leak test machines ict requirements
TRANSCRIPT
Manufacturing Engineering
General Assembly
ICT LAUNCH MANAGEMENT PLANT FLOOR DEVICE STANDARD
(MEGA.ICT-8519-10_A.01)
Leak Test Machines ICT Requirements
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 2 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
1) OVERVIEW
This document summarizes the current ICT requirements for new Leak Test Machines to be
purchased and installed in Fiat Chrysler Automobiles (FCA) US LLC Assembly Plants.
This document is managed by the ICT Assembly System Launch Management Group
(ASLM) of FCA US LLC. For the latest version of this document, please contact a member
of this group.
Please refer to the latest Corporate Controls Standards (previously known as the BOIG; Book
of Implementation Guidelines) for specific controls information.
Deviations to equipment from this document must be approved through the launch deviation
process.
2) SCOPE
This document applies to new equipment built from 12/1/2003 forward. It does not imply that
any existing equipment shall be modified to meet these requirements. It can be used as a
reference for existing equipment that is being refurbished.
3) OPERATION OF EQUIPMENT
QAS operation guideline (Refer to ICT documentation for additional requirements)
1) A standard Fill machine is CLx based
2) A single Ethernet connection is required, 2 communications ports will be utilized, and one
for solicited PFS data, the second for unsolicited QAS downloads.
3) QAS will be utilized to deliver style information to the processor.
4) Limit switches will be used by the OEM to track the position of their fill heads
5) The operation shall not be performed without a known valid VIN number
6) Pass/Fail fields should default to a Z (bypass) at the start of a cycle. As each test or
function is executed, the appropriate Pass or Fail should be entered in the correct field.
7) A Handheld scanner is required for backup; Hand scanned data will override all VIN's
currently in the machine.
8) Utilize a Panel view to allow the operator to correct failed read conditions; this Panel view
will allow the operator to enter the correct VIN number, hand scanning should be
performed prior to going to Panel-view and inputting manually the VIN
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 3 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
4) GENERAL PROCESS FLOW
This is a general process flow from the ICT perspective:
1) Vehicle enters station
2) QAS downloads unsolicited style information to processor
3) Processor acknowledges on same port that it has received the information
4) If no information received:
a) Hand Scan VIN
b) ALS (See ICT integrator for more information)
c) Manual VIN entry
5) Operator performs fill operation
6) Machine send data to PFS
5) AVI (AUTOMATIC VEHICLE IDENTIFICATION)
If a scanner is used in the system, then AVI standards apply, specifically to hardware model
numbers and the requirement for items such as beam control and stack lights.
Refer to BOIG documents 14.1.1, 14.2.2 (PLC-5 implementations) or 14.3.2 (CLx
implementations), and 14.2.3 (PLC-5 implementations) or 14.3.3 (CLx implementations), for
detailed AVI Reader Implementation information.
If the system is CLx based:
1) A Barcode reader requires an ICT Clx processor in slot 9. AVI and PFCS drivers
will be installed in this processor.
2) A QAS download with no barcode reader will require that PFCS drivers are installed
in the OEM processor and no ICT CLX is required.
3) A QAS Download will require a handheld scanner as a backup.
6) FIS (FACTORY INFORMATION SYSTEM)
This equipment is required to connect to FIS for diagnostic and production information
reporting. Use the following bitmap to configure the equipment for FIS reporting.
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 4 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
LEAK TEST BITMAP Word[Bit
Number] DINT state_code TEXT
0[02-15] FAULTED GLx WRONGPROGRAM DOWNLOADED
0[16-31] FAULTED GLx MODULE FAULT
1[00-09] FAULTED Ipxx POWER CB NOT ON
1[10-12] POWER OFF DIAGNOSTIC POWER OFF
1[13-15] POWER OFF CONTROL POWER OFF
1[16-31] POWER OFF E-STOP PUSHED/SAFETY PINS PULLED
2[00-15] FAULTED E-STOP /C-STOP /SAFETY PINS FAULT
2[16-19] PROD STOP CYCLE STOP
2[20-31] SPARES SPARES
3[00-10] FAULTED I/O RACK FAULT
3[11-31] FAULTED MRS SAFETY FAULT
4[00-09] POWER OFF MASTERRESET REQUIRED
4[10-13] OUT OF AUTO CYCLE ENABLERESET REQUIRED
4[14-18] OUT OF AUTO FAULT RESET REQUIRED
4[19-25] OUT OF AUTO NOT READYFOR AUTO
4[26-31] OUT OF AUTO WAITING FORSTARTUP
5[00-01] OUT OF AUTO NO MODE SELECTED
5[02-12] OUT OF AUTO MACHINE MODES "MANUAL/ CALIBRATEMODE/ MAINTENANCE MODE/ NO MODE….etc"
5[13-14] BYPASS BYPASS MODE
5[15-16] BYPASS ADAPTOR REMOVED PHOTO-EYE BYPASSED
5[17-22] IDLE IN IDLE STATE
5[23-27] FAULTED MOTOR OFF
5[28-29] FAULTED AIR OFF
5[30-31] FAULTED FLUID OFF
6[00-09] FAULTED FILL MOTOR OVERLOAD TRIPPED
6[10-31] FAULTED TANK xx OVERFILL FAULT
7[00-09] FAULTED VALVE O/L TRIPPED FAULT
7[10-16] FAULTED VOLUME TRANSDUCER FAULT
7[17-31] FAULTED VOLUME SENSOR FAULT
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 5 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
8[00-16] FAULTED VACUUM TRANSDRE FAULT
8[17-31] MAINT. ASSIST TANK xx OVERFILL FAULT
9[00-09] FAULTED BOOSTER EXTEND/EXTRACT FAULT
9[10-15] FAULTED ADAPTER CLAMP PRESS LOW
9[16-25] FAULTED ABS CPU FAULTS
9[26-31] SPARES SPARES
10[00-31] MAINT. ASSIST TANK xx LOW FAULT
11[00-15] FAULTED VACUUM SENSOR FAULT
11[16-31] SPARES VACUUM FAULTS/ALARMS
12[00-15] FAULTED PRESSURE SENSOR FAULT
12[16-31] FAULTED FILLOVER-PRESSURE FAULT
13[00-31] SPARES SPARES
14[00-15] FAULTED xxxNxx SHORTED SOLENOID FAULT
14[16-31] FAULTED xxxNxx OPENSOLENOID FAULT
15[00-31] FAULTED DNETNODE xx FAULT
16/17[0-31] FAULTED PFCS FAULTS
EX. MAINT. ASSIST PFCS DRIVER'S FAULTS
EX. MAINT. ASSIST PFCS SOL.RESPONSE ERROR
EX. MAINT. ASSIST PFCS SOL.MESSAGE ERROR
EX. MAINT. ASSIST PFCS SOL. MESSAGE RESP. TIMEOUT
EX. MAINT. ASSIST PFCS UNSOL. RESPONSE ERROR
EX. MAINT. ASSIST PFCS UNSOL. MESSAGE ERROR
EX. MAINT. ASSIST PFCS UNSOL. MESSAGE RESP. TIMEOUT
EX. MAINT. ASSIST PFCS NOCLIENT COMM DETECTED
EX. MAINT. ASSIST PFCS ETHERNET SLOT ERROR
EX. MAINT. ASSIST PFCS ETHERNET WCC IP ERROR
EX. MAINT. ASSIST PFCS UNDEFINED STYLE RECEIVED
18[00-31] FAULTED E-NET COMMLOST TO CLX(xxx) FAULTS
19[00-10] ALARM STYLE CHANGED MANUALLY
19[11-15] FAULTED HMIxx COMMUNICATION LOST
19[16-19] STARVED BLOCKEDUP STREAM
19[20-23] BLOCKED DOWN BLOCKED DOWNSTREAM
19[24-31] ALARM PROCESSOR's ALARMS/CLx BATTERYLOW,….,etc
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 6 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
20[00-15] FAULTED MODULES FAULTS
20[16-31] SPARES SPARES
21[00-31] QUALITY ALERT CYCLES FAULTS
EX. QUALITY ALERT ADAPTOR VACUUM TEST CYCLE FAULT
EX. QUALITY ALERT INITIAL PRES. CHECK CYCLE FAULT
EX. QUALITY ALERT LEAKE TEST OVERALL TEST (P)ass/(F)ail
EX. QUALITY ALERT VACUUM LARGE LEAK CYCLE FAULT
EX. QUALITY ALERT VACUUM SMALL LEAK CYCLE FAULT
EX. QUALITY ALERT FINAL VACUUM CYCLE FAULT
EX. QUALITY ALERT VACUUM LEAK DECAY CYCLE FAULT
EX. QUALITY ALERT FILL ABORT CYCLE FAULT
EX. QUALITY ALERT FILL TIME EXCEEDED CYCLE FAULT
EX. QUALITY ALERT STABALIZE TEAT (P)ass/(F)ail/(Z)NO TEST
EX. QUALITY ALERT AIR TOLERANCE ALARMS
EX. QUALITY ALERT AIR PRESSURIZATION TEST(P)ass/(F)ail/(Z)NO TEST
EX. QUALITY ALERT FILL OVERPRESSURE CYCLE FAULT
EX. QUALITY ALERT FILL VOL.< MINIMUM CYCLE FAULT
EX. QUALITY ALERT/FAULTED PREMATURE PRESSURE FAULT
EX. QUALITY ALERT/FAULTED HIGH CAR PRESSURE FAULT
EX. QUALITY ALERT FILL VOL.> MAXIMUM CYCLE FAULT
22[00-01] MAINT. ASSIST PARAMETER CHANGES ADJUSTMENT/MODIFICATION
22[02-03] MAINT. ASSIST FLUID FILL PASS/FAIL-QUALITY ALERT
22[04-05] MAINT. ASSIST PARAMETER SCREEN NOTIFICATION/CHANGES USED BY PASSxxx
22[06-07] MAINT. ASSIST NOTIFICATION PASS. CHANGED
22[08-09] MAINT. ASSIST TIME COUNTER EXCEEDED LIMIT -MAINT. ACTIVITY
22[10-13] MAINT. ASSIST CALIBRATION CHECK/VERIFICATION VALUES CHANGED
22[14-15] MAINT. ASSIST FLUID PRESSURE SUPPLIES LOW-"UNDER SET POINT"
22[16-17] MAINT. ASSIST PORTABLE PUMPING STATION TOTES LOW
22[18-19] MAINT. ASSIST PORTABLE PUMPING STATION TOTES EMPTY
22[20-31] MAINT. ASSIST SPARES
23[00-31] POWER OFF/FAULTED/ALARM CIRCUIT BREAKERS/FUSES ALARMS
24[00-31] FAULTED SPARES
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 7 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
25[00-31] FAULTED SPARES
7) PFCS (PLANT FLOOR COMMUNIATIONS SYSTEM)
The device shall conform to PFCS Vendor Specifications:
1. The connection to PFCS shall be made via Ethernet (TCP/IP). (Must be made through a
dedicated NIC, not through a switch or router internal to the machine)
2. Have a unique IP address assigned by the plant.
3. Have a unique Machine ID(s) and DCNO Port(s) assigned by the Plant ICT group.
4. Use PFCS group-certified communication software (a combination of the hardware,
firmware and software). No device will be connected to the FCA US LLC network until
this certification process has been completed.
5. If operation requires unsolicited data downloads from PFCS (QAS), it must receive this
download on a separate port. One port sends data to PFS and VIN requests to AVI, the
other port receives unsolicited QAS VIN and Style data.
6. Utilize the USD communications driver.
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 8 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
8) PFS (PERFORMANCE FEEDBACK SYSTEM)
Every machine will be tested at the OEM's facility for its ability to communicate to PFS
before delivery to the assembly plant. Please contact your ICT ASLM representative for more
information.
DATA FORMAT
Start End Length Description Format
1 4 4 Machine ID, PC01, etc.
5 7 3 Ack/Nak Area (spaces)
8 13 6 Message Sequence Number (refer to PFCS vendor specs)
14 17 4 Request Type (0002)
18 21 4 Data Byte Count (position 22 to the end, exclude <CR>)
22 25 4 Number Of Records In Block (0001)
26 27 2 Filler Spaces
28 33 6 Last 6 Of VIN
34 39 6 Last 6 Of Track Number If VIN Is Zero
40 51 12 Date and Time (YYMMDDHHMMSS)
52 52 1 Leak Test Overall (P)ass/(F)ail/(Z)No Test (P/F/Z)
53 53 1 Occlusion Test (P)ass/(F)ail/(Z)No Test (P/F/Z)
54 59 6 Occlusion Test Pressure Value (iWC) (xx.xxx)
60 65 6 Occlusion Test Pressure High Limit (iWC) (xx.xxx)
66 71 6 Occlusion Test Pressure Low Limit (iWC) (xx.xxx)
72 77 6 Occlusion Maximum Pressure Value (iWC) (xx.xxx)
78 79 2 Occlusion Test Phase Evaluation Code (xx)
80 83 4 Occlusion Test Time (sec) (xx.xx)
84 87 4 Occlusion Exhaust Time (sec) (xx.xx)
88 88 1 Severe Leak Test (P)ass/(F)ail/(Z)No Test (P/F/Z)
89 94 6 Severe Leak Test Maximum Pressure (iWC) +/(xx.xxx)
95 99 5 Severe Leak Test Minimum Pressure (iWC) +/(x.xxx)
100 105 6 Fill Phase Pressure Value (iWC) (xx.xxx)
106 109 4 Fill Phase Time (sec) (xx.xx)
110 113 4 Balance Phase Time (sec) (xx.xx)
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 9 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
114 118 5 Stabilize Phase Test Pressure Value (iWC) (x.xxx)
119 122 4 Stabilize Phase Time (sec) (xx.xx)
123 127 5 Test Phase Test Pressure Value (iWC) (x.xxx)
128 132 5 Test Phase Differential Pressure Loss Value (∆iWC) +/(x.xxx)
133 133 1 Leak Rate (P)ass/(F)ail/(Z)No Test (P/F/Z)
134 139 6 Leak Rate (sccm) +/(xxx.xx)
140 145 6 Leak Rate High Limit (sccm) +/(xxx.xx)
146 151 6 Leak Rate Low Limit (sccm) +/(xxx.xx)
152 155 4 Leak Rate Test Time (sec) (xx.xx)
156 157 2 Leak Rate Evaluation Code (xx)
158 161 4 Leak Test Exhaust Timer (sec) (xx.xx)
162 164 3
Overall Cycle Time From Cycle Start to Exhaust Complete
(Sec) (xx.x)
165 166 2 Leak Test Cycle Evaluation Code (xx)
167 169 3 Temperature Reading at end of Test Time (F) (xx.x)
170 172 3 Temperature Change from Start to End of test (F) (xx.x)
173 173 1 Leak Tester Used (1,2,3) or (A,B,C) (x)
174 174 1 Operator Abort During Cycle (Y)es/(N)o (Y/N)
175 175 1 Late Start (Past Start Zone) (Y)es/(N)o (Y/N)
176 176 1 End of Travel Actuated During Cycle (Y)es/(N)o (Y/N)
177 177 1 (H)and Scanner/(Q)as (x)
178 179 2 Internal Program Style Selected (I28) (xx)
180 181 2 Broadcast/QAS Download Style Received (xx)
9) QAS DOWNLOAD
QAS Downloads will be sent unsolicited on the machine ID ending with a letter (example:
DF0A). A handheld scanner shall be used as a backup device should QAS not be functioning.
The handheld scanner will make its request, and gets its reply, on the machine ID ending with
a number (example: DF01).
This is a sample QAS style download for a Leak Test machine:
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 10 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
Start End Len Field Name Description
1 4 4 Machine ID’s: DF0A, DF0B…
5 7 3 Spaces
8 13 6 Message Sequence Number Refer to PFCS vendor specs
14 17 4 0003
18 21 4 Data byte count Position 22 to end, exclude <cr>
22 23 2 Aa Broadcast Message Type Code
24 25 2
Bc
B=Model year
C=plant code
26 31 6 Last 6 of the VIN
32 41 8 Label Barcode
42 43 2 Vehicles status
44 49 6 Track Sequence number
50 51 2
Style download to device 00 – Invalid style
01-89 plant specific engine type
90 No Op condition
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 11 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
10) ACCEPTANCE CRITERIA
This is a summary of the ICT acceptance criteria required of the vendor; please refer to the
FCA US LLC Do’s and Don’ts for more detail.
1. PFCS certification must be completed before:
The device can be attached to the plant network
PFS data certification can be conducted
2. PFS certification must be complete before the device ships to the plant.
3. AVI standard point certification must be followed if an AVI barcode reader is used;
this includes testing at the OEM prior to equipment shipping.
4. FIS certification is required.
5. The following line items are examples of what must be tracked in the OEM timeline:
1. ICT Hardware Design
2. ICT Software Design
3. ICT Communications Testing At FCA US LLC (PFCS)
4. ICT System Testing At OEM (PFS Functionality)
5. ICT System Testing at FCA US LLC Assembly Plant
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 12 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY
DOCUMENT REVISIONS
Doc.
Rev.
Date
Doc.
Rev.
Number
Doc. Rev.
Description
Section No.
Revised
5/4/17 2.1 Change Chrysler to FCA US LLC All
Added step 3 in section 7. 7
Updated PFS Data String 8
6/26/17 2.2 Added FIS bit map 6
5/08/19 2.3 Updated PFS Data String 8
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Leak Test Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 13 of 13 Revision: 2.3
Document: Leak Test Machine Revised: 05/08/2019
Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY