Bosch General Delivery Specifications 2007

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General Delivery Specifications
for
Machinery and Equipment
April 2007
Machinery and Equipment (MAE) General Delivery Specifications
can also be found at
www.boschnasuppliers.com
Reference: - OP4.7.04.004
BOSCH General Delivery Specifications for Machinery and Equipment
i
General Delivery Specifications
for Machinery and Equipment
Revision 5 - April, 2007
All prior editions are obsolete and should not be used.
This document is controlled by:
Robert Bosch LLC
ChP/TEF2 - Central Technical Support
8101 Dorchester Rd.
Charleston, SC 29418
(843) 760 - 7492
[email protected]
It is the user’s responsibility to check that this document reflects the latest revision level.
Title Page
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
ii
1 Table of Contents
SECTION 1 - GENERAL PROCEDURES
SECTION 2 - PROJECT MANAGEMENT
SECTION 3 – ENVIRONMENTAL, HEALTH AND SAFETY
SECTION 4 – BOSCH PRODUCTION SYSTEM (BPS)
SECTION 5 - DESIGN
SECTION 6 - QUALITY STANDARDS & RUN-OFF CONDITIONS
SECTION 7 – ACCEPTANCE CHECKLIST
Download
SECTION 8 - DOCUMENTATION & SHIPPING INSTRUCTIONS
SECTION 9 - APPENDICES
SECTION 10 - PLANT SPECIFIC ADDITIONS
Table of Contents
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
1-1
1 General Procedures
1
General Procedures _______________________________________________________________ 1
1.1
Preface _____________________________________________________________________________ 1
1.2
Formal Quotation Requirements________________________________________________________ 2
1.3
Purchase Order and Contract Alterations ________________________________________________ 4
1.4
Work at Buyer’s Facility ______________________________________________________________ 4
1.5
Payment Schedule ____________________________________________________________________ 4
1.1
Preface
1.1.1 This specification has been written to present Robert Bosch LLC/Affiliate’s
(hereinafter referred to as ‘Bosch’) requirements for industrial equipment in an
orderly manner.
1.1.2 Supplier and any subsequent suppliers shall comply with this specification and with
"General Terms and Conditions for the Purchase of Capital Equipment" (See
Appendix 1.1).
1.1.3 It is not intended to limit or inhibit development in industrial equipment design.
Functional design of equipment shall be the equipment supplier’s responsibility.
The application of "Lean Equipment Design" principles is required. (See Section 4 –
Bosch Production System).
1.1.4 If the supplier interprets the requirements of this document or any Bosch
specification to be in conflict with Federal or State regulations, it is the supplier’s
responsibility to get clarification from Bosch’s Project Engineer.
1.1.5 Any deviation to specifications shall be documented at the time of quotation using
the GDS Deviation Request Form (See Appendix 1.2). The deviation request shall
be submitted with quotation package and shall be approved by the Project
Engineer. Subsequent deviations shall be documented via purchasing.
1.1.6 Individual locations may have plant specific requirements which can be found in
Section 10.
Section 1 General Procedures
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
1.2
1-2
Formal Quotation Requirements
1.2.1 General
Request for Quotations (RFQ) are originated by the Project Engineer and
transmitted through the Purchasing Department to the equipment supplier. The
Project Engineer shall provide process and equipment specifications adequate to
define Bosch's requirements for the particular equipment under consideration.
Quotes must be returned to Purchasing Department and must have Bosch RFQ
number. All paper quotations must be submitted in triplicate. Electronically
submitted quotes need buyer's permission.
1.2.2 Parameters of Quote for Machinery & Equipment
1.2.2.1
All production machinery must comply with General Delivery Specifications.
The quotation must include this statement:
“We agree to conform to Bosch’s General Delivery Specifications - for
Machinery and Equipment”.
If this is not possible, a request for specific deviations must be included in the
quotation and written approval of the deviations requested must be obtained
from the Project Engineer or his/her immediate supervisor before an order
can be accepted. (See Appendix 1.2)
1.2.2.2
The following information to be included:
a) Bosch RFQ Number
b) Part name(s), number(s), and/or identification number.
c) Name of Project Engineer requesting the quote.
d) Machine tool equipment supplier’s quotation number and date.
1.2.2.3
Quote shall include firm delivery, dated from the date of purchase order.
1.2.2.4
All drawings, documentation, etc., as per Section 8 shall be supplied in
English.
1.2.2.5
Quote shall provide special foundation or other site requirements.
1.2.2.6
Quote shall prove a basic timeline containing critical milestones.
Section 1 General Procedures
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
1-3
1.2.3 Itemized Prices
The following shall be itemized and separately priced on the quote:
a) Basic machine
b) Special Machine Options
c) Fixtures / Work holding
d) Perishable Tools (if requested).
e) Charges, if any, for engineering, source code, drawings, or service information.
f) Auxiliary equipment of a separable nature, such as: Hydraulics, Air Handling,
Coolant Filtration, Conveyors, etc.
g) Environmental and health control devices. This would include but not be limited
to chip removal, mist, and vacuum equipment.
h) Electrical and electronic controls.
i) Automatic gauging and size control (if requested).
j) Spare parts package.
k) Machine run-off costs.
l) Service and installation charges (if required).
m) Cost of training.
n) Warranty Information.
1.2.4 Proposal Description
1.2.4.1
The items quoted shall be accurately described by proposal drawings and/or
text. Data on obtainable production rates, (in pcs /hr. @ 85% OEE),
maximum change-over times, buffer capacity between stations, and process
and gage capabilities shall be included where applicable. Complete cycle
detail is required on each station (See Appendix 4.2 for OEE). Estimated
power consumption, coolant, water, steam, compressed air, gas, etc.,
consumption and/or flow rates required at machine must be included.
1.2.4.2
Number of pieces that will be run-off for each part number is defined in
Appendix 6.1. These are the quantity of parts that will be run at no charge as
part of the quote package, and are expected to be good parts per Bosch’s
requirements. Pieces required for set-up, tryout, or to qualify equipment shall
be supplied by Bosch.
1.2.4.3
Information required for Control System Overview (See Appendix 5.2) should
be included in proposal as much as possible. Information not available at
time of proposal must be submitted along with concept approval drawings.
1.2.4.4
Machine startup, shutdown and E-stop recovery times shall be described in
the quotation.
1.2.4.5
The supplier shall inform the Project Engineer of any known or suspected byproducts of machine fluids used which may be hazardous to health.
1.2.5 Project Completion
At the completion of each project; parts, drawings and support documentation that
belong to Bosch are to be returned.
Section 1 General Procedures
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
1.3
1-4
Purchase Order and Contract Alterations
1.3.1 Purchase orders and amendments to purchase orders are issued by Bosch through
the Purchasing Department only. No statement of intent to purchase or to amend
an existing order is a commitment by Bosch until issued by the Purchasing
Department. Any request for changes or alterations which are outside the scope of
work shall be quoted and any affect on cost or delivery shall be justified,
documented, and communicated via purchasing as soon as reasonably possible
after the proposed change request is made. Supplier shall not act on requested
modification until the revised quotation has been approved via purchasing.
1.3.2 When the product design is changed, new prints will be submitted to the equipment
supplier by the Project Engineer, with a written request to quote modification of the
equipment under construction required to comply with the revised product design;
including changes to price and delivery. After approval of the proposed modification
by Bosch, an amendment will be issued by the Purchasing Department to cover the
additional costs.
1.3.3 Acknowledgment of the order acceptance and confirmation of delivery or price shall
be received by the Bosch Purchasing Department and the Project Engineer
responsible as soon as possible, but not later than three weeks after receipt of
purchase order by the equipment manufacturer.
1.4
Work at Buyer’s Facility
See also: General Terms and Conditions for the Purchase of Capital Equipment (See
Appendix 1.1)
1.4.1 Equipment supplier to provide installation supervision or instruction to assure that
equipment is installed properly and fulfills requirements of the warranty.
1.4.2 All equipment suppliers must sign and adhere to each facility’s Contractor Safety
Declaration. This requires the supplier to follow plant-specific lock out, tag out
requirement, confined space entry, etc.
1.4.3 Welding, cutting, soldering jobs, heating and thawing with welding torches, gasoline
or gas burners, etc., are forbidden unless specific permits are obtained from Bosch.
1.4.4 Bosch draws particular attention to the fact that smoking may be restricted or
forbidden in certain areas of our plants. Safety glasses and appropriate working
attire and footwear are required within all Bosch facilities. Other safety equipment is
as required by OSHA regulations.
1.5
Payment Schedule
See also General Terms and Conditions for the Purchase of Capital Equipment,
Sections 5 and 7.3 (See Appendix 1.1)
1.5.1 Robert Bosch LLC payment schedule for the Purchase of Capital Equipment is as
follows:
a) 80% Net 30 of complete purchase price upon Delivery of equipment to specified
Section 1 General Procedures
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
1-5
Bosch Facility.
b) 20% Net 30 of complete purchase price upon Final Acceptance at specified
Bosch Facility.
Section 1 General Procedures
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
2-1
2 Project Management
2
Project Management............................................................................................................................ 2-1
2.1
Project Timing ____________________________________________________________________ 2-1
2.2
Design Review Requirements_________________________________________________________ 2-2
2.1
Project Timing
2.1.1 To ensure equipment delivery meets critical timing phases and final shipment dates,
it is the responsibility of the supplier to provide and maintain a project time line and
tracking system.
2.1.2 A draft of this timeline is to be provided with the quotation. The final timeline is to
be provided to the project engineer within 2 weeks after receipt of a formal purchase
order.
2.1.3 The project time line must be detailed enough to show all critical milestones and as
a minimum include the following items:
a)
Kick-off meeting
b)
Process flow chart
c)
Process FMEA review
d)
Preliminary design (mechanical and electrical)
e)
Preliminary design review
f)
Purchase of critical long lead-time components
g)
Final design (mechanical and electrical)
h)
Final design review
i)
Purchase of remaining material
j)
Equipment control programming
k)
Equipment control program review
l)
Receipt of purchased/produced components
m)
Floor plan layout and foundation requirement
n)
Equipment build/assembly
o)
Tryout part availability
p)
System tryout and debug
i. manual mode
ii. automatic mode
q)
Measurement system calibration
r)
Preliminary gage capability study
s)
Preliminary process capability study
t)
Documentation review
u)
Pre-acceptance at supplier
v)
Package & ship
w)
Installation at Bosch
x)
Tryout and debug at Bosch
y)
Final capability studies
z)
Final acceptance sign-off
Section 2 Project Management
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
2-2
2.1.4 The project time line is to be updated and submitted to the project engineer every
two weeks throughout the project life. It is the equipment supplier’s responsibility to
provide any action plan to correct problems that are causing significant shifts in the
time line.
2.2
Design Review Requirements
2.2.1 Design Reviews
A minimum of two design reviews will be held to insure that the project goals and
specifications are being met. The actual number of design reviews will be
determined by the project engineer.
2.2.2 First Design Review
2.2.2.1
The first design review will be a comprehensive concept design review and
preliminary PFMEA (Process Failure Mode and Effect Analysis) review.
2.2.2.2
The following points are to be discussed, whereby the supplier must make
available necessary documents:
a) Review of relevant topics of the BPS (Bosch Production System)
Assessment, (See Appendix 4.1).
b) A concept drawing of the overall machines. This drawing must show the
overall completed machine or assembly. It must have at least two views,
a plan or top view, and one side or elevation view. Sufficient detail must
be shown to convey the overall completed appearance of the equipment
including control panels. It must be drawn to scale and show overall
dimensions of height, width, length, location and dimensions of auxiliary
control cabinets, the location of the work piece or part, and the direction
of index travel.
c) Additional concept drawing(s) of all equipment operations and processes.
Sufficient detail must be shown to communicate the operation(s) of the
machine. Main components must be shown and labeled.
d) A control system overview which will contain a listing of major
components.
e) Material handling overview.
f) Review of Ergonomics.
g) Hazard assessment of robots and hazardous material (MSDS).
h) Review of Required Clearance Space, (Appendix 4.3 and Appendix 5.3).
i) Machine guarding.
j) A completed Machine Data Sheet, Appendix 2.1.
k) Literature and specifications for any major machine components that
were not elected from the recommended parts list(s).
l) Approval Prints
The supplier must provide two copies of all of the above documentation.
At the design review, the project engineer and the supplier will sign and
date each copy of the approval prints to indicate that the concepts have
been approved. Any changes or modifications that are required will be
noted on the prints. A follow-up review may be required to evaluate
modifications.
m) Completion of Design Review Checklist, Appendix 2.2.
Section 2 Project Management
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
2-3
2.2.3 Final Design Review
2.2.3.1
The final design review will be a review of all engineering documentation and
PFMEA. This review will be completed before construction of the equipment
begins.
The supplier must provide the following:
a)
Mechanical Assembly and Subassembly Drawings
b)
Detail Drawings and Parts Lists
c)
Pneumatic & Hydraulic Schematics and Parts Lists
d)
Control System Functional (Sequence) Plan
e)
Electrical Control System Diagrams, Drawings, & Parts Lists
f)
Critical and Proprietary Parts
g)
Updated Machine Data Sheet, Appendix 2.1
h)
Hazardous Material List
i)
Foundation Drawing
j)
Approval Prints
k)
Anticipated PM Requirements (Labor, Material, & Frequency)
l)
Completion of Design Review Checklist, Appendix 2.2.
2.2.3.2
The supplier must provide two copies of all of the above documentation. At
the design review, the project engineer and the supplier will sign and date
each copy of the approval prints to indicate that the concepts have been
approved. Any changes or modifications that are required will be noted on
the prints. A follow-up review may be required to evaluate modifications.
Section 2 Project Management
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
3-1
3 Environmental, Health and Safety Standards
3
Environmental, Health and Safety Standards__________________________________________ 3-1
3.1
General___________________________________________________________________________ 3-1
3.2
Safety Design Standards_____________________________________________________________ 3-2
3.3
Environmental Considerations _______________________________________________________ 3-2
3.1
General
Equipment must be designed to meet local, state, and national (federal) requirements
for Health, Safety and Environmental Protection. These government standards are to
be interpreted as minimum requirements.
3.1.1 In view of constantly changing laws, regulations, codes, and standards, it is the
responsibility of the supplier to comply with all regulations. The latest version and
applicable sections of the following standards in effect at the time of the order’s
acceptance:
a)
b)
c)
d)
e)
Occupational Safety and Health Administration, Department of Labor,
General Industry Standards, Series 1910 (latest revision).
American National Standards Institute Codes.
National Fire Protection Association (NFPA) Regulations.
National Fluid Power Association “Systems Standard for Industrial
Machinery”.
United States Environmental Protection Agency, Code of Federal
Regulations, Title 40 – Protection of the Environment.
3.1.2 A written risk assessment as per ANSI/RIA R15.06-1999 is required for all robots
prior to final acceptance.
3.1.3 All chemicals must be approved and no Bosch prohibited substances shall be used
(e.g. asbestos, PCBs, mercury, lead paint, CFCs). A prohibited material list is
available from the Project Engineer (Bosch Norm N93 A18).
3.1.4 Equipment with lasers shall be classified and certified to meet applicable Standards
(21 CFR 1010-1050), provide “Laser Product Report” and accession number from
the Center for Devices and Radiological Health (CDRH).
3.1.5 Equipment must meet appropriate requirements for fire protection (i.e., NFPA). This
includes the ability to automatically shut down systems with reservoirs greater than
100 gallons of combustible materials during a fire event. Contact your Project
Engineer for plant specific fire system guidelines.
3.1.6 Chemicals used must be on the EPA TSCA inventory. A MSDS in English is to be
provided for all substances.
Section 3 Environmental, Health and Safety Standards
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
3.2
3-2
Safety Design Standards
3.2.1 Each energy source shall have a lockable means to shut off the supply and relieve
stored energy. Shutoff devices shall be in readily accessible locations, clearly
labeled and designed to prevent accidental shutoff of the equipment.
3.2.2 To avoid rapid, uncontrolled movements when switching on systems that employ 3
position valves, a filling circuit/valve shall be used.
3.2.3 Air receivers and surge tanks shall be designed:
a)
To conform to the ASME Unfired Pressure Vessel Code and to applicable
governmental pressure vessel codes.
b)
So that they cannot be dismantled while containing pressure.
c)
With a separate port of adequate size for a safety relief valve.
d)
permanently marked ”CAUTION PRESSURE VESSEL”.
3.2.4 Tamper-Resistant Protection: Where a hazard or damage may result if operating
pressures are exceeded, tamper-resistant (e.g. internal positive stop,
nonadjustable, etc.) overpressure protection must be provided.
3.2.5 Noise Standard: All steady state or cyclical noise levels (measured per OSHA
guidelines) produced by machinery or equipment shall not exceed 80dB(A), when
running under all anticipated operating conditions while producing parts.
3.2.6 Arc Flash considerations shall be reviewed with facilities and appropriate measures
shall be planned for at the time of quotation.
3.2.7 Control shall be such that loss of power in any form (electrical, pneumatic, and
hydraulic) shall not present a hazard to personnel, damage the equipment or work
in process. Emergency controls (E-Stop) shall be provided at each operator’s work
station.
3.2.8 Minimum working space in front of electrical enclosures shall be maintained. See
Section 9 - Appendix 5.3 for more detail. Electrical cabinet doors shall be
removable or able to open at least 120 degrees. Doors that do not inherently
remain fully open shall include means to hold door open.
3.3
Environmental Considerations
3.3.1 Equipment is to meet ISO14001 Environmental Management System requirements
including waste minimization, recyclability, etc.
3.3.2 Equipment shall be designed to contain all process fluids (oil, coolant, etc.) with no
leaks or splashing onto the operator or floor.
3.3.3 Equipment that generates oil/coolant mist must be filtered to emit less than 0.2
mg/m3. Bosch specified filtration equipment must be used. (See Section 10).
Section 3 Environmental, Health and Safety Standards
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
4-1
4 Bosch Production System
4
Bosch Production System __________________________________________________________ 4-1
4.1
Bosch Production System____________________________________________________________ 4-1
4.2
Floor Plan Layout __________________________________________________________________ 4-2
4.3
Ergonomic Guidelines ______________________________________________________________ 4-2
4.1
Bosch Production System
The Bosch Production System (BPS) supports world-wide improvements in Quality,
Delivery, and Cost of our products with the goal of effectively increasing value
contribution. The eight principles of BPS are Perfect Quality, Process Orientation,
Flexibility, Standardization, Pull System, Transparent Process, Waste Elimination and
CIP, and Associate Involvement and Empowerment.
The Project Engineer is to specify detailed requirements. BPS compliance will be
evaluated at machine acceptance.
4.1.1 Perfect Quality: Stable processes are a precondition for consistent and shortened
throughput times. Therefore, simple and reliable systems with a very high OEE are
required instead of complex highly automated systems which require frequent
adjustments and/or potentially long downtimes. Equipment must demonstrate an
OEE > 95% during the acceptance run-off given the specified Takt time and number
of Changeovers/shift with 100% Performance and Quality rates. See OEE
Calculation Sheet (Appendix 4.2). Poke Yoke concepts must be employed to help
achieve Perfect Quality.
4.1.2 Process Orientation: Pull Systems are to be used on assembly lines as well as
Individual machines where applicable. As much as possible, processes should be
designed as single piece flow with stable cycle times so that a stable rhythm is
achieved. The layout should be designed to optimize operator motions and provide
good material flow.
4.1.3 Flexibility: Equipment must be designed for quick changeovers and tool changes
which require minimal or no adjustments once equipment is in operation. Consider
Internal vs. External Set-up and minimize Internal Set-up time. Where possible use
Chaku-Chaku which utilizes varying numbers of operators and adjusting operator
flow to allow for Flexible output.
4.1.4 Standardization: Proven and approved processes are to be implemented. The
lessons learned from TPM tier 1-3 are to be implemented in new MAE. Please
contact BPS for the latest TPM findings and best practices.
Section 4 Bosch Production System
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
4.2
4-2
Floor Plan Layout
4.2.1 General Requirements: The supplier shall furnish preliminary and final layout
drawings that define the overall equipment/machinery configuration which shall
include but not limited to the following considerations:
a)
Overall dimensional size of equipment/machinery (L x W x H)
b)
Location, size, range of movement, and direction of movement of doors for
all Electrical panels an Access areas.
c)
Access to the required lubrication points (fluid tanks fill and drain points, etc.)
d)
All necessary clearance dimensions shall be shown.
e)
Location and size of support equipment (e.g. filters, pumps, chip carts, mist
collectors, drip pan, etc.).
f)
Location and size of part loading and unloading devices.
g)
Location of all facility tie-ins shall be identified.
4.2.2 Floor Layout Drawings: Within thirty (30) days after final drawing approval, the
equipment supplier shall transmit to the Project Engineer a print or a CAD file. For
format of CAD files see plant specific requirements, Section 10.
4.2.3 Machine Leveling: Machine leveling devices shall be supplied with equipment.
4.3
Ergonomic Guidelines
4.3.1 Workstations
4.3.1.1
The preferred workstation layout is to accommodate Chaku-Chaku (standing,
mobile operators not confined to one station only). If this type of workstation
layout is not possible, operators should be given the option of either sitting or
standing while performing their work if it is feasible both technically and
based on the scope of work.
4.3.1.2
Workstations which accommodate a sitting operator should be equipped with
an adjustable chair and adjustable footrest.
4.3.1.3
If a conveyor is in front of a workstation where a person is seated, adequate
clearance must be provided under the conveyor for the person’s legs.
4.3.2 Workplace Measurement: Recommended measurements for working height,
distance to work area, leg room and area of free movement per workplace are
provided in Appendix 4.3.
4.3.3 Task Lighting - The following light intensities are required:
a)
1,000 lux for testing and adjusting delicate components.
b)
1,500 lux for assembling delicate parts and electronics.
Reflecting workstation surfaces should be avoided.
4.3.4 Controls and Indicators - Placement of Controls and Indicators shall be within
operator’s normal reach and field of vision. See also Appendix 4.3.
Section 4 Bosch Production System
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
4-3
4.3.5 Lifting - In general, any manual lifting >30 lbs. should be avoided. All heavy or
repetitive lifting (tools, fixture changes, loading, unloading) must be evaluated using
the NIOSH lifting guide. If above the action limit (AL), mechanical lifts are required.
The plant will specify the systems that may be used (supplier, make and model). It
should be quoted separately.
4.3.6 Access - When a person has to reach a full arm’s length, clearance for the body
shall be provided to allow both hands to reach the tools without placing the operator
in an uncomfortable or hazardous position relative to the surrounding conditions. All
tool changes must be accomplished with both feet of the operator on normal floor
level. The layout of the workstation should provide easy access for maintenance,
cleaning, housekeeping, material handling, etc.
Section 4 Bosch Production System
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
5-1
5 Design
5
Design __________________________________________________________________________ 1
5.1
Mechanical Design Standards __________________________________________________________ 1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.2
Electrical Design Standards____________________________________________________________ 4
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.1
Components ________________________________________________________________________________ 1
Drawing Standards __________________________________________________________________________ 1
Drawing Content ____________________________________________________________________________ 2
Pneumatic Controls __________________________________________________________________________ 3
Lubrication_________________________________________________________________________________ 3
Paint ______________________________________________________________________________________ 3
General____________________________________________________________________________________ 4
Functional _________________________________________________________________________________ 4
Equipment _________________________________________________________________________________ 5
Wiring Methods_____________________________________________________________________________ 6
Programmable Logic Controllers and Computers ___________________________________________________ 7
Data Management and Networking ______________________________________________________________ 7
Mechanical Design Standards
5.1.1 Components
5.1.1.1
Use of BOSCH Products - BOSCH products shall be used for special
purpose machines. For Information contact responsible BOSCH group (see
Appendix 5.1).
5.1.1.2
Plant specific preferred components shall be used (See Section 10).
5.1.1.3
Measurement Instruments shall have means of calibration. Masters and
teach tooling, shall be provided at pre-acceptance. For masters and gages, a
certification of calibration and traceability to a standard shall be supplied by
the equipment supplier. (See plant specific requirements, Section 10).
5.1.1.4
Where adjustable mechanical stops are required, precise adjustment means
shall be used.
5.1.2 Drawing Standards
5.1.2.1
Language - All documentation must be in English.
5.1.2.2
Dimensions/Standard Projection - Details shall conform to the International
System of Units (SI). Inch equivalents may be shown in parentheses
adjacent to the SI dimension.
5.1.2.3
Drawings using “Third Angle Projection” are preferred. On drawings using
“First Angle Projection”, a prominent note shall be placed on EACH detail
declaring “Note: Drawn in First Angle Projection”.
Section 5 Design
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
5.1.2.4
5-2
Drawing Size
a) Assembly Drawings - Assembly and subassembly drawings shall be
drawn on ANSI D or DIN A1.
b) Detail Drawings - Each detail shall be placed on an individual sheet and
the size of this detail drawing shall be appropriate for the level of detail on
the drawing.
c) Parts Lists (Bill of Materials) shall be placed either on the assembly
drawings or on A-size sheets.
d) Drawings Numbers - Drawings shall contain a Bosch assigned drawing
number in the title block. All machines, including duplicate machines,
shall have unique drawing numbers. Contact Project Engineer who will
issue specific numbers for each machine.
e) CAD-drawings shall be provided. For format of CAD files see plant
specific requirements, Section 10.
5.1.3 Drawing Content
5.1.3.1
Mechanical Drawings – shall consist of:
a) Main Assembly Drawing
b) Assembly Drawings / Parts List
c) Subassembly Drawings
d) Detail Drawings
5.1.3.2
All Piping Systems (e.g. pneumatic, hydraulic, cooling, and process fluids)
shall have Schematic Diagrams and Parts List.
5.1.3.3
Assembly Drawings - The main assembly drawing shall show complete
machine or assembly and shall have two views minimum: plan or top view,
and one elevation or side view. Drawings shall be drawn to scale and show
overall dimensions of height, width, and length; location and dimensions of
auxiliary control cabinets; the location of the work piece/part; the direction
travel; and operator location.
5.1.3.4
Subassembly Drawings - Details shown on an assembly or subassembly
drawing shall have a position number assigned with a leader line. The
position number shall be noted on Parts List.
5.1.3.5
Detail drawings shall have all dimensions and tolerances (GD&T) necessary
to manufacture the part. Materials shall be designated per AISI, SAE or DIN
standards. Heat treatment and surface finish requirements shall be shown.
5.1.3.6
All assembly, subassembly, schematic, and panel layout drawings, shall
have a Parts List which specifies all manufactured and purchased parts
required to complete the “assembly”. Common fasteners may be omitted.
Manufacturers and part numbers of purchased items shall be listed.
Section 5 Design
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
5-3
5.1.4 Pneumatic Controls
5.1.4.1
General
f) Pneumatics shall be designed to operate with non-lubricated air.
g) Electrical logic controls are preferred. Pneumatic control logic requires
prior approval of Project Engineer.
h) Pneumatics shall function at 4.5 bar.
i) Solenoid Valves shall be 24V DC.
j) Pneumatic lines shall be labeled on both ends with the valve id and letters
“A” or “B” added (e.g. 100Y201A).
5.1.4.2
Equipment Requirements
5.1.4.2.1 Components
k) A Filter, Regulator, and Separator shall be provided. Filter shall be a 5
micron filter.
l) Cylinders shall have a dampening means (external or internal).
m) Air discharge shall be provided with mufflers to reduce noise to 80 dBA or
less.
5.1.5 Lubrication
Maintenance-free components shall be used. Any components which require
lubrication must be approved by the Project Engineer via a Deviation Request.
Should such a request be approved, oil from such lubricated air shall be trapped
and lubrication points and levels shall be visible and accessible without removing
guards and shall be permanently labeled.
5.1.6 Paint
5.1.6.1
Paint shall be resistant to oil, test fluid, synthetic coolants and any other
fluids in the environment.
5.1.6.2
Surfaces which could be a source of contamination shall not be painted.
Non-painted surfaces shall not rust or degrade; use non-contaminating
coatings or stainless steel where applicable.
5.1.6.3
All surfaces exposed to high temperature shall be heat resistant.
5.1.6.4
Colors
Section 5 Design
Use
Color
Specification
Equipment
(See Section 10)
(See Section 10)
Sprinkler Lines
Red
OSHA RED
Gas Lines
Yellow
OSHA YELLOW
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
5.2
5-4
Electrical Design Standards
5.2.1 General
5.2.1.1
Control Systems Overview - A Control Systems Overview form shall be
completed when the project is quoted. (See Appendix 5.2)
5.2.1.2
Documentation - All drawings shall be drawn with CAD and drawing files
shall be provided in plant specific format (See Section 10). Drawings shall
also be provided in Adobe Acrobat PDF format. Electrical Drawings shall be
“A” or “B” size (DIN Size A4 or A3).
5.2.1.3
Software Licenses - All software needed to use or modify any component of
the machine shall be licensed and provided. All software shall be in English.
Development Software and license shall be provided. Source code of the
project application shall be provided and becomes the property of Bosch.
5.2.2 Functional
5.2.2.1
Manual Control - Manual controls shall be provided for tool changing, setup
and maintenance operation. The controls shall be interlocked to prevent
machine or part damage. Manual controls shall be disabled during automatic
cycle.
5.2.2.2
Independent Control - Separate control systems shall be used for each
individual machine.
5.2.2.3
Diagnostics – A unique diagnostic indication shall be provided for each
possible state of the machine. The indication shall display the specific
component, the desired action and expected result. Diagnostics shall include
checks to verify proper sensor operation for each state (i.e. back checks).
5.2.2.4
Anti-Repeat - On equipment where continuous consecutive cycling is not a
normal condition, the controls shall be designed to prevent such operation.
5.2.2.5
Control Parameters/Values - Setup parameters which can affect the quality
or the cycle time of the station shall be locked or password protected.
Process values which can affect quality shall be monitored and should shut
down the machine if not within tolerance.
5.2.2.6
Field Bus Systems – (See plant specific requirements, Section 10).
5.2.2.7
Lamp Test - All lamps shall have a method of testing for defective bulbs.
5.2.2.8
Cycle Counters - Both a non-resettable and a resettable cycle counter shall
be included.
Section 5 Design
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
5-5
5.2.3 Equipment
5.2.3.1
Machine Voltage
5.2.3.1.1 The primary voltage for machines shall be 480 VAC, 3 phase, 60 Hz.
5.2.3.1.2 Control voltage shall be regulated 24 VDC from a listed power supply
(e.g. UL Listed).
5.2.3.1.3 Input and Output Modules of Programmable Electronic Systems shall be
less than 50 V and separated from high voltage enclosures.
5.2.3.1.4 Receptacles for 115 VAC shall be GFCI standard US grounded 3 prong.
5.2.3.2
Components
5.2.3.2.1 Equipment shall be constructed utilizing Bosch “Preferred Electrical
Components” (See plant specific requirements, Section 10).
5.2.3.2.2 Transformers and power supplies shall have 30% excess capacity.
5.2.3.2.3 Controller outputs shall have individual over-current protection for each
circuit.
5.2.3.2.4 Workplace Lighting shall be energy efficient, T8 or T5 with electronic
ballast; switch controlled and supplied by less than 150V.
5.2.3.3
Enclosures
5.2.3.3.1 Expansion - Enclosures shall be designed with 20% expansion capability.
This shall include but not be limited to space for terminal blocks,
over-current protection, contactors, relays, wireways, and controller I/O.
5.2.3.3.2 Lighting controlled by a door switch shall be provided on enclosures over
0.425 m3 (15 cu. ft.) and supplied by less than 150V.
5.2.3.3.3 Programmable Devices - All machines with a programmable device shall
have a 115 VAC GFCI, receptacle labeled “For programming device
only”. A programming interface shall be readily accessible.
5.2.3.3.4 Connectors - Wiring to enclosures not mounted on the machine shall
have connectors. Plugs and sockets must be permanently labeled and
keyed to prevent improper connection.(See plant specific requirements,
Section 10).
5.2.3.3.5 Location - Bottom of enclosures shall be a minimum of 100 mm above the
floor. The control enclosure should be positioned so that the machine can
be observed while working in the enclosure. (See Appendix 5.3)
Section 5 Design
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
5.2.3.4
5-6
Motors - AC motors shall be High Energy Efficient TEFC, 480 VAC, 3Φ, 60
Hz. All motors 25hp and above shall have continuous conductors from the
control enclosure to the motor. No intermediate terminations are permitted.
Such motors shall also have power factor corrected to above 90%.
5.2.4 Wiring Methods
5.2.4.1
Grounding - Transformers and power supplies shall have their neutral or
common conductors grounded at the source. Special earth grounds shall be
specified by the supplier during initial design review and detailed in the
installation specifications.
5.2.4.2
Test Points - All control and power wiring shall have readily accessible test
points in the control enclosures.
5.2.4.3
Wire Termination and Labeling - For screw or screw clamp terminations, all
wire ends shall be fitted with ferrules or crimp connectors. Wire identification
method shall be specified by the customer. The machine builder is
responsible for determining customer preference. Wires shall be identified
either with wire numbers or termination labels. Wire numbers or termination
labels shall be used exclusively. Each termination point shall have a
maximum of two wires.
5.2.4.3.1 When wire numbers are used, each individual wire shall have the same
number at all termination points. Terminal block labels shall match the
wire numbers. Wires connecting to controller I/O shall be labeled with an I
for Inputs and Q for Outputs followed by the I/O address.
5.2.4.3.2 When wire termination labels are used, the termination label shall identify
the terminal name where the wire should terminate. Example: The wires
connected to terminal A1 of –K911A shall be labeled –K911A:A1.
5.2.4.4
Splicing is prohibited. Wiring shall run uninterrupted from termination to
termination.
5.2.4.5
Wiring external to an enclosure shall include 15% extra wire length.
5.2.4.6
Wire Type - Wire shall be stranded copper. Wire jacketing shall be type MTW
for wires not leaving electrical enclosures. Elsewhere, wire jacketing shall be
compatible with the associated fluids and working environment:
a) Type PUR: for areas with coolant, oil and diesel/gasoline calibration
type fluids (e.g. VISCOR™)
b) Type PVC: for brake fluid areas
5.2.4.7
Wire Color
5.2.4.7.1 See plant specific requirements, Section 10.
Section 5 Design
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
5-7
5.2.5 Programmable Logic Controllers and Computers
5.2.5.1
See plant specific requirements, Section 10.
5.2.6 Data Management and Networking
The Bosch Corporate Network (BCN) is a private, global data network which
interconnects all Robert Bosch sites throughout the world.
5.2.6.1
Infrastructure and Interfaces - The physical connection to the BCN is
provided via RJ-45 jacks installed as required near the equipment. These
network drops will be terminated external to the equipment.
5.2.6.2
Managed Cisco routers and switches comprise the backbone of the
corporate network. Any network devices in equipment shall use manageable
Cisco switches. Contact the Project Engineer for recommended equipment
model numbers.
5.2.6.3
TCP/IP over Ethernet is the standard protocol. Some sites may require
specific subnetting or support for other management protocols for
manufacturing devices. Be sure to check with the Project Engineer. Sitespecific static IP addresses will be assigned by Bosch.
5.2.6.4
Virus Protection - The BCN has multi-layered anti-virus protection starting at
company firewalls cascading down to each desktop computer. Bosch
requires that vendors evaluate the vulnerability of their equipment to
computer viruses and employ reasonable safeguards.
5.2.6.5
When real-time anti-virus scanning is not possible, manufacturing computing
systems may be isolated from the general-use BCN using Virtual Local Area
Networks (VLANs).
5.2.6.6
Physical and Data Security - Unauthorized data transmission of any nature to
external parties is strictly forbidden. Modems are not permitted on any
computer connected to the BCN.
5.2.6.7
Unauthorized software is not permitted. Supplier shall ensure machine is
clear of inappropriate images, files or other software.
Section 5 Design
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
6-1
6 Quality Standards & Run-off Conditions
6
Quality Standards & Run-off Conditions ........................................................................................... 6-1
6.1
General___________________________________________________________________________ 6-1
6.2
Guidelines for Statistical Evaluation___________________________________________________ 6-2
6.3
Gage, Process and Machine Capability ________________________________________________ 6-2
6.4
Gage Scale and Signal Output ________________________________________________________ 6-3
6.5
Equipment Effectiveness and Durability Demonstrations _________________________________ 6-3
6.6
Run-off Conditions _________________________________________________________________ 6-3
6.7
Software Validation ________________________________________________________________ 6-4
6.1
General
6.1.1 It is the policy of Robert Bosch LLC to conduct a pre-acceptance evaluation of new
machines and test stands for proper quality of operation at the equipment supplier’s
facility by a Bosch Project Engineer prior to authorizing shipment. The final
acceptance evaluation will be conducted at the Bosch facility under plant operating
conditions. The same or better quality level achieved during pre-acceptance trials
must be achieved during final acceptance trials.
6.1.2 All quality requirements outlined in the Purchase Order, its supplements and
supporting documents (specifications, standards, drawings, etc.) must meet the
evaluation criteria stated below or as indicated in Appendix 6.1 and Appendix 6.2.
6.1.3 A pre-acceptance evaluation will be conducted only after the equipment supplier
has presented data or sample parts indicating that the equipment meets the
requirements of the Purchase Order.
6.1.4 All pre- and final acceptance trials shall be witnessed or conducted by Bosch
personnel using Bosch-supplied parts. Supporting equipment, gages, calculators,
etc., and labor shall be provided by the supplier unless otherwise agreed upon.
Acceptance plan, method of measurement and data record format must be
approved by Bosch.
6.1.5 For pre-acceptance trials, gage calibration may be certified by manufacturers’ data
sheets and calibration data records. For final acceptance, calibration certification
must be current.
Section 6 Quality Standards & Run-off Conditions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
6.2
6-2
Guidelines for Statistical Evaluation
6.2.1 As a general rule, quality of operation will be evaluated by statistical methods.
Specific characteristics to be examined during pre- and final acceptance trials shall
be provided to the equipment supplier as part of the equipment specification.
6.2.2 Parts to be provided by Bosch for pre- and final acceptance trials will be production
parts, pre-qualified for characteristics that could influence capability studies.
6.2.3 See Appendix 6.1 for a Sample Size table which provides guidelines for determining
numbers of parts to be used or manufactured during acceptance trials. Nonstandard sampling plans for acceptance are to be specified in the Purchase Order.
6.2.4 Where more than one part is produced simultaneously or for multi-spindle/station
machines, the total production is to be divided equally among the work piece
locations. Parts are to be identified with the location from which they came.
6.3
Gage, Process and Machine Capability
6.3.1 Gage, process and machine capability shall be demonstrated using appropriate
procedures (See plant specific requirements, Section 10).
6.3.2 The following capability requirements apply unless otherwise agreed upon in the
Purchase Order:
6.3.2.1
Gage Capability:
a) If a standard gage Repeatability and Reproducibility (R&R) test is used,
Study Variation / Tolerance shall be <10%
b) If the Shainin ISOPlot(sm) test is used as an alternative to (i), the
discrimination ratio DR = Tolerance / Delta M shall be >12.5.
(This calculation should be done using the Shainin Red X Tracker (™)
software, not by hand.)
The ISOPlot(sm) is valid only for cases where the operator does not
influence the measurement result. If the operator can affect the
measurement, e.g., use of a hand-held depth gage, consult the AIAG
Measurement Systems Analysis manual and plant-specific requirements
for standard R&R procedures.
6.3.2.2
Machine capability: Cmk shall be >1.67; and
6.3.2.3
Process capability: Cpk shall be > 1.33.
Note: To be valid, Cmk and Cpk calculations must be based on
measurements that are statistically stable and that are approximately
normally distributed. Statistical stability must be verified before proceeding
further. (See AIAG SPC Reference Manual.) If non-normality is confirmed,
use an appropriate data transformation method to obtain an equivalent
normal distribution from which reliable Cmk and Cpk values may be
calculated.
Section 6 Quality Standards & Run-off Conditions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
6.4
6-3
Gage Scale and Signal Output
6.4.1 The least count of electrical gages or least division of mechanical gages shall be
less than or equal to one-tenth OF THE SMALLEST PART TOLERANCE to be
measured. Special consideration may be given to gaging used to measure
characteristics with tolerances less than 0.010 mm.
6.4.2 All gages shall display a variable data result unless otherwise specified. Electronic
gages which measure pertinent product dimensions shall include an appropriate
data output port (preferably RS232) with the capability for remote access for
recording functional and quality data. Questions regarding what dimensions are
pertinent shall be resolved prior to design approval. In general, all parameters
useful in analyzing machine performance and quality of operation should be
monitored.
6.5
Equipment Effectiveness and Durability Demonstrations
6.5.1 The minimum acceptable Technical Availability during production shall be 95% (e.g.
downtime related to issues for which the manufacturer is responsible not to exceed
5%) unless otherwise agreed upon and specified in the Purchase Order.
Calculations shall be based on Appendix 6.2 guidelines (VDI 3423).
6.5.2 All part-type changeovers (last good part to first good part) shall be performed in
accordance with the Bosch Production System (BPS) guidelines (<10 minutes for
equipment, <5 minutes for assembly). Changeovers to be as simple as possible
(executable by the operator).
6.5.3 A separate dry-cycle run (i.e., without work pieces) shall be conducted (minimum of
eight (8) hours duration) to demonstrate equipment durability. All operating,
positioning, and robot operation shall perform without failure during this period.
Should a failure occur, the Project Engineer shall determine the extent of additional
demonstration to be required after repairs are completed.
6.6
Run-off Conditions
6.6.1 Process Data or Set-up Sheet
6.6.1.1
The equipment supplier shall supply a set-up or process data sheet
specifying the machine or gage operating parameters to be used during the
pre- and final acceptance.
6.6.1.2
The set-up sheet should quantitatively define set-up parameters, cycle time,
tool change and adjustment procedures, relevant specifications (e.g., warmup period, feeds, speeds, dressing frequencies, strokes, cylinder pressures,
sequence diagrams/timing charts), masters, test parameters, control settings
and alignment/calibration procedures.
Section 6 Quality Standards & Run-off Conditions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
6.6.1.3
6-4
The set-up sheet format is to be defined and agreed upon at least one (1)
month prior to start of pre-acceptance trials. When possible, Bosch forms
should be used.
6.6.2 Adjustment Frequency Limitation
6.7
6.6.2.1
Operational adjustments to be allowed as part of normal machine operation
shall be defined by the equipment supplier and approved by the Project
Engineer prior to pre-acceptance trials, and preferably during the design
phase.
6.6.2.2
The average number of unplanned machine cycle interruptions, including
adjustments, shall not exceed once in 1.5 hours with the machine operating
at 100% capacity.
6.6.2.3
If unplanned interruptions are required more often than allowed above, the
cause(s) must be identified and resolved. Unless waived by the Project
Engineer, the production run portion of a trial must be repeated after
corrective action is completed.
6.6.2.4
A minimum of one change per tool, following the established set up
procedure, should occur during the run-off.
Software Validation
6.7.1 All modes and features of software operation, including output of printed reports,
shall be demonstrated. Where applicable, operation on the plant network and
remote access must be demonstrated during final acceptance trials. Arrangements
for remote access shall comply with the requirements of Section 5.2.6, Data
Management and Networking. Project engineers should contact their local
RBNA/CIT group to investigate the feasibility of using the Bosch Remote Access
System (RAS) to meet the project needs.
6.7.2 Software that processes measurement system data or sets machine operating
conditions which cannot be observed visually must be validated by an independent
means. For such cases, equipment suppliers shall include appropriate test plan
steps that independently demonstrate the proper operation of the software. This
includes verification of calculation implementation.
Section 6 Quality Standards & Run-off Conditions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7 Acceptance Checklist
7
7-1
Download
Acceptance Checklist ........................................................................................................................... 7-1
7.1
Section 1: General Procedures________________________________________________________ 7-2
7.2
Section 2: Project Management – N/A _________________________________________________ 7-2
7.3
Section 3: Environmental, Health & Safety Standards ____________________________________ 7-3
7.4
Section 4: Bosch Production System ___________________________________________________ 7-8
7.5
Section 5: Design ___________________________________________________________________ 7-9
7.6
Section 6: Quality Standards and Run-off Conditions ___________________________________ 7-15
7.7
Section 7: N/A ____________________________________________________________________ 7-16
7.8
Section 8: Documentation and Shipping Instructions ____________________________________ 7-17
7.9
Section 9: Appendices – N/A ________________________________________________________ 7-17
7.10
Section 10: Plant Specific Additional Requirements – See Section 10 _______________________ 7-17
7.11
General Information_______________________________________________________________ 7-17
7.12
Instructions: _____________________________________________________________________ 7-17
Section 7 Acceptance Checklist
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.1
1.1
Section 1: General
Procedures
Does the machine conform to all
equipment specifications as stated in
the RFQ including any documented
changes?
Has supplier agreed to conform to
the GDS dated: Apr-2007 with all
deviations documented and
approved?
Are all documentation, (drawings,
service manuals, etc.) available and
in English?
1.2
1.3
Ref.
GDS/
Other
No
Comments/Test Results or
N/A
Date
Needed
1.2.2a
1.2.2d
8.1.1
Are the quoted conditions below
achieved?
1.4.1
ƒ
Cycle Time?
1.2.1
Quote
1.4.2
ƒ
Machine Utilization?
6.5.1
1.4.3
ƒ
Changeover Time Min.?
6.5.2
1.4.4
ƒ
Production Rate: Pieces/Hr.?
Quote
1.4.5
ƒ
Tool Life?
Quote
1.4.6
ƒ
Gage Capability?
6.3.2
1.4.7
ƒ
Process Capability?
6.3.2
1.4.8
ƒ
Facility Utilities (i.e. power,
steam, air, etc.)?
2.2.3g
7.2
F/A
Yes
1.2.1
1.4
Section 1
Project Engineer signature
P/A
Yes
7-2
Pre:
Final:
Section 2: Project Management – N/A
Section 7 Acceptance Checklist
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.3
Section 3:
Environmental, Health
& Safety Standards
Ref.
GDS/
Other
P/A F/A
Yes Yes
No
7-3
Comments/Test Results
or N/A
Date
Needed
Emergency Stop
3.1
3.2
3.3
3.4
3.5
3.6
Are Emergency Stop buttons for
electrical, pneumatic and hydraulic
systems accessible and properly
labeled?
Does Emergency Stop function and
prevent additional movement?
OSHA
1910.212
Are measures taken to prevent
unintended movements after any
stopping of the machine? (by
operator, loss of power, machine
fault, etc.)
Does Emergency Stop require
Manual Release and pushing the
Start Button for the machine to
restart?
Is Emergency Stop located within
close reach of operator and/or
technician near point of operation?
3.1.1c
NFPA 79
2007
9.2.5.1.2
OSHA
1910.212
Is the initiation of hazardous
conditions prevented when the stop
function is reset?
3.1.1c NFPA
79 2007
9.2.5.3.3
OSHA
1910.212
OSHA
1910.212
Electrical
3.7
Does equipment have a complete
nameplate? Does it include Short
Circuit Current Rating?
3.8
Do control cabinet and compartment
3.1.1c
NFPA79
doors and hinged panels open at
2007 11.5.1
least 120 degrees?
3.9
Do electrical cabinets have at least 1
meter clearance?
3.1.1c
NFPA70
2005
670.3(A)
3.1.1c
NFPA79
2007
Machine Guarding
3.10
OSHA
1910.212
3.11
Are all hazard areas guarded (push,
stroke, capture, retract, clip and
squeeze areas, sharp edges,
hot/cold surfaces):
Rotating shafts are enclosed?
3.12
Belts, chains, etc., are enclosed?
OSHA
1910.212
3.13
All pinch points guarded?
OSHA
1910.212
Section 7 Acceptance Checklist
OSHA
1910.212
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.3
Section 3:
Environmental, Health
& Safety Standards
Ref.
GDS/
Other
3.14
Are guards clear where viewing is
required?
OSHA
1910.212
3.15
Are guards not easily removable by
operator?
OSHA
1910.212
3.16
Are guards for setup interlocked and
not easy to defeat?
OSHA
1910.212
3.17
Are protective barriers installed to
protect other associates from flying
objects (e.g., machining)?
P/A F/A
Yes Yes
No
7-4
Comments/Test Results
or N/A
Date
Needed
OSHA
1910.212
ANSI
B11.19-2003
Controls
3.18
Two hand control: Is check function,
anti tie-down, anti repeat, distance
acceptable?
OSHA
1910.217
3.19
Are all instructions/labels in English?
8.1.1
3.20
Are light barriers, light curtains,
safety mats, etc., verified for proper
operation?
NFPA79
18.6
3.21
Do all safety switches/ protective
gates operate properly?
OSHA
1910.212
3.22
Are all necessary interlocks provided
for safe operation?
3.1.1c
NFPA79
2007 9.2.5.1
3.23
Are all safety door interlocks verified
to operate properly?
OSHA
1910.212
3.24
Does the exhaust system operate
properly (must stop/ must not stop) if
emergency stop is activated?
3.4.3
3.25
Are machine controls accessible and
away from revolving spindle, moving
tools or other hazards?
OSHA
1910.212
3.26
Is control panel access adequate
with no blockage?
3.27
Are general operating controls
configured for safe operation?
NFPA79
2007
10.1.2.2
3.28
Are there interlocks for point of
operation guarding?
OSHA
1910.212
3.29
3.1.1c
Are control elements that initiate
contrary motions interlocked against NFPA 79
2007 9.3.4.1
incorrect operation? (mechanically
and electrically)?
Section 7 Acceptance Checklist
Appendix 5.2
NFPA 70
110.26
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.3
3.30
Section 3:
Environmental, Health
& Safety Standards
Ref.
GDS/
Other
P/A F/A
Yes Yes
No
3.2.8
Is the minimum workspace for
Appendix 5.3
electrical enclosures maintained.
(See Appendix 5.3) and do enclosure NFPA 70
110.26
doors open 120 degrees.
7-5
Comments/Test Results
or N/A
Date
Needed
Labeling
3.31
Are the following labels posted (in
English):
3.31.1
ƒ
Danger Signs?
OSHA 1910.
145
3.31.2
ƒ
Caution Signs?
OSHA 1910.
145
3.31.3
ƒ
Confined Space?
OSHA 1910.
145
3.31.4
ƒ
Notice Signs?
OSHA 1910.
145
3.31.5
ƒ
Safety Instructions?
OSHA 1910.
145
3.31.6
ƒ
Hazardous Materials?
OSHA 1910.
145
3.31.7
ƒ
Electrical/Utilities?
1910.1200
3.31.8
ƒ
Fluids and Lubricants?
1910.1200
3.32
Are Electrical Enclosures over 50V 3.1.1c
labeled to warn of potential electric NFPA70
2005 110.16
arc flash hazards? Is the label
clearly visible?
Lockout/Tagout (LO/TO)
3.33
Are lock-out devices provided for all
utility shutoffs (Pneumatic, hydraulic
and electrical systems)?
3.2.1
Chemicals
3.34
Are MSDS’s available and in English
for all associated hazardous
materials?
Section 7 Acceptance Checklist
3.4.1
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.3
Section 3:
Environmental, Health
& Safety Standards
Ref.
GDS/
Other
No
Norm 93 A18
3.35
Is safe storage provided for all
hazardous materials?
3.36
Are flammable liquids in metal
(OSHA approved) safety containers?
Is grounding provided?
OSHA
1910.106
3.37
Do all chemicals and materials meet
Bosch requirements for approval
(including N2580 prohibited
substances)?
Has proper PPE been identified?
3.1.3 Norm
93 A18
3.38
P/A F/A
Yes Yes
7-6
Comments/Test Results
or N/A
Date
Needed
OSHA
Norm 93 A18
Hazard Assesment
3.39
Have all operational hazards been
identified (A11 Hazard
Assessment)?
OSHA
1910.119
Norm 93
3.40
Have special requirements for
Division I Class I areas been
addressed?
OSHA
1910.307
3.41
Are LEL sensors provided for
Division I Class I areas?
OSHA
1910.307
3.42
Have adequate fire protection
systems been included (if required)?
3.43
Has associates been properly
instructed (PQIs, training)?
3.1.5
Norm 93 A8
Sound
3.44
Does sound level not exceed 80
dB(A) under normal operating
conditions?
3.3
Lasers
3.45
Does laser comply with all
requirements of ANSI Z136.1 Safe
Use of Lasers?
3.1.4
3.46
Is laser labeled, classified and
certified?
3.1.4
Robotic Operations
3.47
Has a robot risk assessment per
ANSI/RIA R15.06 been completed
and documented?
Section 7 Acceptance Checklist
3.1.2
RIA R15.06
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.3
Section 3:
Environmental, Health
& Safety Standards
Ref.
GDS/
Other
P/A F/A
Yes Yes
RIA R15.06
3.48
Are all power disconnects and
interlocks installed as required?
3.49
Have all mechanical stops and range
of motion stops been verified?
R15.06
3.50
Is there full envelope guarding?
R15.06
No
7-7
Comments/Test Results
or N/A
Date
Needed
Environmental
3.51
Are all wastes known and approved Bosch Norm
93 S1
(wastewater, solid waste, hazardous
waste)?
3.52
Are air emissions known, properly
controlled and permitted?
3.53
Does equipment properly contain all Norm 93 A18
process fluids including possible
leaks?
Section 3
HSE signature
Section 7 Acceptance Checklist
3.1.1e
Pre:
Final:
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.4
Section 4: Bosch
Production System
Ref.
GDS/
Other
4.1
4.1
Has the BPS Investment
Assessment been updated?
4.2
Are Poke Yokes present?
4.1.1
4.3
Is the machine layout such that
operator motions and material flow is
optimized?
4.1.2
4.4
Is the machine designed to facilitate
quick changeovers and tool
changes?
4.1.3
4.5
Are workplace dimensions according
to the Bosch Workplace
Measurement specifications?
4.3.2
4.6
Is task lighting adequate, no glare?
4.3.3
4.7
Are all secondary tasks at proper
working heights (actuating or reading
controls, handling parts bins, etc.)?
4.3.4
4.8
Are all lifting tasks within NIOSH
limits (changing of tools, fixtures,
bins, etc.)?
4.3.5
4.9
Are lifting aids provided for heavy
items?
4.3.5
4.10
Is maximum lifting weight 30 lbs.?
4.3.5
4.11
Is the following assessed:
4.11.1
ƒ
Improper/unnecessary lifting?
NIOSH (LE)
4.11.2
ƒ
Repetitive motions?
Appendix 4.2
4.11.3
ƒ
Operator posture?
4.12
Is accessibility for material handling,
adjusting, maintenance, and cleaning
adequate?
Section 4
BPS signature
Section 7 Acceptance Checklist
P/A
Yes
F/A
Yes
No
7-8
Comments/Test Results
or N/A
Date
Needed
4.3.2
4.3.6.b
Pre:
Final:
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.5
7-9
Section 5: Design
7.5.1 Section 5.1
Mechanical Design
Ref.
GDS/
Other
5.1.1
Masters and teach tools supplied as
needed. Calibration demonstrated if
applicable.
5.1.1.3
5.1.2
Complete drawing package supplied
according to requirements
5.1.2
5.13
5.1.3
Machine functions properly at 4.5 bar
pressure.
5.1.4.2
5.1.4
Lubricated air, if used, is separated
at discharge point
5.1.4.2
5.1.5
Maintenance free components used?
5.1.5
5.1.6
Valve Manifold and pneumatic tubing
is properly labeled.
5.1.4.1
Section 5.1
Maintenance Group Leader
signature
Section 7 Acceptance Checklist
Pre:
P/A
Yes
F/A
Yes
No
Comments/Test Results
or N/A
Date
Needed
Final:
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.5.2 Section 5.2:
Electrical Design
5.2.1
5.2.2
5.2.3
5.3.4
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
Ref.
GDS/
Other
3.1.1c NFPA
Are multi-device enclosures
79 2007
equipped with terminal blocks or
13.3.5
attachment plugs for all outgoing
control conductors? Wiring directly
to terminal connection points on input
or output modules of programmable
electronic systems shall be
permitted.
Are supply circuit conductors on the 3.1.1c NFPA
79 2007
line side of the disconnecting means
5.1.6
separated from other internal
conductors?
3.1.1c NFPA
Is branch-circuit over current
79 2007
protection (UL 489, not UL 1077)
7.2.1.3
used when required? Note! Branchcircuit OCP is required for motor
circuits per NFPA 70 430 and for
disconnecting means with integrated
OCP as per NFPA 70 670.4(B).
3.1.1cNFPA
Are conductors identified at each
79 2007
termination by number, letter, color
13.2.1.1
or a combination thereof? Does
conductor identification correspond
to the technical documentation?
3.1.1c NFPA
Percentage Fills of Raceways
79 2007
(Ducts). Is the combined cross13.5.2
sectional area of all conductors and
cables less than 50% of the interior
cross-sectional area of the raceway?
3.1.1c NFPA
Are control cabinet devices and
79 2007
components identified with the same
16.5.4
designation as shown on the
machine drawings, adjacent to (not
on) the device?
3.1.1c NFPA
Are devices external to the control
79 2007
cabinet identified with the same
16.5.5
designation as shown on the
machine drawings, adjacent to (not
on) the device?
5.2.1.2
Are electrical drawings created with
CAD and provided in plant specific
format and also in Adobe Acrobat
PDF format?
5.2.1.2
Are electrical drawings provided on
paper in “A”, “B”, “DIN A4” or “DIN
A3” size?
5.2.11
Can Bosch make changes to all
software?
5.2.1.3
5.2.12
Are controls designed so that loss of
power (electrical, pneumatic, and
hydraulic) does not present a hazard
to personnel or damage to
equipment or damage to work in
process?
Are manual controls provided and
interlocked to prevent damage to
machine or work in process?
5.2.2.1
5.2.13
Section 7 Acceptance Checklist
P/A
Yes
F/A
Yes
No
7-10
Comments/Test Results
or N/A
Date
Needed
5.2.2.1
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.5.2 Section 5.2:
Electrical Design
Ref.
GDS/
Other
5.2.2.1
NFPA 79
2007 9.2.3
5.2.14
Are manual controls disabled during
automatic cycle?
5.2.15
Are separate control systems used
for each individual machine?
5.2.2.2
5.2.16
Do machine controls include
diagnostic indication for all machine
states?
5.2.2.3
5.2.17
Are abnormal continuous
consecutive machine cycles
prevented?
5.2.2.4
5.2.18
Do passwords limit access to
parameters?
5.2.2.5
5.2.19
Do out of tolerance process values
cause the machine to stop?
5.2.2.5
5.2.20
Do field bus systems meet plant
specific requirements?
5.2.2.6
5.2.21
Can all lamps be tested?
5.2.2.7
5.2.22
Are cycle counters present?
5.2.2.8
5.2.23
Is input power 480 VAC, 3 phase 60
Hz?
5.2.3.1.1
5.2.24
Is control voltage regulated 24 VDC
from a listed Power Supply?
5.2.3.1.2
5.2.25
Are Programmable Electronic
Systems I/O modules less than 50V
and separate from greater than 50V
enclosures?
Are all receptacles for 115 VAC
GFCI standard US grounded 3
prong?
5.2.3.1.3
5.2.27
Is equipment built with plant specific
"Preferred Electrical Components"?
5.2.3.2.1
5.2.28
Are control transformers and power
supplies sized 30% above maximum
load?
5.2.3.2.2
5.2.29
Do controller output circuits have
individual circuit protection?
5.2.3.2.3
5.2.30
Is workplace lighting energy efficient
T8 or T5 with electronic ballast,
switch controlled and supplied by
less than 150V?
5.2.3.2.4
NFPA 79
2007
15.2.2.1
5.2.26
Section 7 Acceptance Checklist
P/A
Yes
F/A
Yes
No
7-11
Comments/Test Results
or N/A
Date
Needed
5.2.3.1.4
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.5.2 Section 5.2:
Electrical Design
Ref.
GDS/
Other
5.2.3.3.1
5.2.31
Do enclosures have room for 20%
expansion?
5.2.32
5.2.3.3.2
Do enclosures larger than 0.425 cu.
m (15 cu. ft.) have lighting controlled
by a door switch and supplied by less
than 150V?
5.2.3.3.3
Do enclosures with programmable
devices have a 115 VAC GFCI
receptacle labeled "For programming
device only"?
5..2.3.3.3
Do programmable devices have a
readily accessible programming
interface?
5.2.33
5.2.34
5.2.35
Does wiring to enclosures that are
not mounted on the machine have
connectors?
5.2.3.3.4
5.2.36
Are plugs and sockets permanently
labeled and keyed per plant specific
requirement?
5.2.3.3.4
5.2.37
Are enclosures at least 100 mm
(3.75") off floor?
5.2.3.3.5
5.2.38
Are the control enclosures positioned
so the machine can be observed
while working in the enclosures?
5.2.3.3.5
5.2.39
Are AC motors High Energy Efficient
TEFC, 480 VAC, 3Φ, 60 Hz?
5.2.3.4
5.2.40
Do motors 25hp and above have
continuous conductors between
control enclosure and motor?
5.2.3.4
5.2.41
Do motors 25hp and above have
power factor corrected to above
90%?
5.2.3.4
5.2.42
Are all transformer neutral
conductors and power supply
common conductors grounded at the
source?
Does all control and power wiring
have readily accessible test points in
electrical enclosures?
5.2.4.1
Where screw or screw clamp
termination systems are used, are all
wires fitted with either ferrules or
crimp connectors?
Are 'wire numbers' or 'termination
labels' used exclusively?
5.2.4.3
5.2.46
Where 'wire numbers' are used, does
each wire have the same number at
all termination points?
5.2.4.3.1
5.2.47
Where 'wire numbers' are used, are
wires connecting to controller I/O
labeled I (input) or Q (output)
followed by the I/O address?
5.2.4.3.1
5.2.43
5.2.44
5.2.45
Section 7 Acceptance Checklist
P/A
Yes
F/A
Yes
No
7-12
Comments/Test Results
or N/A
Date
Needed
5.2.4.2
5.2.4.3
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Ref.
GDS/
Other
7.5.2 Section 5.2:
Electrical Design
5.2.48
Where 'termination labels' are used,
are wires labeled with the terminal
name?
5.2.4.3.2
5.2.49
Are all conductors installed without
wire splices?
5.2.4.4
5.2.50
Does wiring outside enclosures
include 15% extra wire length?
5.2.4.5
5.2.51
Are only stranded copper conductors
used?
5.2.4.6
5.2.52
Is MTW wire jacketing used on wires
not leaving control enclosures?
5.2.4.6
5.2.53
Is PUR cable used in oil, coolant or
VISCOR splash/mist areas, and PVC
cable used in brake fluid splash/mist
areas?
Do wire colors meet plant specific
requirements?
5.2.4.6
5.2.55
Does computer hardware and
operating system meet plant specific
requirement?
5.2.5.1
5.2.56
Does computer software meet plant
specific requirement?
5.2.5.1
5.2.57
Do program printouts and remarks
meet plant specific requirement?
5.2.5.1
5.2.58
Does use of software modules meet
plant specific requirement?
5.2.5.1
5.2.54
P/A
Yes
F/A
Yes
No
7-13
Comments/Test Results
or N/A
Date
Needed
5.2.4.7
Data Management / Networking
5.2.59
Will the machinery be connected to
the BCN?
5.8
5.8.1
5.2.60
Is all 3rd party software properly
licensed? (Proof of ownership and
original media are required.)
5.8.4
5.2.61
Have virus protection measures be
considered / implemented? (Please
explain.)
5.8.2
5.2.62
Is CAT5 UTP cabling used for all
data network connections?
5.8.1
5.2.63
Is TCP/IP protocol used?
5.8.1
Section 7 Acceptance Checklist
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.5.2 Section 5.2:
Electrical Design
Ref.
GDS/
Other
5.2.64
Have security measures been
implemented to protect against loss
or theft of data? (Please explain.)
5.8.3
5.2.65
Will the machinery be integrated into
an existing data collection system?
5.8.1
5.8.3
5.2.66
Is there a contingency plan that will
provide for “continuous production” in
the event of hardware/ software
failure or virus infection? (Please
explain.)
5.8.1
5.8.2
5.8.3
5.8.4
Section 5.2
Maintenance Group Leader
signature
Section 7 Acceptance Checklist
Pre:
P/A
Yes
F/A
Yes
No
7-14
Comments/Test Results
or N/A
Date
Needed
Final:
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.6
Section 6: Quality
Standards and Run-off
Conditions
Ref.
GDS/
Other
P/A
Yes
F/A
Yes
No
Comments/Test Results
or N/A
6.1
Are sample sizes selected per
Appendix 6.1?
6.2.3
6.2
Are production samples divided
equally among work piece locations?
6.2.4
6.3
Are Gage, Machine and Process
capability studies conducted per
paragraph 6.3 and Plant Specific
Requirements?
Do results meet the following
acceptance criteria:
6.3
ƒ
Gage Capability: < 10%
6.3
Test Results:
6.4.2
a)
<10% of tolerance;
or
6.3
Test Results:
6.4.3
b) Alternatively,
ISOPlot(sm)
Discrimination Ratio
DR>12.5?
Machine Capability: (Cmk >
1.67)?
6.3
Test Results:
6.3
Test Results:
Process Capability:
(Cpk > 1.33)?
6.3
Test Results:
6.4
6.4.1
6.4.4
ƒ
6.4.5
ƒ
6.5
Is gage scale least count or least
division < 10% of smallest part
tolerance?
6.6
Do gages display variable data
unless otherwise specified?
6.4.2
6.7
Is technical availability > 95% as per
Appendix 6.2?
6.5.1
6.8
Does changeover time meet BPS
guidelines (<10 min. for equipment,
<5 min. for assembly)?
6.5.2
6.9
Is dry-cycle run for durability
conducted?
6.5.3
6.10
Are process data or set-up sheets
available:
6.6.1
6.10.1
ƒ
Set-up parameters included?
6.6.1
6.10.2
ƒ
Tool change/ adjustment
procedures included?
6.6.2
Section 7 Acceptance Checklist
7-15
Date
Needed
6.4
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.6
Section 6: Quality
Standards and Run-off
Conditions
Ref.
GDS/
Other
6.11
Are frequency of operational
adjustments adequate?
6.6.2
6.12
Is at least one change per tool, using
equipment supplier set up procedure,
accomplished during run-off trial?
6.6.2
6.13
Are all modes and features of
software operation and data output
demonstrated:
6.13.1
ƒ
Test plan available?
6.7
6.13.2
ƒ
Calculations verified?
6.7
6.13.3
ƒ
Remote access verified?
6.7
6.13.4
ƒ
Data transmission to Bosch
network?
6.7
Section 6
QMM signature
7.7
Pre:
P/A
Yes
F/A
Yes
No
7-16
Comments/Test Results
or N/A
Date
Needed
Final:
Section 7: N/A
Section 7 Acceptance Checklist
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.8
Section 8:
Documentation and
Shipping Instructions
8.1
Is machine documentation provided
as per Section 8.1 of the GDS?
8.2
Does service manual format meet
Appendix 8.1 guidelines of the GDS?
Section 8
Maintenance Group Leader
signature
Ref.
GDS/
Other
8.1.2
P/A
Yes
F/A
Yes
No
7-17
Comments/Test Results
or N/A
Date
Needed
8.1.2.b
Pre:
Final:
7.9
Section 9: Appendices – N/A
7.10
Section 10: Plant Specific Additional Requirements – See Section 10
7.11
General Information
7.11.1 All tests conducted at equipment supplier are preliminary acceptance tests. Final
acceptance will always be conducted at Bosch.
7.11.2 Bosch will provide qualified components for acceptance. Provision for
gauges/measurement equipment and personnel to be coordinated with the project
engineer.
7.11.3 Evaluation of quality will be done with statistical method, when applicable, described
in Section 6.
7.11.4 Acceptance shall be based on the production result. Performance data and process
time to be verified and documented.
7.12
Instructions:
7.12.1 Supplier compliance with the GDS will be evaluated in part by the following
checklist. Bosch Project Engineer/Leader is responsible for the completion of the
Machinery & Equipment pre-acceptance checklist.
7.12.2 The first “Yes” column P/A is for Pre-Acceptance; the second “Yes” column F/A is
for Final Acceptance.
7.12.3 Items that are Not Applicable shall be recorded as N/A in the comments section.
7.12.4 All items that have checks in the “No” column require corrective action unless
deviations have been authorized.
Section 7 Acceptance Checklist
OF04.7.04.011
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
8-1
8 Documentation and Shipping Instructions
8
Documentation and Shipping Instructions............................................................................................ 1
8.1
Machine Documents .................................................................................................................................... 1
8.2
Shipping Instructions .................................................................................................................................. 2
8.3
Ocean Freight Shipping............................................................................................................................... 3
8.4
Package Identification ................................................................................................................................. 3
8.5
Shipping Documentation............................................................................................................................. 3
8.6
Invoicing ....................................................................................................................................................... 4
8.1
Machine Documents
8.1.1 The use of the English language is mandatory on all papers, documents and
machine labeling. This includes support equipment located on machine (e.g.
measuring devices, dressing appendages).
8.1.2 All machine documentation shall cite the Purchase Order Number.
8.1.3 All machine documents shall be submitted in standard electronic format as specified
by Project Engineer. One set of hardcopy documents shall be delivered with the
machine. The following documents are to be included, if applicable:
a) Operation, Set-up, and Maintenance Instruction (See Appendix 8.1 for format
guidelines)
b) Service Manual (See Appendix 8.1 for format guidelines)
c) Hydraulic Diagram, with parts list
d) Pneumatic Diagram, with parts list
e) Layout - Including location of switches, motors, solenoid valves, etc.
f) Electrical Diagram - Including internal circuit diagrams, KVA ratings, fuse
amperages, parts lists, general diagram on installation Position and panel layout
diagram.
g) PLC Program - program printout, symbol table and cross reference table in that
order.
h) Software, including source code
i)
j)
k)
l)
m)
n)
Function Plans
Computer Program Listings
Computer Program Flowcharts
Preventative Maintenance Schedule
Assembly and Detail Drawings
Spare Parts List with manufacturer’s name & stock number
in electronic format (See Appendix 8.2)
o) Tooling List
Section 8 Documentation and Shipping Instructions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
p)
q)
r)
s)
t)
8-2
Certificates of Compliance (pressure vessel, calibration, high freq. etc.)
Robotic Risk Assessment
Laser Product Report and accession number from CDRH
Safety Instructions
Component Manuals
8.1.4 The above documents have to be updated within thirty (30) days after final
acceptance and sent to the Project Engineer.
8.2
Shipping Instructions
8.2.1 For direct shipment, all delicate equipment and parts are to be sufficiently secured
or packed and labeled for the most extreme transportation conditions. When
crating, screws shall be used instead of nails.
8.2.2 During disassembly each joint must be labeled on both sides.
8.2.3 Equipment supplier must comply with the following inbound routing instructions
when delivery terms of our purchase order are “FOB Shipping Point”.
8.2.4 Bosch/Affiliate will charge back to equipment supplier for all freight costs resulting
from non-compliance with shipping instructions according to routing orders.
8.2.5 If air freight is required due to late delivery it must be shipped prepaid at equipment
supplier expense.
8.2.6 Bosch/Affiliate is to be informed by the supplier in sufficient time about shipping
date and transport means to handle insurance, etc. If this is neglected, supplier will
be liable for transport damage exclusively. For damages not covered by insurance
due to inappropriate lading and/or packing, the supplier is liable.
8.2.7 Supplier will contact Project Engineer at least one (1) week prior to shipment with
weight, dimensions, and an estimate of the number of trucks and types.
8.2.8 All shipments and separate partials of tools, machines, and auxiliary equipment
shall be stenciled (with black paint) in a conspicuous location with the Bosch
/Affiliate’s Purchase Order number.
8.2.9 Special transport, rigging and lifting instructions shall be provided and be clearly
visible to handlers, i.e. weight, height, lift points, labels such as “This End Up”,
“Protect From Rain”, etc.
Section 8 Documentation and Shipping Instructions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
8.3
8-3
Ocean Freight Shipping
8.3.1 The Purchase Order Number, BOSCH Part Number and Release Number must
appear on:
a) Packing List
b) Certification
c) Outside Container
d) Bill of Lading
If applicable, Freight Authorization Number must appear on:
e) Consignee's copy of the Air Bill/Bill of Lading
f) and Invoice
8.3.2 All freight should be shipped collect, unless it is:
a) Reshipment due to defective goods
b) Shipment via Premium freight due to late delivery
c) Shipment via non-designated carrier
THE ABOVE SHIPMENTS SHALL BE PREPAID AT EQUIPMENT SUPPLIER’S
EXPENSE.
8.4
Package Identification
8.4.1 Mark each package or separate piece as below:
Robert Bosch LLC or Affiliate name
City - U.S.A.
Purchase Order No.:_____________
Made in:______________________
One copy of Packing List should be placed in each package or case.
8.5
Shipping Documentation
8.5.1 The following shall be air mailed directly to Robert Bosch LLC or it’s Affiliates.
a) Five (5) copies of Commercial Invoice
b) Three (3) copies of original Bill of Lading
c) Three (3) copies of the Packing List stating contents of each package or case.
8.5.2 Documentation for U.S. Customs Clearance
To enable U.S. Customs to clear the shipment three (3) commercial invoices have
to accompany the shipment:
a) 1 copy in package
b) 1 copy in envelope attached to the outside of the package
c) 1 copy attached to the Air Way Bill (AWB).
Section 8 Documentation and Shipping Instructions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
8.6
8-4
Invoicing
8.6.1 Equipment supplier to supply invoice according to purchase order terms.
8.6.2 All invoices must show purchase order number and be sent directly to the Accounts
Payable Department of Robert Bosch LLC or it’s Affiliates as specified on the
Purchase Order.
8.6.3 Invoice should contain the following information in English, or in German with
English translation:
a) Individual price must be shown for each item, or set. If items are supplied in
sets or groups this must be clearly stated on invoice and Packing List.
b) Total gross, tare and net weight.
c) Costs of packing.
For International Orders only:
d) Cost of freight from manufacturer to dock shipping agent.
e) If shipment is made at “no charge”, such as a sample, the value must be
stated on a Proforma invoice for Customs purposes. The shipment should
be marked “SAMPLE”. The Proforma invoice should be marked “NO
COMMERCIAL VALUE”.
f) Kilowatt rating for electric motors (For Customs purpose only).
g) Return shipment of repairs must show the value of the part and the cost of
repair, including repair materials.
h) Signature.
8.6.4 Commercial invoice quantities and values must match exactly to shipping
documents. Reference to specific page and line item from Purchase Order
required.
Section 8 Documentation and Shipping Instructions
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendices
9 Appendices
9.1
Appendix 1.1
Equipment
General Terms and Conditions for the Purchase of Capital
9.2
Appendix 1.2
GDS Deviation Request Form
- OF04.7.04.012
Download
9.3
Appendix 2.1
Machine Data Sheet
- OF04.7.04.013
Download
9.4
Appendix 2.2
Design Review Checklist
- OF04.7.04.014
Download
9.5
Appendix 4.1
BPS Investment Assessment
- OF04.7.04.015
Download
9.6
Appendix 4.2
OEE Calculation
- OF04.7.04.016
Download
9.7
Appendix 4.3
Workplace Measurements
9.8
Appendix 5.1
US Contacts for Bosch Products
9.9
Appendix 5.2
Control Systems Overview form – OF04.7.04.017 Download
9.10
Appendix 5.3
Required Clearance Space for Electrical Panels
9.11
Appendix 6.1
Parts to Produce for Total Test, Sample Size
9.12
Appendix 6.2
Technical Availability
9.13
Appendix 8.1
Format of Manuals
9.14
Appendix 8.2
Spare Parts List Form
Appendices
- OF04.7.04.018
Download
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.1-1
Appendix 1.1 - General Terms and Conditions
General Terms and Conditions ...................................................................................................................... 1
1
Complete Agreement. ...................................................................................................................................... 2
2
Scope of Work ................................................................................................................................................. 2
3
Taxes.................................................................................................................................................................. 2
4
Contract Price................................................................................................................................................... 2
5
Payment Terms................................................................................................................................................. 2
6
Delivery, Performance and Delivery Dates.................................................................................................... 3
7
Pre-acceptance and Acceptance...................................................................................................................... 3
7.1
7.2
7.3
7.4
7.5
8
General ...................................................................................................................................................................... 3
Pre-acceptance........................................................................................................................................................... 3
Final Acceptance ....................................................................................................................................................... 3
Remedies ................................................................................................................................................................... 3
Testing Materials ....................................................................................................................................................... 4
Seller’s Warranties........................................................................................................................................... 4
8.1
8.2
8.3
8.4
General ...................................................................................................................................................................... 4
Warranty.................................................................................................................................................................... 4
No Limitation. ........................................................................................................................................................... 4
Third Party................................................................................................................................................................. 4
9
Insurance........................................................................................................................................................... 5
10
Work at Buyer's Facility ................................................................................................................................. 5
11
Documentation ................................................................................................................................................. 5
12
Subcontractors ................................................................................................................................................. 5
13
Confidentiality and Trade Secrets, and Know-How ..................................................................................... 5
14
Ownership of Improvements........................................................................................................................... 6
15
Excusable Delays .............................................................................................................................................. 6
16
Spare Parts........................................................................................................................................................ 6
17
Software ............................................................................................................................................................ 6
18
Federal Contractor........................................................................................................................................... 6
19
Termination for Default .................................................................................................................................. 7
20
Termination for Convenience ......................................................................................................................... 7
21
Right to Offset .................................................................................................................................................. 7
22
Arbitration........................................................................................................................................................ 7
23
Changes ............................................................................................................................................................. 7
24
Patent Indemnity.............................................................................................................................................. 8
25
General Indemnity ........................................................................................................................................... 8
26
Miscellaneous.................................................................................................................................................... 8
Appendix 1.1 - General Terms and Conditions
Final Version LEG05012000
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.1-2
1 Complete Agreement.
These Terms and Conditions for the Purchase of Capital Equipment ("Terms and Conditions"), including the general delivery
specifications (GDS), design and performance specifications, standards, and any other documents attached or referenced on
Buyer's purchase order (collectively "the Contract Documents") issued hereunder constitute the Complete and Final
Agreement (the "Agreement") of the Robert Bosch LLC ("Buyer") and the Seller ("Seller"), and all prior negotiations, proposal
and writings pertaining to the "Agreement" or the subject matter thereof, are superseded hereby. Any reference to Seller's
quotation, bid or proposal contained on Buyer's purchase order does not imply acceptance of any terms, condition or
instruction contained in such document unless expressly stated otherwise on Buyer's purchase order. In the event of any
ambiguities, express conflicts or discrepancies in the documents referenced in Buyer's purchase order and these terms and
conditions, Seller shall immediately submit the matter to Buyer for its determinations and shall comply with the determination
of Buyer in such matter. All headings and numberings contained in these terms and conditions are for convenience of
reference only.
2 Scope of Work
Except as expressly stated otherwise in the Agreement, Seller is responsible for (i) all labor, materials, equipment, tools and
supervision necessary to perform the Agreement; (ii) designing, assembling, constructing, and building the Equipment listed in
the Agreement, and (iii) conducting testing and training procedures related to the operation and maintenance of the
Equipment listed in the Agreement (hereinafter collectively "Scope of Work"). If the Agreement does not require Seller to
install the Equipment at Buyer's facility, Seller agrees to provide Buyer installation supervision services at Buyer's facility.
3 Taxes
Any tax imposed on Seller by any federal, state, local or other legal government taxing authority which arises out of or is
based upon the sale of the Equipment (for greater certainty, excluding and excepting any taxes based on Seller’s income),
whether characterized as present or future sales, use, excise, value added, or other similar tax applicable to the price, sale, or
delivery of any products or services furnished hereunder or to their use by Seller or Buyer will be for Buyer’s account and will
be quoted as separate itemized charges. In addition to the Contract Price specified herein, Buyer shall pay the gross amount
of any such present or future sales, use, excise, value added, or other similar tax; or Buyer shall furnish Seller with evidence
of an acceptable exemption to the taxing authorities.
4 Contract Price
Buyer shall pay Seller the Contract Price identified on Buyer's purchase order as full consideration for Equipment and the
Scope of Work covered thereby by this Agreement subject to changes only as provided in paragraph 22 of this Agreement.
Unless expressly stated otherwise on Buyer's purchase order, the Contract Price shall be based upon FOB destination, and
includes all costs related to testing at Buyer's and/or Seller's facility, installation (if any), start up, training, applicable taxes,
excises, duties, quotations fees or any other governmental impositions on or related to the Equipment. The Contract Price
referred to in Buyer's purchase order is stated in U.S. dollars unless expressly provided otherwise.
5 Payment Terms
Buyer will make payments to Seller in accordance with the Payment Schedule set forth on Buyer's purchase order issued by
Buyer, provided Buyer receives an invoice from Seller in accordance therewith. Payments shall be made net thirty (30) days
of Buyer's receipt of a correct invoice. The Acceptance of any payments by the Seller shall constitute a release of Buyer from
any other liability, except retainage, due to any reasons arising or incurred prior to the date of the invoice to which the
payment relates. Acceptance of final payment by Seller constitutes a general release of Buyer. If Seller chooses not to
release Buyer from any liabilities by not accepting payment, Seller agrees to return payment in entirety with a written affidavit
of an officer of Seller listing every issue Seller is contesting. Buyer will not be obligated to make any payment to Seller if any
one or more of the following conditions exist: (a) Seller is in material default of any of its obligations under this Agreement, (b)
any part of such payment is attributable to work which is defective or not performed in accordance with this Agreement;
provided however, such payment will be made as to the part attributable to work performed in accordance with this Agreement
and which is not defective, (c) Seller has failed to make payments promptly to Seller’s subcontractors or for material or
services related to the Equipment for which Buyer has made payment to Seller, (d) if Buyer reasonably determines that the
portion of the amount remaining unpaid under this Agreement will not be sufficient to complete the work in accordance with
this Agreement, no additional payments will be due Seller unless and until Seller, at its sole cost, performs a sufficient portion
of the work so that such portion of the amount remaining unpaid is determined by Buyer to be sufficient to complete the work,
or (e) Seller has failed to complete the work within the time period stated in this Agreement. In addition, Buyer may set off
from payments otherwise due under this Agreement claims arising under other contracts or purchase orders with Seller. Upon
receipt of payment from Buyer, Seller will promptly pay each subcontractor the amount to which said subcontractor is entitled,
reflecting the percentage actually retained, if any, from payments to Seller on account of subcontractor's work. Seller will, by
agreement, require each subcontractor to make payments to his sub-contractors in similar manner. Buyer has no obligation
to pay or to see to the payment of any moneys to any subcontractor except as otherwise may be required by law.
Appendix 1.1 - General Terms and Conditions
Final Version LEG05012000
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.1-3
6 Delivery, Performance and Delivery Dates
TIME IS OF THE ESSENCE FOR THIS ORDER. Except as otherwise stated on the purchase order, delivery shall be F.O.B
Buyer's facility or the destination designated by Buyer. Seller agrees to deliver the Equipment in compliance with this
Agreement, including all scheduled performance and delivery dates set forth on Buyer's purchase order. Seller will ensure that
the Equipment is packed and shipped in an appropriate and suitable manner. Buyer's count of the Equipment and
components thereof, will be final for all shipments shipped without an accompanying packing list. Seller will notify Buyer
immediately of any circumstance which may delay the delivery of the Equipment, along with any corrective action Seller has
taken to minimize the effect. In the event delivery is not in compliance with this Agreement, including delivery of the
Equipment in accordance with the scheduled delivery dates (unless caused by an excusable delays as defined in paragraph
15), at Buyer's sole discretion, Buyer shall have the right to (i) require Seller shall ship the Equipment, either completed or not
completed at Buyer's option, at the earliest possible moment and by the fastest manner (air freight) at Seller's sole cost and
expense; (ii) terminate this Agreement, by written notice to Seller, and shall, in addition to all other remedies available at law
or in equity, be entitled to a refund of all monies paid by Buyer to Seller under this Agreement; or (iii) terminate part of the
work to be performed under this Agreement or the applicable purchase order, and Seller shall, in addition to all other
remedies available at law or in equity, be responsible for all costs incurred by Seller to complete the work in accordance with
this Agreement. Any additional costs incurred by Buyer as a result of nonconformance with this Agreement will be paid by
Seller, including additional production charges, labor charges, and transportation costs.
7 Pre-acceptance and Acceptance.
7.1
General
Seller will submit to Buyer all production, function and quality control test reports and other data as Buyer may
request from time to time concerning the Goods. Seller grants to Buyer the right to enter Seller’s premises at any
reasonable time to make an inspection and examination of the Goods, their component parts and the
fabrications/assembly techniques proposed or used by Seller as Buyer may deem appropriate. Seller agrees to fully
cooperate with Buyer in such inspections.
7.2
Pre-acceptance
Upon completion of fabrication of the Equipment at Seller' facility, Seller shall provide Buyer notice that the
Equipment is ready for shipment/pre-acceptance testing. Buyer shall have the right to inspect the Equipment prior to
shipment at Seller's facility within thirty (30) days of the date Buyer receives such notice ("Pre-acceptance Inspection
Period"). During the Pre-acceptance Inspection Period, Buyer shall confirm that the Equipment complies with all
applicable specifications and requirements. Any defects or deficiencies discovered by Buyer shall be promptly
repaired or replaced by Seller's at Seller's sole cost and expense, and the Equipment shall be subject to another preacceptance inspection or test by Buyer.
7.3
Final Acceptance
All Equipment ordered under this Agreement shall be subject to final acceptance by Buyer ("Final Acceptance").
Buyer shall notify Seller at least ten (10) days prior to the date of the final acceptance testing, which shall be
designed by Buyer to evaluate whether the Equipment is in compliance with all applicable specifications and
operates as contemplated in the Agreement. In the event the Equipment fails to operate in compliance with this
Agreement and/or does not meet all specifications and requirements contained in this Agreement (including the
applicable purchase order), Seller shall at Seller's own expense, immediately make such repairs or adjustments so
as to render the Equipment in compliance therewith and the Acceptance Test shall be repeated. Notwithstanding
payment or any prior inspection, Final Acceptance will not occur until (i) Seller has corrected all deficiencies related
to the Equipment identified by Buyer, (ii) Seller has provided all documentation pursuant to paragraph 12, (iii) Seller
provides evidence to Buyer that all of Seller’s subcontractors have been paid, including lien waivers if appropriate,
and (iv) Seller has satisfied all other requirements as are specified in the Agreement. In the event Final Acceptance
by Buyer is not achieved within thirty (30) days of the date Buyer first began final acceptance testing, Seller shall be
deemed in material breach of this Agreement, and Buyer may revoke the Agreement, terminate this Agreement for
default, and/or reject the Equipment, in whole or part, in addition to any other remedies Buyer may have at law or in
equity.
7.4
Remedies
In the event that the Equipment or any portion of the Equipment is not in compliance with any laws, the specifications
contained in the Agreement, or are otherwise defective, Buyer may return the defective Equipment or part thereof to
Seller, who shall refund to Buyer its cost plus freight to Buyer’s facility and freight for return to Seller. If Buyer prefers
to accept the defective or non-conforming Equipment instead of requiring correction or replacement, the Agreement
will be adjusted to reflect a reduction in the total Contract Price as appropriate and equitable. Such adjustment will
be effected whether or not final payment has been made.
Appendix 1.1 - General Terms and Conditions
Final Version LEG05012000
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
7.5
Appendix 1.1-4
Testing Materials
For only the first pre-acceptance test and the first final acceptance test performed, Buyer shall be responsible for its
own travel costs and the costs of providing any materials or supplies that Buyer deems necessary in order to verify
the proper operation and performance of the Equipment. For all pre-acceptance and final acceptance tests
performed after the first one, Seller shall be responsible, at its sole costs and expense, for any materials or supplies
that Buyer supplies or that Seller requests Buyer to supply in order to verify the proper operation and performance of
the Equipment. In addition, Seller shall be responsible for any and all travel expenses and other related costs
incurred by Buyer as a result of the non-compliance of the initial pre-acceptance test or final acceptance tests
performed or due to any subsequent pre-acceptance and/or final acceptance testing that are performed. The preacceptance testing and final acceptance testing parameters shall be established by Buyer and shall be based upon
the specifications and requirements set forth in this Agreement.
8 Seller’s Warranties.
8.1
General
Seller warrants that the Equipment, including all material and work furnished pursuant to this Agreement, (i) will be of
the highest grade and quality unless otherwise specified by Buyer in writing; (ii) will be free and clear of all liens,
claims or encumbrances arising or resulting from the acts or omissions of Seller or anyone claiming by or through
Seller; (iii) will not be less than merchantable and fit for the particular purpose(s) known by or disclosed to Seller as
applicable thereto; and (iv) shall meet and conform to this Agreement, including but not limited to all design,
manufacture and performance the specifications and requirements specified in the Agreement. If requested by
Buyer, Seller will furnish satisfactory evidence as to the kind and quality of material and work furnished under this
Agreement and/or incorporated in the Equipment. Seller further warrants that the Equipment will comply with all
applicable federal, state, and local laws and regulations. Unless otherwise stated herein, Seller warrants that it is a
seller in the ordinary course of goods of this kind. Seller warrants that the Software (as defined in paragraph 17) will
conform to the Documentation in all material respects, and that if the Software is used in accordance with the
Documentation, the Equipment will operate in accordance with the Specifications. These warranties are in addition
to any “shrink-wrap”, “click-on” or other warranty regarding the Software that may be included with the Equipment.
8.2
Warranty
For a period of twelve (12) months after the date of Final Acceptance of the Equipment or eighteen (18) months
following the date the Equipment is delivered to Buyer's facility, whichever occurs later, Seller agrees to promptly (not
more than 24 hours from the date of Buyer's notice to Seller) perform any corrective work in connection with the
Equipment which may be required without cost to Buyer. Seller shall also be responsible, at its sole cost and
expense, for all labor and travel expenses incurred by Seller to perform any warranty service hereunder or to send its
personnel to Buyer's facility). Seller further agrees that all materials, components, parts, and equipment incorporated
into the Equipment will carry manufacture and/or vendor warranties involving terms and duration which are, at a
minimum, not less favorable to Buyer than those typically offered and meeting industry standards of such materials
and equipment.
8.3
No Limitation.
Nothing contained in paragraphs 8.1 or 8.2 of this Agreement will be construed to establish a period of limitation with
respect to any other obligation which the Seller might have under this Agreement. The establishment of a time
period of twelve (12) months after final acceptance of the Equipment or eighteen (18) months after the date the
Equipment is delivered to Buyer, or a longer period of time as may be prescribed by law or by the terms of any
warranty required by this Agreement relates only to specific obligation of Seller to correct the Equipment.
8.4
Third Party
In the event Seller fails to respond to any of its obligations under this warranty within the time frame established
herein or to complete any warranty work within a timely manner as deemed by Buyer given the facts and
circumstances, Buyer shall have the right to perform the necessary corrective action or repairs necessary by itself or
by retaining a third party. In such cases, Seller will be charged any and all direct costs incurred by Buyer to perform
the work covered under this warranty. Notwithstanding the foregoing, where the failure or any delay to correct such
failure may result or threatens to create significant liability or damages or unreasonable costs to Buyer if not
immediately repaired, Buyer shall have the right, without notice to Seller, to immediately perform the necessary
repairs or corrective action by itself or through a third party, and Seller agrees to reimburse Buyer for any and all
direct costs incurred by Buyer relating to the performance of such work.
Appendix 1.1 - General Terms and Conditions
Final Version LEG05012000
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.1-5
9 Insurance
Seller and its subcontractors shall maintain (i) Commercial General Liability Insurance, including coverage for products liability
and completed operations arising out of or related to the Equipment or Seller’s performance under this Agreement, with a per
occurrence limit of not less than $2,000,000, and a general aggregate of not less than $5,000,000; (ii) Automobile Liability
Insurance with a combined single limit of $1,000,000 per occurrence for bodily injury and property damage covering use and
operation of owned, non-owned and hired vehicles. Seller’s insurance shall be primary and non-contributing to any other
insurance which may apply. Seller will furnish certificates of insurance to Buyer at the time the Agreement is issued by Buyer.
The insurance policies will provide for cancellation only after thirty (30) days’ prior written notice to Buyer. Buyer’s failure to
require or demand any evidence of insurance does not constitute a waiver of any requirement for Seller to obtain insurance,
nor does it limit Seller’s other obligations. Seller agrees to insure all shipments of Equipment for full value unless expressly
specified otherwise on Buyer's purchase order. Seller shall provide workers’ compensation insurance and unemployment
compensation insurance as required by applicable law. In the event Seller is required to perform work to complete the
Agreement on Buyer’s property, Seller will provide such additional insurance coverage as Buyer requests. Under no
circumstance will employees of Seller be deemed to be the employees of, or under the direction or control of, Buyer for any
reason.
10 Work at Buyer's Facility
In the event this Agreement requires the performance of service work, removal, moving or installation of the Equipment by
Seller upon any property, premise or project of Buyer, Seller shall examine the same to determine whether they are safe for
such services and shall advise Buyer promptly of any situation Seller considers to be unsafe. Seller (its agents, employees,
and sub-contractors) shall comply with the requirements of all applicable safety and health laws, regulations, rules, ordinances
and orders. These include, but are not limited to the Occupational Safety and Health Act of 1970 ("OSHA"), the Toxic
Substance Control Act ("TSCA"), the Construction Safety Act of 1969 ("CSA"), and all standards promulgated thereunder, and
with Buyer's local/plant safety program. Seller shall comply with and is directly responsible for compliance therewith on the
part of its respective agents, employees, material persons and subcontractors. Seller shall keep those portions of the Buyer's
premises where Seller is performing work or services clean of debris, and upon completion of the work shall leave the
premises clean an ready for use. If Seller fails to clean up to Buyer's satisfaction, Buyer may do so and the cost will be
charged to Seller or deducted from the Contract Price. Seller shall directly receive and be responsible for all citations,
assessments, fines or penalties which may be incurred by reason of its failure or failure on the part of their agents,
employees, material persons or subcontractors, to so comply. Notwithstanding the provisions of any Workers Compensation
statute, Seller agrees to and shall indemnify, protect, defend and save harmless Buyer from and against all costs (including
reasonable attorney's fees), damages, and liability arising out of or allegedly arising out of any violations by Seller, its
employees, agents, and subcontractors of any applicable safety and health laws, regulations, rules, ordinances, and orders,
including but not limited to OSHA, TSCA, and CSA. Seller warrants that all certificates and licenses that may be required for
the performance of any services or work under this Agreement will be obtained by Seller. Seller will coordinate all work and
services to be performed at Buyer's premises with the Buyer in advance to ensure that suitable power, materials handling
equipment and other items are available.
11 Documentation
Seller will provide Buyer at no additional cost to Buyer, with (i) a complete listing of recommended spare parts for the
Equipment, (ii) operation, maintenance, and training manuals, and (iii) copies of the technical and mechanical specifications
relating to the Equipment, including layouts, drawings, diagrams, software and models of the Equipment (collectively
hereinafter "Documentation"). In addition, no more than thirty (30) days after receipt of Buyer's purchase order, Seller will
provide Buyer with any site/facility specifications relating to the requirements necessary for the proper set up of the
Equipment, including necessary floor loads to hold the Equipment, height, depth and width requirements, electrical, power,
water, and heating requirements, and all other requirements necessary to properly and safely install, set up, maintain and
operate the Equipment. Any and all Documentation provided to Buyer shall be written in English. Seller further agrees, at its
own cost and expense, to ensure that any Documentation provided to Buyer accurately reflects the description, design,
specifications, etc. of the Equipment as of the date of Final Acceptance by Buyer.
12 Subcontractors
Seller will furnish to Buyer in writing all names and addresses of the persons or entities (including those who are to furnish
materials or equipment fabricated to a special design) proposed for the principal portion of the Equipment. Buyer will promptly
reply to Seller in writing stating whether or not Buyer has objection to any such proposed person or entity. Neither party will
make a substitution for any subcontractor, person or entity previously selected if the other party objects to such substitution.
13 Confidentiality and Trade Secrets, and Know-How
. Seller will at no time directly or indirectly reproduce, disclose, advertise, publish or otherwise make known (a) the fact that
Seller and Buyer have entered into this Agreement, or that Seller has contracted to or has furnished Equipment to Buyer, or
(b) any information, design, specification, idea, concept, plan, copy, formula, drawing, process, procedure, performance
characteristics or other confidential information which has been or will be disclosed to Seller in connection with the Equipment
Appendix 1.1 - General Terms and Conditions
Final Version LEG05012000
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.1-6
or their evaluation, study, design, production, testing, installation or performance, or received in performing this Agreement
(collectively, the “Information”). Seller will not use any of Buyer’s Information which is disclosed to or in possession or control
of Seller except in performing this Agreement, unless in compliance with written instructions of Buyer. Upon Buyer's request,
Seller shall execute a separate confidentiality/non-disclosure or development agreement, which shall be incorporated into this
Agreement by this reference.
14 Ownership of Improvements
Seller agrees to, and hereby does, assign its entire right, title and interest in all intellectual property, including, but not limited
to, all writings, designs, mask works, software, inventions, improvements and discoveries, conceived or made by all
employees and agents of Seller in connection with their provision of services or the Equipment to Buyer under this Agreement
(collectively hereinafter "Improvements"), with the understanding that patent rights retained by Seller in the Equipment shall
remain the intellectual property of Seller. Seller further agrees to do all lawful acts and sign all assignments and other papers
Buyer deems necessary, appropriate or advisable relating to applications for patents, mask works, registrations, trademarks,
and copyrights related to the Improvements, both United States and foreign, or relating to the conduct of any interference,
litigation or other controversy in connection therewith, provided that all expenses incident to the filing of such applications, the
prosecution thereof and the conduct of any interference, litigation or other controversy, including Seller’s employees’ time and
travel expenses incurred in connection with such applications, shall be borne by the Buyer. Seller further agrees not to assert
any intellectual property right against Buyer in relation to Buyer’s use of any Improvements in connection with Seller’s
performance under this Agreement, and grants a royalty free, irrevocable, non-exclusive, worldwide license to any patent
rights in the Equipment provided that Buyer use is limited to Buyer and its affiliates to use, operate and maintain the
Equipment supplied under this Agreement.
15 Excusable Delays
Either party may suspend performance during the occurrence of an excusable delay. An excusable delay may include any
delay not the result of fault or negligence of the party whose performance is prevented by the delay and which results from the
acts of God or public enemy, restrictions, prohibitions, priorities or allocations imposed by governmental authority, embargoes,
floods, fires, earthquakes, epidemics, unusually severe weather, delays of similar nature or governmental causes, and strikes
or labor disputes (of or involving the delayed party’s employees only). Notwithstanding the foregoing, Seller shall not be
excused from performance hereunder where the reason for the delay was reasonably foreseeable and/or avoidable, or where
alternate sources of materials, goods or services are reasonably available even if at a higher cost to Seller. If the Seller
anticipates any event that could constitute a delay in delivery or in its ability to comply with any of its performance obligations
under this Agreement, Seller shall promptly notify Buyer in writing of the same. In the event of excusable delay, performance
of this Agreement will be extended for a reasonable period of time to be determined by Buyer and not to exceed a period
equal to the length of the delay itself. Buyer reserves the right to visit Seller’s facility during normal business hours and, after
due notice, to inspect Seller’s operations to evaluate the progress of the Work and determine adherence to the Contract
Schedule. Seller shall promptly take all commercially reasonable steps to avoid or end delay without additional cost to Buyer.
Notwithstanding anything to the contrary set forth in this Agreement, in the event an excusable delay affecting Seller's
performance exceeds thirty (30) days, Buyer may terminate this Agreement without liability notwithstanding anything to the
contrary stated in this Agreement.
16 Spare Parts
Unless otherwise specified by Buyer on Buyer's purchase order, Seller agrees, for a period of ten (10) years after the delivery
of the Equipment, to maintain an adequate inventory of all unique or specially manufactured parts to properly support and
maintain the Equipment purchased under this Agreement. For parts that are commercially available at a comparable price,
Seller will identify for Buyer the manufacturers, vendors, or other sources of Seller’s supply of such parts, as well as parts
numbers and prices, and agrees to maintain for a period of seven (7) years after delivery of the Equipment an adequate
inventory of such purchased parts to properly support and maintain the Equipment purchased. The prices of all parts shall be
adjusted in accordance with Seller’s price list.
17 Software
In the event that software is required for the installation, testing, calibration, operation or maintenance of the Equipment
(“Software”), Seller hereby grants to Buyer an irrevocable, perpetual, paid-up, worldwide, nonexclusive license to use the
Software for such purposes. Any Software that is custom developed by Seller for Buyer under this Agreement ("Custom
Software") shall be delivered to Buyer with the applicable source code. All rights, title, ownership and interest in such Custom
Software shall best in Buyer upon payment by Buyer to Seller for the work performed. At the time of delivery of the
Equipment, Seller shall deliver written documentation to Buyer that adequately describes the functionality and operation of the
Software (“Documentation”).
18 Federal Contractor
Seller acknowledges that the Buyer serves from time to time as a subcontractor for the United States government. In those
Appendix 1.1 - General Terms and Conditions
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BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.1-7
cases Seller shall comply with the federal laws regulations and rules applicable to subcontractors of government contractors
including but not limited to those relating to equal employment opportunity and affirmative action in the employment of
minorities (Executive Agreement 11246), women (Executive Agreement 11375) the handicapped (29 USC 793), and certain
veterans (36 USC 2012), and contracting with women-owned or small and disadvantaged business concerns. Where
applicable, Seller certifies that it maintains no segregated employee facilities as provided in 41 CFR 60-I8 and that it is not
debarred from being awarded federal or federally assisted contracts.
19 Termination for Default
In the event Seller shall be adjudged bankrupt, make a general assignment for the benefit of its creditors, or if a receiver shall
be appointed on account of Seller's insolvency, or in the event Seller is in default of any material provision or requirement of
this Agreement that breach is not remedied within ten (10) days of notice given by Buyer to Seller, Buyer may terminate this
Agreement in whole or part, in addition to any other rights or remedies which Buyer may have, cancel further performance by
Seller under this Agreement. In the event of such termination, Buyer may complete the performance of this Agreement by
such means as Buyer selects, and Seller shall be responsible for any additional costs incurred by Buyer in so doing. Seller
shall deliver or assign to Buyer any completed work or work in progress as Buyer may request. Any amounts due Seller for
goods and services completed by Seller in full compliance with the terms of this Agreement prior to such termination shall be
subject to offset Buyer's additional costs of completing the Agreement and other damages actually incurred by Buyer as a
result of Seller's default. Waiver by Buyer of any default of Seller shall not be considered to be a waiver of Buyer of any
provision of this Agreement, or the waiver of any other defaults. Any failure of Buyer to insist on the performance of any term
or condition of this Agreement shall not be deemed a waiver of Buyer's rights thereunder.
20 Termination for Convenience
Buyer shall have the right to cancel for its convenience further performance of all or any separable part of this Agreement at
any time by written notice to Seller. On the date of such cancellation stated in the notice, Seller shall discontinue all work
pertaining to this Agreement, shall place no additional orders, and shall preserve and protect materials on hand purchased for
or committed to this Agreement, work in progress and completed work both in Seller's and in its suppliers’ plants pending
Buyer's instruction, and shall dispose of same in accordance with Buyer's instructions. Buyer shall give such instruction within
5 days of its written notice to cancel, failing which Seller may make reasonable disposition which shall be deemed to have
been done in accordance with Buyer’s instructions. In the event of cancellation by Buyer for convenience, Buyer shall
compensate Seller, upon demand for all costs and expenses already incurred or commitments made by Seller in connection
with the processing, handling and fabrication of said equipment including reasonable and necessary expenses resulting from
the cancellation, as substantiated by documentation reasonably satisfactory to Buyer, plus reasonable amounts for overhead
and profit on such costs and expenses, though not for anticipated profit or anticipated overhead charges. Cancellation
payment to Seller or refund to Buyer, if any, shall be made promptly. Seller shall not be entitled to any loss of profits,
contribution to overhead or incidental, consequential or other damages because of such cancellation. Seller shall deliver or
assign all goods with all-applicable warranties or dispose of goods as instructed by, or as deemed to have been instructed by,
Buyer prior to final payment.
21 Right to Offset
Buyer, without waiver or limitation of any rights or remedies of Buyer, shall be entitled from time to time, to deduct from any
amounts due or owing by Buyer to Seller in connection with this Agreement, or any other agreement with Seller, any and all
amounts owed by Seller to Buyer. Buyer, without waiver or limitation of any rights or remedies of Buyer, shall be entitled from
time to time, to deduct from any amounts due or owing by Buyer to Seller in connection with this Agreement, or any other
agreement with Seller, any and all amounts owed by Seller to Buyer.
22 Arbitration
The parties agree to submit all disputes between them arising out of or related to this Agreement or the breach, alleged
breach or interpretation thereof to binding arbitration. Within thirty (30) days after either party has notified the other in writing
that it is submitting a dispute to arbitration, one arbitrator shall be selected under the then current rules of the American
Arbitration Association (“AAA”) pertaining to commercial disputes. The arbitration shall be held in Chicago, Illinois (unless the
parties otherwise agree in writing) and shall be conducted in accordance with the Commercial Arbitration rules of the AAA
except the AAA shall not have authority to make any award for damages excluded herein. The arbitration award shall be by a
written decision and shall be final and binding, and enforceable by any court of competent jurisdiction.
23 Changes
Buyer shall have the right to make changes in the specifications and drawings for goods or services covered by this
Agreement. Buyer shall initiate such change by written direction to Seller. If Seller believes that any such change affects the
price or delivery date for the goods or services, Seller shall so notify Buyer in writing, with adequate supporting
documentation, within five (5) business days after acknowledged receipt of said written direction, or a maximum of ten (10)
business days total. Seller shall suspend performance of the change unless thereafter released, in writing, by Buyer to
Appendix 1.1 - General Terms and Conditions
Final Version LEG05012000
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.1-8
perform said change, and Buyer and Seller shall mutually agree in writing upon an equitable adjustment in the Contract Price
and/or applicable performance or delivery schedule(s) to reflect the effect of such change. Seller's request for any
adjustments shall be deemed waived unless submitted in writing within ten (10) business days after Seller receives initial
written direction to make such changes. To the extent possible, Seller shall not suspend performance of the unaffected
portion of the Work while Buyer and Seller are in the process of making such changes and any related adjustments, or at any
time thereafter unless so instructed in writing by Buyer. If released in writing by Buyer, Seller shall comply with and perform
such change in accordance with the terms of this Agreement during the time Seller and Buyer require to mutually agree upon
an equitable adjustment. No substitutions shall be made in this Agreement without the prior written authority of Buyer.
24 Patent Indemnity
Seller shall, at its sole expense, indemnify, hold harmless and defend Buyer, its officers, employees, successors and
customers from and against any suit or proceeding brought against Buyer based on a claim that the manufacture, use or sale
of the Equipment or services or any part thereof, supplied under this Agreement, constitutes infringement of any patent,
copyright, trademark or proprietary information right of others, and Seller shall pay all damages and costs awarded therein
against Buyer. Seller shall be promptly notified, in writing, of the suit or proceeding and shall be given adequate authority,
information and assistance, at Seller's expense, for the defense of same, subject to the right of Buyer to participate at its
expense and to be fully advised by Seller in advance of all actions taken. In case said goods or any part thereof are, in such
suit, held to constitute infringement or the sale or use of said goods or parts thereof are enjoined, regardless of whether such
determination constitutes a final judgment, Seller shall, at its expense, either procure for Buyer the right to sell and use said
Equipment or part thereof; replace the same with substantially equal but non-infringing Equipment or parts thereof; or, if
approved by Buyer, remove said Equipment or parts thereof, and refund the purchase price and the transportation and
installation costs thereof. The preceding shall not apply to any claim to the extent it arises from designs furnished and
required by Buyer, nor shall it apply to claims that arise from the use of the Equipment in combination of with equipment or
parts not supplied by Seller hereunder with other goods infringes any patents, if such process or other goods were not
supplied by Seller and Seller's supplying the Equipment hereunder does not constitute contributory patent infringement.
25 General Indemnity
For and in consideration of the covenants of Buyer under this Agreement, including the agreement of Buyer to pay to Seller
the amounts which may become due and payable under the terms of this Agreement, Seller hereby agrees to assume the risk
of and to release, defend, indemnify and save harmless Buyers and the related entities, directors, officers, employees, agents
and assigns of Buyer ("Indemnitees") from and against all loss, damage, liability, cost and expense (including reasonable
attorney's fees) arising out of any injury or death to any person or damage to any property, including damage to or failure of
the goods furnished hereunder or damage to other components caused by such failure, resulting from or in any way
connected with the performance of this Agreement or Seller's breach of this Agreement or the Equipment furnished
hereunder, regardless of whether or not such loss, damage, liability, cost or expense is caused in part by an Indemnitee.
Neither this Article nor any other provision of this Agreement shall be construed in any circumstances to constitute an
indemnification against any loss, damage, liability, cost or expense caused solely by the negligence of such Indemnitee. The
indemnity obligations in this Agreement shall be deemed to be modified as required to exclude indemnification which is
expressly prohibited by applicable law. Seller acknowledges receipt of specific payment of Ten Dollars ($10.00), incorporated
into the purchase price, as legal consideration of Seller's indemnity under this Article and all other indemnities as may be
provided in this Purchase Order.
26 Miscellaneous
All agreements contained in this Agreement shall bind and inure to the benefit of the respective successors and assigns
whether so expressed or not, except that Seller shall have no right to assign its rights or any interest herein without the prior
written consent of Buyer. No amendment, modifications, termination or waiver of any provision of this Agreement will be
effective unless in writing and signed by both parties, and then such waiver or consent will be effective only in the specific
instance and for the specific purpose for which given. In performing its obligations, Seller is and will be deemed to be an
independent contractor and not an agent or employee of Buyer. This Agreement shall be governed under the laws of the
State of Illinois. If any provision provided in this Agreement is or becomes invalid or unenforceable under any law of
mandatory application, the Parties agree that such provision will be deemed severed and omitted from the Agreement and the
remainder of this Agreement will remain in full force and effect.
Appendix 1.1 - General Terms and Conditions
Final Version LEG05012000
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 1.2
Download
GDS Deviation Request
Quote Number
Asset No:
Investment No:
PO Number:
Description:
Date:
Project Engineer:
Reason for Deviation:
System/Component to be used in place of GDS specified:
Approvals:
Optional Signatures as Required
Project Engineer
Signature
Date
Signature
Date
Signature
Date
Signature
Date
Signature
Date
Signature
Date
Signature
Date
Signature
Date
Manufacturing Director
MAE Purchasing
Appendix 1.2
OF04.7.04.012
4/12/2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 2.1
Machine Data Sheet
Asset No:
Investment No:
Download
PO Number:
Description:
For Component:
Production Rate:
Requested By:
Name
Delivery Date:
Dept
Installation Date:
Date
Runoff/ Acceptance Date:
Supplier Data
Supplier:
Model No:
Supplier Proj Eng:
Serial No:
Dim:
Weight:
Height
Width
Depth
Utility Requirements
Main Breaker:
Volts
Motors
Amps
Full Load Current:
Amps
Short Circuit Current Rating:
Amps
Elect. Panel Attached:
Yes / No
Compressed Air:
SCFM @
GPM
GPM
Chilled Water:
GPM
BTU/hr
SCFM @
bar
Steam:
lb/hr @
bar
Vacuum:
CFM @
kPa
Nitrogen:
CFM @
bar
Propane:
CFM @
bar
Argon:
CFM @
bar
Gal.
Flow Rate:
System Type:
Voltage Current
Size:
Filter Media Type:
Phase
Communications
Environmental
GPM
Exhaust Air:
SCFM
Temp:
Solid Waste Type:
External Tank Cap:
Deg F
Volume:
Contaminates - Smoke:
Mist:
Dust:
VOC:
Waste Treatment
Drip Pan?
Yes / No
Chip System
Waste Water:
GPM
Chip Material:
Waste Oil:
GPD
System Type:
Other Systems
Cranes:
RPM
Num. Ethernet Devices on Corp. Net:
Machining Coolant System
System Capacity:
kW
bar
DI Water:
Other:
Qty
(Ref: UL508A SB)
Potable Water:
Natural Gas:
Function
Volume:
Special Foundation Requirements
Max Weight:
Special Hazards:
OSHA Req.
Special Requirements and Notes
Appendix 2.1
OF04.7.04.013
4/12/2007
Bosch General Delivery Specifications for Machinery and Equipment
Appendix 2.2
Download
DESIGN REVIEW CHECKLIST
Project:
Date:
Project Engineer:
Vendor Representative:
Reviewed?
Yes
No
N/A
1.0
First Design Review
1.1
Review of BPS Assessment
1.2
Concept Drawings
1.2.1
Main/Final Assembly Drawing
1.2.2
Machine Operation and Process Drawings
1.2.3
Control System Overview
1.3
PFMEA Review
1.4
Material Handling, Ergonomics
1.5
Hazard Assessment
1.6
Special Attention Points, Machine Guarding
1.7
Machine Data Sheet
1.8
Component Specifications & Literature
1.9
Approval Prints
1.10
Other:
Acceptable?
Yes
No
N/A
2.0
Final Design Review
2.1
Mechanical Assembly and Subassembly Drawings
2.2
Detail Drawings and Parts Lists
2.3
Pneumatic & Hydraulic Schematics and Parts Lists
2.4
Control System Functional (Sequence) Plan
2.5
Electrical Control System Diagrams, Drawings, & Parts Lists
2.6
Critical and Proprietary Parts
2.7
PFMEA Review
2.8
Updated Machine Data Sheet
2.9
Hazardous Material List
2.10
Foundation Drawing
2.11
Approval Prints
2.12
Anticipated PM Requirements (Labor, Material, & Frequency)
2.13
Other:
Appendix 2.2
OF04.7.04.014
4/12/2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix4.1
Download
BPS-Assessment with qualitative criteria:
BPS-Principle
Value
Criteria
Project:
0
1
2
Comment
3
4
Process Orientation
1
The equipment layout is according to the sequence of operations (routing). There are no
processes layed out in a pool orientation.
2
The move batch size between processes is defined, small and constant throughout the value
stream (SNP- Standard Number of Parts)
3
The transportation distances in the value stream are reduced to a minimum with a material
flow oriented layout
Pull System
1 Workpiece carriers are limited to 3 per station in the production lines when a fault occurs
2
The finished goods of a process are stored at the supplying process (in Supermarkets if
needed), the transportation to the following process is based on consumption
3 The replenishment lead time for the internal transportation is defined and minimal (<2h)
Perfect Quality
1
The maintenance strategie and procedures is put into action in the GB/plant according to the
Bosch TPM modell
2 Structured and systematic utilization of Poke-Yoke solutions is used to prevent problems
3
The equipment detects process problems and automatically stops production (Autonomation Jidoka). Bypass stations are eliminated
4
FIFO principle (First-In-First-Out) is maintained within buffers (e.g. supermarkets) and internal
transportation of products
Flexibility
1
Short changeover time (<10 min for equipment, < 5 min for assembly and testing) allow for
small lot sizes and the EPEI is ≤ 1 day
2
Changes to product order (routing) or new products can be integrated quickly (Layout
changes < 1 week)
3
The shop floor has standard equipment and processes that allow for a flexible integration of
new products
4
Changes in customer takt (± 20%) can be accommodated for (within a week) without a loss in
productivity with flexible utilization of associates
5 Customer order variations of ±10% can be fulfilled within a day with proportional effort
Standardization
1
The material transportation processes are repetitive in a defined rhythm, material foot
prints and quantity of material are defined.
2
For the whole plant a packaging concept exists with standardized containers (dunnage),
every part has a description with defined packaging (Plan for every part)
Deviations for the standard are quickly recognized, escalation levels are defined, there is a
3 structured process to eliminate deviations from the standard. A responsable person for
deviations management is defined.
Transparency
1 The transportation routes and information flow are visualized and easy to understand
The preventative maintenance schedule/instructions and improvment activities are visualized,
2 Target and Actual values are displayed and their trends are shown for key indicators of the
equipment
3
The current status of production is visualized real time with simple systems or metrics and
understood by all (Andon-System)
4 Change over processes are visualized, the next change over is transparent
Associate Involvement
Ergonomics reviewed with "Checklist":
_____________
__________
Name
Date
Equipment is ergonomically designed, safety is ensured and visualized at all work stations. Work station design takes
1 place in teamwork (Employee of work station, Industrial Engineer).
Measurement Scale
4
3
2
1
0
Appendix 4.1
Characteristic is completely and exemplary implemented
Characteristic is extensively implemented > 60% of the area evaluated
Characteristic is implemented in some areas > 25% of the area evaluated
Characteristic is present in isolated cases
Characteristic is not present
OF04.7.04.015
x
x
x
x
x
Function /
(Industrial Engineer)
No increase of capital expenditure
No increase of capital expenditure
Increase of capital expenditure by 10%
Increase of capital expenditure by 20%
Increase of capital expenditure by 20%
4/12/2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 4.2
Download
Calculation Sheet
Originator:
Takt, OEE, Planned Cycle Time, Utilization
Demand Period
Equipment ID:
Cell Number:
Monthly
Sample
Date:
Part ID:
Part-No.:
Planning Data
A.
Monthly
Customer Demand
B.
Working Days / Month
C.
Shifts Per Day
3 shifts/day
D.
Number of Cells (Lines)
1 cells
E.
Required Output for each Cell
220000 pcs/month
23 days
3188
(A/B/C/D)
pcs/shift/day
Planned Operating Time
F.
Total Available Time:
G.
Planned Downtime per shift:
Frequency
Lunch
1
Breaks
2
Scheduled Maintenance
1
Meetings
1
H.
480 min/shift
(Time available/shift given NO planned or unplanned downtime)
Duration
30
10
10
10
each
each
each
each
min
min
min
min
70
min/shift
410
min/shift
7.7
sec / pc
13
min/shift
(H - J)
397
min/shift
(K/H x 100)
96.8%
Planned Operating Time:
Total G:
(F - G)
Takt Time
I.
Takt Time
(H x 60 / E)
Unplanned Downtime
J.
Unplanned Downtime per shift:
Frequency
Changeover
5
each
Duration
5 min
Percent
98%
or
Minutes Lost
8 min
Technical Availability
K.
Net Operating Time:
L.
Equipment Availability:
Total J:
Performance Efficiency
M.
Time Lost to Operators' Personal Needs
(H/60 x 2.25)
0 min/shift
( 2.25 min/work hr as per Bosch Norm N62C 2.6 pg.3)
N.
Performance Efficiency
100.0%
((K-M)/K x 100)
Quality Rate
O.
Total Defect Rate
P.
Bad Parts
Q.
Quality Rate:
0.00% Percent
(Scrap & Rework)
0
(100 - O)
100.0%
(L x N x Q)
96.8%
pcs/cell/shift
Overall Equipment Effectiveness
R.
OEE:
Planned Cycle Time per Cell
S.
Planned Cycle Time:
Utilization
T.
Appendix 4.2
Utilization:
(I x R)
0.12 min/pc
or
7.5
sec / pc
(per N62C,6.3.4)
(S x E x C)/(1440min/day)
OF04.7.04.016
82.7%
4/12/2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 4.3-1
Workplace Measurements
for Manual and Machine Work Stations (Dimensions in mm)
Controls and Displays
Operating
Mounting
frequency
Height
per Shift
<100
max. 1800
>100
max. 1500
s
e
d
s
Max. 1400
“Unobstructed”
View
s
Max. Positioning
Height d: 1500
s
s
e
c
c
H1
max.
300
A
b
k
e
max.
300
k
A
b
H2
A
H2
α
α
600
BOSCH FMS-Worktable
i
i
t1
Fig. 1
Description
Fig. 2
e
H1
Working Height
H2
Working Surface Height
A
From Tabletop to Work
Area
c
Leg Room Depth
Foot Room Depth
Leg Room Width
Footrest:
free room for knees
Inclination
Room for foot movement:
Clearance Height
Seating Height
t1
t2
t3
1
i
t1
t2
Distance to Work Area
Visual Distance
BOSCH FMS-Worktable
k
α
i
b
s
Sitting (Fig. 1)
2
2t
Fig. 3
Sitting/Standing (Fig. 2)
t1
t2
Standing (Fig. 3)
0 to 325
Aim for a minimum distance from the front edge
Influences: Arm Position, Visual Distance s, Head Inclination
Pay Attention to Dimension c
Reference values for working height: see Fig. 4 and Table 1
(the work area of the fingers is decisive)
min. 900
900 to 1080
Depends on: Body Height
Influences:
Arm Position
Above, A = 950
Fixture Height
Visual Distance
k = 520 to 750 is possible
Workpiece Height
Head Inclination
Make as small as possible. Large distances cause unfavorable arm
positions (holding posture). Compromise between visual distance and
arm position. (Compare Fig. 4 and Table 1.)
min 350
min. 80
min. 550 (for free movement)
min. 150
min. 800, Getting up from chair must be possible by swiveling the chair
min. 600
Installed at workplace (platform continues to rear)
520 – 750 (adjustable), at A = 900 only k = 520 to 700 possible
5° to 10°
Also for chair legs
min. 120
Adjustment range min. 250, preferably 300, adapted to height of work
area
s is almost independent from body height when
s is heavily dependent on body height when standing
seated and can be adjusted via seating height.
and can be influenced via working height.
1)
Visual distance is dependent on several parameters.
Reference values can be determined by comparing similar workplaces or by experimenting.
The following Parameters must be comparable:
Size and shape of recognizable details
Type of Activity
Contrasts (objects/Surroundings)
Illumination intensity
Individual power of vision
Deviations from the given values must be tested in individual cases (e.g. with the aid of a “Template for the Human Figure”,
software ERGOMAS).
© 2007 Robert Bosch LLC
Appendix 4.3 – Workplace Measurements
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 4.3-2
Figure 4
Visual distances and underarm positions illustrated depending on body height and work height.
1870
1760
1660
1540
1200
1100
1000
950
900
Table 1
Reference values for working heights H1 and H2 depend on work requirements and body height
5th and 95th percentile for Female (F) and Male (M).
Work Requirements
Examples
Working Height
H 1 (Sitting)
Percentile
5th
95th
F
High requirements for
Visual control
Fine biomechanical
coordination
Adjustments
Visual Inspections
Assembly of very small parts
Medium requirements for
Visual control
Fine biomechanical
coordination
Wiring work,
Assembly of small parts with
minimal use of muscular force
Minor requirements for
Visual control
High requirements for
Movement of arms
Sorting
Packaging
Assembly of heavier work
pieces with increased use
of muscular force
H 2 (Standing)
Percentile
5th
95th
M
F
M
F
M
400
450
500
550
1100
1200
1250
1350
300
350
400
450
1000
1100
1150
1250
900
1000
1050
1150
250
350
F
M
© 2007 Robert Bosch LLC
Appendix 4.3 – Workplace Measurements
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 4.3-3
Movement Area and Access Dimensions
for Workplaces and Working Systems
Access Dimensions for U-Shaped Working Systems
Requirements:
• Only valid for sitting / walking workplaces
• Danger for safety and health must be averted
• Material delivery from outside
• No material transport and no material storage within the U-Shape
• Empty containers from inside to outside.
Conditions
Standing / Walking Workplaces
standing back to back
2.60 m
Sitting / Standing Workplaces
1.20 m
Associates are standing with a
minimum of 800 mm fixed allocation
to workplaces
1.20 m
Associates are walking from
workplace to workplace, walk paths
are not crossing each other
0.80 m
Only 1 associate in the working
system, associate walks from
workplace to workplace, Walking
with manual part transport, no
bending or stooping motions
x
x
1.80 m
x
Minimum
Dimension x
800 mm
x
Shape of Layout and Associate Placement
The following minimum dimensions are
established for movement area at
standing workplaces:
600 mm
Movement Area
“(1) The free, unobstructed area of the workplace must be sized so
the employees can move freely during their activities.”
Workshop Regulation (ArbStättV)
dated August 12, 2004, BGBL I, S.2179
Deviations from the indicated dimensions must be evaluated individually.
National regulations take precedence over recommended values.
Appendix 4.3 – Workplace Measurements
© 2007 Robert Bosch LLC
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 5.1-1
Appendix 5.1 - US Contacts for Bosch Products
•
Bosch Rexroth
Industrial Hydraulics, Electric Drives and Controls, Pneumatics,
Linear Motion and Assembly, Assembly and Material Flow Technology
Contact:
Bosch Rexroth
Suite 500
2810 Premiere Parkway
Duluth, GA 30097
•
Phone:
Mobile:
Fax:
E-mail:
Web site:
678-957-4055
770-310-1398
678-417-6637
[email protected]
www.boschrexroth-us.com
Phone:
877-267-2499
Web Site:
www.boschtools.com
Bosch Tool Corporation
Power Tools
Contact:
Bosch Tool Corporation
1800 West Central Road
Mount Prospect, Illinois
60056
Appendix 5.1 - US Contacts for Bosch Products
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 5.2
Download
Control Systems Overview
Controller Type
Appendix 5.2
Manufacturer
Model
Programming
Language
Programming
Device
OF04.7.04.017
Comments
4/12/2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 5.2
Control Systems Overview Form
Instructions
Each programmable device for a project shall have an entry in the Control Systems Overview form. Programmable in the previous
sentence includes any device which requires the purchaser of the equipment to configure the equipment prior to its use in the
intended application. This however shall not include any equipment that is configured entirely by jumpers, dip switches or potentiometers.
This shall include but not be limited to computers, PLC's, CNC's message displays, robots, motor controllers, networks, data collection
equipment, intelligent modules or interfaces, etc.
Controller Type
This field should contain the type of equipment used, such as PLC, motor controller, etc.
Manufacturer
The manufacturer of the equipment.
Model
The model number of the equipment including enough information to completely order the item, such as
revision level, ROM version, etc.
Programming Language
The programming language or languages used to configure or program the described equipment including
version or revision level.
Comments
Provide more descriptive information, clarifications, or comments regarding the described equipment.
Appendix 5.2
OF04.7.04.017
4/12/2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 5.3-1
Appendix 5.3 - Required Clearance Space for Electrical Panels
Spaces around Electrical Cabinets and Compartments:
1.
Working Space Depth and Width
As per:
NFPA 70 National Electric Code 2005
110.26(A)(1)
110.26(A)(2)
(Minimum depth requirement
for Bosch shall be 1 meter.)
The width of the working
space in front of electrical
cabinets and compartments
shall be the width of the
electrical cabinet or
compartment, or 750 mm (21/2 ft.), whichever is greater.
Depth
of working space
min. 1 meter
Width
of working space
per 110.26(A)(2)
Fig. 1
2.
Working Space Height
Recess cannot be
more than 150mm
As per:
NFPA 70 National Electric Code 2005
110.26(A)(3)
The height of the working
space shall be the greater of 2
m or the height of the
equipment. Within the height
requirement, electrical cabinets
shall not be recessed from the
front of the equipment more
than 150 mm.
Electrical
Cabinet
Fig. 2
Fig.1 and Fig.2 are examples of many possibilities.
For more details, see the entire NFPA 70 110.26.
Appendix 5.3 - Required Clearance Space for Electrical Panels
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 6.1-1
Appendix 6.1 - Parts to Produce for Total Test
1.1
Acceptance Run
Acceptance tests for production machines shall be designed to produce parts for at
least 8 hours running at maximum rate. The run duration shall be extended, as
necessary, to complete a minimum of 300 parts. For test stand acceptance, the
component type and nature of the test(s) will determine the number of parts required.
1.2
Sample Size
For those characteristics that can be studied using X-bar and R-charts, a short-term
study should be conducted using measurements from at least 125 parts*, sample size
5, to produce at least 25 subgroups. To the extent feasible, tests should be designed
to capture machine performance over time, including effects of tool change,
temperature and humidity variation and start-up/shut-down that would be associated
with a shift change. Circumstances may warrant a reduction in the number of
measurements required. Any departure from these requirements must be approved by
the Project Engineer.
*Where more than one part is produced simultaneously at a single station, a total of at
least 125 measurements is required. For multi-spindle/multi station machines, the
requirement is for at least 125 measurements per spindle/station.
1.3
Calculation example:
Cycle time:
15 seconds (one part produced at a time)
To be evaluated: Dimensions
a) Number of parts to be produced = 8 x rated hourly output
= 8 x 3600/15 = 1,920 Pcs.
(Excludes any preliminary production for system tuning or warmup)
b) Number of sample batches to be taken = Total sample size/n
= 125/5 = 25
c) Frequency of sampling (piece-based)
= approx. every 80 Pcs.
= A/(B-1)** = 1,920/(25-1)
** First sample should be taken just after start of test.
References: AQC/AIAG Production Part Approval (PPAP) manual
AQC/AIAG Statistical Process Control Reference Manual
Appendix 6.1 - Parts to Produce for Total Test
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 6.2-1
Appendix 6.2 - Technical Availability
Technical availability VT
The technical availability provides the percentage of operating time for machines / systems available to production
without technical defects.
TT
TT
V = N = 100% 100%
= 1
100%
T
T
TB
TB
Technical downtime TT
Technical downtime is the total of all downtimes, caused by design or construction defects of a machine / system.
These are the manufacturer's responsibility.
which consequently results in downtimes for
• repair ( troubleshooting)
• waiting on spare parts
• waiting on service technicians
• trial run to find defect
• trial run after troubleshooting
Defects, for example are:
• material defects
• design or construction defects
• defects in documentation
These downtimes are basis for negotiation between user and manufacturer about technical degree of utilization
and/or the availability of machines.
Observation period
(e.g. all year, month, shift, warranty period)
Loading time TB
(planned loading time of machine, e.g. according to production plan
Utilization time TN
Scheduled
downtime TO
Technical
downtime TT
Non-loaded time (e.g.
insufficient orders)
unplanned time
(e.g. Sundays and
Holidays)
Maintenance
time TW
(can possibly run into
idle time)
Testing time TC
Loading time TB
Loading time is the portion of time within the observation period, in which the machine / system is planned to be used
(see graph above).
Appendix 6.2 - Technical Availability
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 8.1-1
Appendix 8.1 - Format of Manuals
When a vendor does not have a manual format which is agreed upon with the Project
Engineer, the following guidelines should be followed for manual organization and layout.
1.1
Order of contents:
i
Title Page
ii
Table of Contents
iii
List of Tables
iv
List of Illustrations
v
Safety Considerations
1.0
Introduction
2.0
General Description
3.0
Detailed Description
4.0
Theory of Operation
5.0
Operations
6.0
Calibration Procedures
7.0
Troubleshooting
8.0
Service and Maintenance
9.0
Recommended Spare Parts List
Appendices (optional, as required)
1.2
Paragraph numbering system
Each topic and sub-topic should be numbered in a coordinated fashion. Example:
5.0
OPERATIONS
5.1
CONTROLS AND INDICATORS
5.1.1 Normal Indicators
5.1.2 Abnormal Indicators
5.2
STARTUP PROCEDURE
5.2.1 Ventilation
5.2.2 Air Supply
5.2.3 Fuel Supply
5.3
SHUTDOWN PROCEDURE
5.3.1 Normal Shutdown
5.3.2 Abnormal Shutdown
1.3
Page Numbering
Page Numbers shall include section identification. Example:
• SECTION 2 pages would be numbered 2-1, 2-2...2-12, etc.
• The Table of Contents, List of Tables, List of Illustrations and Safety Considerations shall
be numbered using lower case Roman numerals (i.e. i, ii, iii, iv...xii).
1.4
Section Content
1.4.1 Section 1.0 Introduction
Provides background or special information that may help familiarize the readers
with the equipment. References other manuals that may be included with the
machine. Identifies manufacturer and provides point of contact information (i.e.
Appendix 8.1 - Format of Manuals
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 8.1-2
address, telephone numbers).
1.4.2 Section 2.0 General Description
Prepares the reader for the detailed description by providing information regarding
the components and nomenclature and define terms.
1.4.3 Section 3.0 Detailed Description
States the function and location of major components in order for the reader to
follow the Operations section of the manual. Includes a functional block diagram.
(Note: for small, non-complex machines, sections 2.0 and 3.0 may be combined,
but the intent of section 2.0 should be preserved.)
1.4.4 Section 4.0 Theory of Operation
Explains why the machine and components operates as it does. Defines principles
that play an important role in the components operations. Describes sequence of
machine operations. This theory becomes important when the maintenance
person cannot solve the problem using the Troubleshooting section.
1.4.5 Section 5.0 Operation
Consists of directions that command the readers to perform specific operations.
The directions are written in the imperative mood (i.e. Place the Purge Bypass
switch to the “ON” position). Contains Startup and Shutdown Procedures.
1.4.6 Section 6.0 Calibration Procedures
Provides clear direction for the calibration of components. Reference other
manuals that contain the calibration procedures for third-party components.
1.4.7 Section 7.0 Troubleshooting
Provides fault isolation steps that correspond to the steps outlined in the Operation
section.
1.4.8 Section 8.0 Service and Maintenance
Provides recommended preventive maintenance checks, procedures and schedule.
Refers to third-party manuals as required.
1.4.9 Section 9.0 Recommend Spare Parts List (See Appendix 8.2)
1.5
Modifications
to this format shall be agreed upon in writing by the Project Engineer and the vendor.
1.6
Language
The language of the manual must fit the intended user. Sections 1.0 through 3.0 and
5.0 should be written for the machine operator and setup person; section 4.0, 7.0 and
8.0 should be written for the maintenance technician and section 6.0 should be written
for the calibration technician.
Appendix 8.1 - Format of Manuals
Apr-2007
BOSCH General Delivery Specifications for Machinery and Equipment
Appendix 8.2
Spare Parts List
Equipment Description
Machine Builder Contact Info
Fields in red are mandatory for upload to quote system.
Machine Builder to Complete this Section
Machine
Builder
Machine
Machine Builder Detailed
Builder Part #
Part Description
(of item)
Appendix 8.2 - Spare Parts List
Download
This form shall be completed electronically and the completed spreadsheet sent to the Project Engineer
Part OEM Name
OEM PART#
OEM Part Description
OF04.7.04.018
Total Qty
Used On this
Equipment
WHERE
USED
Price
Currency
UOM
Lead
Time
SAP
number
Vendor
4/12/2007
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