safety area approval, the machine would be released for the due tests.
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
17. TEST AND ASSEMBLY BENCHES
This item is embodied to the PPRPS as similar and shall attend items listed in the Convention.
Chutes or scrap boxes red painted, sensored, difficult for parts removing through inlet door and
difficult for sensor direct actuating by operator. When possible, it should belong to the machine or bench
body.
Electric cables beds and pneumatic piping.
Zinc or nickel plated 25 mil limeters steel plate surface benches.
Benches assembled with extruded anodized aluminum profiles (Bosch standard or similar).
For Assembly Benches Painting follow standard shall be used:
Electric boards Gray RAL 9002
Devices Chemical Nickel or Zinc Blue
Precision or sliding parts Black Oxidizing
Steel plate benches surfaces Chemical Nickel or Zinc Blue
Movable sets and parts Orange RAL 2011
Safety or protection grids Orange RAL 2011
Needed paintings shall be electrostatic powder or similar, provided it does not jeopardize or
contaminate the product.
To possess an appropriated support for components, related to TRW standard boxes and/or MTM
Marfinite standard boxes (that must be properly positioned, i.e., taking into consideration operators
posture, attending ergonomics requirements).
To possess an appropriated TRW standard support for work routines (similar to attached draft):
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
Signalizing lamps colors:
Green Approved parts
Yellow Parts under test
Red Faulty or rejected parts
Blue Cycle initiating condition
White Energization
Software basic requirement:
Hand operated or automatic cycle as well as audit for simulated defect standard passing (item No.
13)
Programs or products selection;
Test periods, maximum and minimum leakage specifications;
To allow test results visualizing when made and to file last part data;
In a natural manner, to make all cylinders and valves or gates actuations available, being actuation
done through IHM by pressing F7 and F9 keys, keeping activated all bench safety controls (optical
barrier, safety relays, safety blockage, etc.);
Different passwords for hand access and parameterization;
Emergency, when actuated, shall stop in current position, automatically fully depressurizing the
pneumatic net (to possess no-return valves);
IN-OPERATION INDETIFIED
VISUALIDENTIFICATION
LABEL RAIL
ISOFLEXFOLDERSSUPPORT
ISOFLEXFOLDERLETTER SIZE
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
Should light curtain emergency buttons and safety switch be actuated, the machine or equipment
shall stop in current position and posses hand operated reset, i.e., reset button shall be actuated in
order to relocate the bench in original conditions.
Reset shall be hand operated, at blue button (positioning). When actuated, it shall relocate thewhole system in cycle initial position (origin conditions;
To diagnose with two level alarm message in defects case of mechanical or pneumatic or electric
and product failures actuations (rejection, leakages, etc.);
All sensors shall be verified on what concerns their status change to assure they are not burned or
with glued contact;
Pages structure attending according to lay-out shown at item No. 12.16;
Any rejected part shall stay bound to the device; red button or release part switch actuating
needed for rejected parts releasing from device. When possible, the rejected part should
automatically be discarded.
All production scrap shall be confirmed in sensored chutes or scrap boxes for a new cyclereleasing.
APPROVED and REJECTED parts counter;
Whenever the assembly or test initial conditions would not be achieved, a red lamp shall blink and
a sounding signal emit to call operators attention. (e. g.: minimum test pressure or vacuum not
achieved);
Both-hand actuation shall be done with optical keyboards with simultaneous control safety relay
class 4 (over buttons protections should be available).
IHM with alphanumeric keyboard and a display with at least 04 lines;
Should a vacuum test application be required, the bench test shall possess equipments able to
assure all parameters indicated in test standards;
Should pneumatic and or hydraulic cylinders be used for operations performing where pressure
variation may alter the final product quality (to rivet, to form, to assemble, etc.,) the bench and or the device
shall possess some controls for it to only operate within the pressures parameterized in the IHM
(transducers, pressure switches, etc.);
Date code engraving machines approved by TRW:
Micro punching engraving system: Couth, Telesis and Technifor
All with CPU and keyboard for configuration and adjustments.
The engraver shall obey NV6-01-01 and TS1-20-02 standards.
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
Ink-jet engraving system: Willet
Every POKA YOKE device shall obey TRW E-211 Error-proof Verification specification to be
homologated.
Leakage standards calibrated whole type for simulated defects patterns making as well as for test
bench calibration shall be supplied together with leakage/sealing test benches.
IHM building reference.
SELEODE PRODUTOS
MENSAGENSDISP. 1
MENSAGENSDISP. 2
MENSAGENSDISP. xx
PEASAPROVADAS
PEASREPROVADAS
TECLAF1
MANUALDISP. 1
MANUALDISP. 2
MANUALDISP. xx
TECLAF2
PARMETROSDE MQUINA
PARMETROSDISP. 1
PARMETROSDISP. 2
PARMETROSDISP. xx
TECLAF3
RESULTADOSDISP. 1
RESULTADOSDISP. 2
RESULTADOSDISP. xx
TECLAF4
VISUALIZAODAS ENTRADASANALGICAS.- TRANSDUTORLINEAR,- TRANSDUTORDE PRESSO,-CLULAS DECARGA,-OUTROS
TECLAF5
COMANDOPARA
AVANAR
TECLAF7
COMANDOPARA
RETORNAR
TECLAF9
REFERNCIA DE ESTRUTURAO PARA O SOFTWARE DA IHM
LIVRE DESENHA
TELA P/MANUTENOSENHA: 1234
PARMETROSDE
ENGENHARIASENHA: 0531
LIVRE DESENHA
LIVRE DESENHA
F7 E F9S FUNCIONAM
NO MODO DEMANUTENO
(TECLA F2)
PASSARPADRO,
INIBE REFUGO
TECLAF6
TELA P/PRODUOSENHA: 2222
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
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ELECTRONICALLY VALID DEED
IHMSOFTWAREBUILDINGREFERENCEPASSWORD MAINTENANCE SCREEN ENGINEERING PARAMETERS PASSWORD PASSWORDFREE PASSWORD 1234 PASSWORD 0531 FREE FREE
F1KEY F2KEY F3KEY F4KEY F5KEY
PRODUCT MANUAL PARAMETERS RESULTS ANALOGIC ENTRIESSELECTION DEV.NO.1 DEV.NO.1 DEV.NO.1 SIGHT
MESSAGES MANUAL PARAMETERS RESULTS LINEAR TRANSDUCERDEV.NO.1 DEV.NO.2 DEV.NO.2 DEV.NO.2 PRESSURE TRANSDUCER
LOAD CELLSMESSAGES MANUAL PARAMETERS RESULTS OTHERSDEV. NO.2 DEV.NO. XX DEV.NO. XX DEV.NO. XX
MESSAGES MACHINE F6KEY F7KEY F9KEYDEV.NO. XX PARAMETERS
PATTERN ADVANCING RETURNAPPROVED PASSING COMMAND COMMANDPARTS REJECTED
I INHIBITIONREJECTED
PARTS PRODUCTION SCREEN F7&F9KEYSPASSWORD 2222 ONLY WORK IN
MAINTENANCE MODE
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18. AUDIT
An audit at the maker on i tems contained in this procedure shall be done 10 days before the Machine
or the Equipment deliver. Item not in accordance shall be corrected within the deliver at TRW date.
At the delivery, another audit shall be done to check first audit pending items correction.
19 SAFETY
Whatever process that could haze, vapors and particulate generate shall possess an exhaust system
as well as specific filters.
Whatever machine or equipment or device shall attend ergonomic features, i.e., height, legs room
physical endeavor, support points for upper limb components micro pauses, actuations, temperature,
components at operator range, etc...
Analysis and application of machine or equipment or bench safety controls is of makers
responsibility.
RISK EVALUATION IN ACCORDANCE WITH NBR 14153S Wound severityS1 Light (revertible)
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S2 Heavy (irreversible) fatal enclosed Categories
Starting point for riskEvaluation ofSafety control area
FFREQUENCY AND EXPOSITION TIMEF1 Rarely and or small expositionF2 Frequent to continuous and or long exposition
P Possibility of danger avoiding(they usually refer to speed and frequencywith which the analyzed part moves andthe operator distance from it
P1 possible under specific conditionsP2 little possible
Law no. 5280 states legislation observance for imported machines.
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SAFETY STANDARDS IN BRAZIL
NBR 14009
Risk appreciation principles
(EN1050)
EN 60204-1
Machines safety Machines Electric
equipments Part No. 1
General requirements specifications
NBR NM 213 - 1-2
Machines Safety
Basic concepts, general principles
for projects part EN 292 1/2/3
A TypeStandards
NBR 14154 Machines safety
Unexpected start prevention
(EN 1037)
NBR 14153 Machines safety:
Control systems parts relat
With safety, general project principles
(EN 954-1)
NBR 13760 Minimum clearances to avoidhuman body parts smashing
(EN 349)
NBR 13761 Safe distances for
dangerous zones accessing by upper limbcomponents
(EN 294)
B1 TypeStandards
Safety General Features
NBR 14152 Machines safety
B oth hands command devices
Functoinal featrures and project
principles (EN574)
NBR 13758 Safe distance for
Dangerous zones acessing to lower limbcomponents
(EN 811)
NBR 13928 General requirements for
protections projecting and building (fixed andmovable)
(EN 953)
NBR 13929 - Interblockage
devices associated to protectioins
Projects and selection principles
(EN 1088)
NBR 13759 Emergency stoppage
equipments, functional features,
project principles
(EN 418)
B@ TypeStandards
Used Components in Safety
B T\ypeStandards
NBR 13996 Blast molding machines forvoid thermoplastic articles
Articles. Technical safety requirements forProjecting and building
NBR 13930
MechanicalPresses
Safety requirementes
(EN 692)
NBR 13536 Plastic and elastomerics
Injection machines Safety technicalrequirements for projecting, building
and using (EN 201)
NBR 13867
Meat meancers
Safety requirements
NBR 13865
Alimentary pasta
cylinders
Safety Requirements
NBR 13862
Continuous conveyors
Project safety requirements
C TypeStandards
Machine and Equipment maker
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EM 08MACHINESANDEQUIPMENTS
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ACCIDENT ACCOUNTABILITIES
When work accident accountability was mentioned, it was specifically based on NBR 14153 that at
its item No. 8.5, referring to a new or re-built machine approval for production, requires the issuing of an
approval deed containing:
Names of responsible persons for the tests
The equipments used in the tests
The several tests that were made
A list of the failures and their corrections
A juridical strong phrase is present in NBR 14153, below transcript:
Results must be documented and filed in an auditable manner.
20.PRESSES AND SIMILAR
To fully obey the collective convention, technical note No. 16, NBRs and other legislation.
Logic programmable safety controller Class 4: (device in accordance with NBR 13930 item No. 4.10
and NBR 14153 item No. 6.2.5 class 4);
Such devices purpose is to press monitor and control. Having a specific technology for the segment,
in accordance with Brazilian and International safety standards, the safety CLP controls all devices related
with a press stoppage that are below described:
Based on EM 60 204-1 standard, that enhances items related to redundancy, diversity and self-test
for safe considered controls, an example may be that of an unit formed by three processors from different
makers and an efficient self-test and failures diagnosis. Such configuration only allows to operate one outlet
should the three processors present same result.
Safety valve (only monitored by the safety PLC) Class 4:
For clutch brake coupling control (safety device for presses, as per items No. 4.7 and No. 4.8 of NBR
13930);
Redundant safety device. It is self-monitored, therefore assuring the machine safe stoppage
(dynamical monitoring), with minimum and maximum pressure switch.
Safety switches (Class 4) for monitoring grids and doors that allow risk area access (movable parts);
Light curtain 14 millimeters resolution (class 4) depending upon the process it shall possess the
fluctuant blank function for the risk area access monitoring (class 4, as per NBR 14153 item No. 6.2.5)
Active optical safety device type 4 (as per IEC 61496-1, -2 and EM 61496-1, -2).
An infrared bi-dimensional radiation protection field is generated between the transmitter and the
receiver. Should this protection field be interrupted the CLP and or the safety relay is instructed to operate
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EM 08MACHINESANDEQUIPMENTS
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ELECTRONICALLY VALID DEED
in the safety mode where the safety valve is disconnected, which interrupts the movement, therefore
protecting the operator from a possible accident.
Emergency stop button with positive rupture and feed back (safety additional, should the contact
block be not properly positioned, the machine does not start). Its purpose is to do an emergency stop and
the CLP and or the safety relay shall monitor such circuit in order that, should either a cable rupture or a
short circuit happen the CLP or the safety relay shall immediately do a safety stop.
Both hands control (class 4, as per NBR 14152):
Bi-hand operation requiring device. The outlet sign will remain active until one hand would be
released. As per NBR 14152, items No. 3.5 and 7, the CLP or the safety relay monitors the synchronous
action of the bi-hands buttons, therefore assuring the command actuation only if the simultaneous actuation
time is smaller or equal to 0,5 sec.
Upper and lower dead point control (hummer monitoring):
Hummer position monitoring device for LDP (lower dead point) [PMI (ponto morto inferior)] finding
and UDP (upper dead point) [PMS (ponto morto superior)]. Only safety CLP monitors this device for safety
routine performing.
OBS: Item No. 4.9 of NBR 13930 must be observed
Safety wedge:
This device is used between tools when small maintenance services are required in them. It shall be
interconnected with the machines emergency system, i.e., i t must be outlet disconnected and placed within
the machine range area, so that once it is disconnected, the machine will not work therefore avoiding the
risk of starting the machine with the wedge in its range
Front door:
Door opening shall be made by means of a pneumatic cylinder and its blockage shall be made my
means of safety key.
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EM 08MACHINESANDEQUIPMENTS
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ELECTRONICALLY VALID DEED
21. AVAILABILITYPLAN/ASSEMBLIESRELIANCE EQUIPMENT WARRANTY AFTER DELIVERY START TO CUSTOMER.
ACQUIRED EQUIPMENTS WARRANTY BY NEGOTIATION.
AFTER APPROVAL OF FIELD TECHNICAL RELEASE CERTIFICATE.
21.1. CRITICALFEATURESFORELECTRO-ELECTRONICTARGETACHIEVING TO DELIVER BENCH OPERATION DETAILED FLOW CHART;
AUTOMATIC MANUAL CYCLE FAILURES MANAGING SOFTWARE;
NOT ALLOWED TO WORK IN CONDITIONS No. 1 AND No. 2 BUT RATHER USE TRANSITION;
TO TEST WITH MESSAGE IN IHM EACH SENSOR OF EACH WORKING PLACE SIGNALIZING;
TO INDICATE THE NUMBER OF THE ERROR, WRITTEN MESSAGE WITH FAILURE
INDICATION (SENSOR OF..);
EVALUATION OF SENSORS PLACES (NEED OF CHANCE OR PROTECTION);
TO PRIORITIZE IN IHM THE ERROR MESSAGE THAT CAUSES PLACE STOP;
MESSAGES MUST BE DEVELOPED FOR ANY USER LEVEL INFORMING;
TO START HELP SYSTEM AT IHM WITH SOFTWARE OPERATION ACCESS PROCEDURES ;
TO SUPPLY SOFTWARE SOURCE WITH COMMENTS, COMMUNICATION PROGRAMS AND
CABLE;
LINE PERIFERALS COURSES BELONG TO TRW (SMAR, ENGRAVERS, TORQUE MACHINE,
ETC);
CLP MUST HAVE ITS PROGRAM SAVED IN MEMORY CARD;
PROCESS / CONTROL PARAMETERS MUST BE INSERTED IN THE MEMORY CARD;
WHATEVER ALTERATION ( SOFTWARE / DRAWINGS AND PNEUMATIC, ELECTRIC AND
HYDRAULIC DIAGRAMS) MUST BE DOCUMENTED AND DELIVERED TO TRW WITHIN 48
HOURS;
OBS: SOFTWARE DELIVER DOES NOT ALLOW UNDER NO CIRCUMSTANCE AT ALL
EQUIPMENT WARRANTY SUSPENSION.
IN-FIELD EVALUATION OF CABLES MOVING SYSTEMS / PROTECTIONS, ETC..
EFFICIENCY;
TIME BASED PILOT RUN MUST BE INFORMED TO TECHNICAL PERSONNEL AFTER LINE
RELEASING. TWO FIRST PILOT RUINS MUST BE MADE BY THE SUPPLIER;
TO INFORM TECHNICAL FEATURES / PARTS, COMPONENTS, SPECIAL ASSEMBLIES, ETC..
SUPPLIER;
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ELECTRONICALLY VALID DEED
SENSORS STANDARDIZE / END OF TRACK KEYS RELATED TO MODEL USED TO FULL
EXTENT.
TIME BASED PILOT RUN MUST BE INFORMED TO TECHNICAL PERSONNEL AFTER LINE
RELEASE, TWO FIRST PILOT RUN. SHALL BE DONE BY THE SUPPLIER (WEARING ITEMS SUCH AS BELTS, SUPPORT POINT,
ETC).
23. 21.2 CRITICALFEATURESFORMECHANICALTARGETACHIEVING
IN-LINE CHECK CORRECT OPERATION (EFFICIENCY) OF EACH DEVICE;
TO PREVIOUSLY INDICATE WEARING COMPONENTS (SPRINGS, PARTS CONTACT, ETC);
TO EVALUATE OUTER INFLUENCES IN DEVICES OPERATION (PROCESS DIRTINESS,
PARTS CONTACT, ETC.);
TO INFORM TECHNICAL FEATURES / PARTS, COMPONENTS, SPECIAL ASSEMBLIES, ETC...
SUPPLIER;
ALL MECHANICS SHALL BE DIMENSIONED TO WORK Q\WITH PRODUCT TOLERANCES;
DEVICES ALIGNMENT (GEOMETRY) VERIFYING STANDARD MUST BE SUPPLIED
MOVING DEVICES / SYSTEMS DURATION MUST BE DEFINED (WEARING ITEMS);
DURATION MUST BE THE LONGEST AS POSSIBLE WITH NO NEED OF PREVENTIVE
MAINTENANCE INTERFERENCE (WEARING ITEMS);
ALL FINE ADJUSTMENTS MUST BE DONE IN MECHANICAL KNOCKER (CYLINDERS, LINEAR
GUIDES, HYDRA SHOCK ABSORBER, ETC);
ALL MOVEMENT SYSTEM MUST HAVE SHOCK ABSORBERS TO AVOID PREMATURE
WEARING;
ALL DOCUMENTATION MUST BE DELIVERED WITH CONSTRUCTIVE DIMENSIONS;
USED BOLTS STANDARDIZING, AS FOR INSTANCE: M5 TO M6 THAT IS MOST USED;
CYLINDERS DIAMETER STANDARDIZATION.
CYLINDERS LENGTH STANDARDIZING TO MAXIMUM POSSIBLE EXTENT.
RODS AMD SLIDING BUSHES STANDARDIZING.
ROLLER BALLS USED IN THE LINE STANDARDIZATION TO MAXIMUM POSSIBLE EXTENT.
TO TPM METHODOLOGY USE FOR EQUIPMENTS ABD DEVICVES ACCESSING.
ALL DEVICE / PART USED IN THE LINE MUST HAVE ITS NUMBER TYPED IN A VISIBLE
PLACE (DEVICE NUMBER / DETAIL).
POKA YOKES LISTING AND INDICATING / LINE CALIBERS WITH DIFFERENT COLOR (TRW
11 COLORS PROCEDURE).
ALL DEVICE / ASSEMBLY MUST BE PINNED AND GUIDED ON THE LINE.
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
Prepared by: Approved by: Issued by:
Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
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Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
CHECK LISTSAFETY AND ENVIRONMENT AUDIT -TRY-OUT
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
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ELECTRONICALLY VALID DEED
TRW Automotive Ltda Machine or Equipment try-out Safety Audit
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
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ELECTRONICALLY VALID DEED
Items to be audited description 1 PHYSICAL Yes No N.A.Noise Is sonorous power (noise) produced over 75 dB/A?Is it of excessive vibration?Should it emit ionizing or non ionizing radiation has it enough protectionAnd is it CNEN No. 27/04 Resolution limit off (when needed duedocumentation must be required from supplier)
Is there heat or has it hot parts with burning risk?
Items to be audited description 2 CHEMICAL Yes No N.A.Does it humidity generate?Does it dust emit ?Does it fume emit?Does it mist emit?Does it gas emit?Does it fog emit?Chemical compounds or substances use in general? (describe the risk)
Items to be audited description 3 B BIOLOGIC Yes No N.A.May it generate viruses, protozoas, bacilluses or parasites proliferation?May it provoke bacteria or funguses proliferation?
Items to be audited description 4 ERGONOMIC Yes No N.A.Does it require intense physical effort?Does it require weight manual raising and transportation?Does It require inappropriate posture?Does it require tweezers taking > 1 kg with > 10 sec. or > 30X/min. duration?Does it require taking effort > 5 kg with > 10 sec. or > 30X/minute duration?> 5 kg parts handling is it done with lif ting equipmentAre there taking points beyond taking area (range) without protruding shoulder ahead?Is it there any operation point beyond comfort area?Does it require radial deviation > 20
oand wrist angle > 30
o>>10 sec. or > 30X;min.?
Does it require wrist flexion or extension > 45o
>10 sec. or > 30X;min.?Does it require arm rotation (pronation and supination) > 150
oor > 5kg or 3X/min.?
Does require arm positioning to the back?Does it require raising hand/arm over shoulder line?Does it require neck inclination > 20
oor > 10 sec. or > 2X/min.?
Does it require column inclination > 20oor > 10 sec. or > 2X/min.?
Does it require column twist (rotate) > 30o
?Does it require lateral column inclination?Does it require knees bending > 30% of the day or > 2X/min.?Does it require toy be upstanding > 30% of the day or > 2X/min.?Does it require to raise > 20 Kg?Does it require to take 10 kg in less than 5 minutes?Is operation point at elbows navel height?Does it require static effort from operator (body partially rigid or stopped)?
Does it require repetitive movements?Are feet fully supported?Is it there employees body parts mechanically compressed?Does it require to work with raised shoulders?Does he stay with the arms elevated or semi-elevated with no support?Has it polished faces that may provoke reflex?Are handles anatomic and do handle allow full contact with hand?Has operator place room for legs?Does operator place possess support point for micro-pauses of upper limb componentswith no protruding corners (saliencies)?Are TRW standard boxes supports heights ergonomic?
Items to be audited description 5 ACCIDENTS 1 NR-10 Yes No N.A.Is electrical installation in accordance with NR-10?Has it an electric diagram?Is command actuating duly signalized on boards?Are phase cables flexible with thermoplastic insulation 690V and are they Black?Are neutral grounded cables flexible, thermoplastic insulated and Yellow / Green?
Are 110 Vac command cables flexible thermoplastic insulated 600V and Red?Are 24 Vcc command cable flexible thermoplastic insulated 600V and Blue?Are 24Vac command cable flexible thermoplastic insulated 600V and Gray?
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
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Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
Items to be audited description 5 ACCIDENTS 1.1. Main switch Yes No N.A.Has it main switch?Is it signalized (main switch and voltage)?Easy of access?Does it allow blockage (padlock hobble)?Has it 70 cm free space beyond open door?
Items to be audited description 5 ACCIDENTS 2 Simple actuation Yes No N.A.Is it there accidental actuation risk?Has it a protection?Are actuating ergonomic?Does it require strength to keep it pressed (DORI)?Are hands free before cycle end?Has it shock when starting?Are there more irregularities at start?
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
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Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
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EM 08MACHINESANDEQUIPMENTS
AQUISITIONAutomotive
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Bruno Battistella Jacques Mambro / Marcio Bueno Manufacturing Engineering
ELECTRONICALLY VALID DEED
Items to be audited description 5 ACCIDENTS 11 Others Yes No N.A.Has it manual and is it in the Portuguese Language?Has it safety recommendations and instructions?Have pressure vessels Reference book, safety book, hydrostatic test and + as per NR 13?Has it a flow control valve should the hopes break off?Have all air d ischarge point noise reducers?
Has hydraulic, pneumatic system general gate blockage placing option?Does it use combustible or inflammable products?
Items to be audited description 5 ACCIDENTS 11 Others Yes No N.A.Are moving parts, pistons, protruding parts, recessed parts, pressing, gyratory,pulleys, gears all protected?Have them protection against chip, particles and oil projection?Does safety switch actuating to current situation automatically depressurize the system?Does safety switch (of s ide doors) actuating to current position automatically system depressurizeDoes belts protection allow sight of their status without protection removing?Have fog, vapors, particles and gases generating systems exhaust system and filters?Have dies / heavy tools replacing table balls on their surfaces
OBSERVATIONSALL ITEMS IN GRAY FIELDS MUST BE CORRECTED
ACTIONSItem Description Resp. Term Obs.
Evaluation Supplier (name) SignatureAnd approval Manufacturing (name) Signatureby partakers Maintenance (name) Signature
Quality SignatureProduction (name) SignatureWork safety (name) Signature