manual machines equipments

8/2/2019 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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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CHECK LISTSAFETY AND ENVIRONMENT AUDIT -TRY-OUT


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TRW Automotive Ltda Machine or Equipment try-out Safety Audit


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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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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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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

manual machines equipments

Documents