General Delivery
Specifications
for
Machinery and Equipment
Machinery and Equipment (MAE) General Delivery Specifications
can also be found at
www.boschnasuppliers.com
Reference: - OP4.7.04.004
Robert Bosch Corporation
April, 2005
April
2005
General Delivery Specifications
General Delivery Specifications
for Machinery and Equipment
Sections 1 - 9
Revision 4 - April, 2005
All prior editions are obsolete and should not be used.
This document is controlled by:
Robert Bosch Corporation
ChW/BPS-LS (Industrial Engineering)
8101 Dorchester Rd.
Charleston, SC 29418
(843) 760 - 7659
wolfgang.hasper@us.bosch.com
It is the user's responsibility to assure that only the latest revision of this standard is used.
SUPANAGEMENT
BOSCH General Delivery Specifications for Machinery and Equipment
CHANGES MADE TO THE GENERAL DELIVERY SPECIFICATIONS SECTIONS 1-9
April 1, 2005
Page
Section
Changes
2-3..5
2.2
2-3
2-4
2.2.1
2.2.2
Restructured section in order to match the Review
Checklist.
Moved Lean Manufacturing statement (BPS) to 2.2.2a.
Added review of special attention points.
4-3
4.1.2
Added awareness statement (AC has some different
drawing standards).
5-2
5-2
5-3
5-4
5-5
5-5
5-6
5-6
5.3.1
5.3.2
5.5.2
5.5.5
5.5.5
5.6.3
5.6.6
5.6.7
5.8
Additional information on drawing formats
All software shall be licensed
Additional b) transformer capacity (deleted in 5.5.5 a))
c) Restated receptacle requirements
Added f) Safety awareness statement.
Entire paragraph rewritten.
Added: stranded copper, calibration fluids
Plants can have different wire colors as per NFPA 79.
Added Data Management and Networking.
6-3
6-4
6-5
6.3.2
6.5.2
6.7.1
Entire paragraph rewritten.
Changed changeover time according to BPS.
Deleted modem, added Remote Access requirement.
3
Sec. 7
4
7 thru 10
9
9
Sec. 7
Sec. 7
Sec. 7
Sec. 7
Restructured Check Sheet: added numbering column and
reference column, separated “yes” column for Pre and Final
Acceptance
Moved electrical cabinet clearance to Electrical Design.
Section 5: Electrical Design completely revised.
Added Data Management and Networking.
Added to Gage Capability: alternatives a) and b).
Sec. 9
Sec. 9
Sec. 9
Sec. 9
Sec. 9
Sec. 9
Appendix 2.1 - Deleted Modem, added Network
requirements.
Appendix 2.2 - Changed 1.1 to BPS Assessment.
Appendix 2.3 - Replaced by BPS Investment Assessment.
Appendix 4.1 - Added contact for Bosch Rexroth and
Bosch Power Tools.
Appendix 5.2 - Added Special Attention Points for
Equipment Suppliers.
Appendix 6.2 – Added information regarding latest
German/English issue.
Changes
Page 1 of 1
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
Other pages of the GDS available for viewing:
- COVER PAGE
- SECTIONS 1-9 OWNER’S PAGE
- CHANGES MADE TO SECTIONS 1-9
TABLE OF CONTENTS
Page
SECTION 1 - GENERAL PROCEDURES
1.1
1.2
1.3
1.4
1.5
Preface........................................................................................................... 1-2
Formal Quotation Requirements ................................................................. 1-2
Order and Alterations .................................................................................. 1-6
Work on Buyer’s Facility ............................................................................. 1-6
Payment Schedule......................................................................................... 1-7
SECTION 2 - PROJECT MANAGEMENT
*
2.1
2.2
Project Timing .............................................................................................. 2-2
Design Review Requirements....................................................................... 2-3
SECTION 3 - SAFETY AND HEALTH STANDARDS
3.1
3.2
3.3
3.4
General ......................................................................................................... 3-2
General Standards........................................................................................ 3-2
Noise Standard.............................................................................................. 3-3
Environmental Considerations .................................................................... 3-3
Table of Contents - i
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
Page
SECTION 4 - MECHANICAL DESIGN
*
4.1
4.2
4.3
4.4
4.5
4.6
Mechanical Design Guidelines ..................................................................... 4-2
Floor Plan Layout......................................................................................... 4-5
Ergonomic Guidelines .................................................................................. 4-6
Pneumatic Controls ...................................................................................... 4-7
Lubrication ................................................................................................... 4-9
Paint .............................................................................................................. 4-9
SECTION 5 - ELECTRICAL DESIGN
*
*
*
*
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
Standards ...................................................................................................... 5-2
Control Systems Overview ........................................................................... 5-2
Documentation.............................................................................................. 5-2
Functional ..................................................................................................... 5-2
Equipment..................................................................................................... 5-3
Wiring Methods ............................................................................................ 5-5
Programmable Logic Controllers and Computers ..................................... 5-6
Data Management and Networking............................................................. 5-6
SECTION 6 - QUALITY STANDARDS & RUN-OFF CONDITIONS
*
*
*
6.1
6.2
6.3
6.4
6.5
6.6
6.7
General.......................................................................................................... 6-2
Guidelines for Statistical Evaluation ........................................................... 6-2
Gage, Process and Machine Capability....................................................... 6-3
Gage Scale and Signal Output ..................................................................... 6-3
Equipment Effectiveness and Durability Demonstrations ......................... 6-4
Run-off Conditions ....................................................................................... 6-4
Software Validation...................................................................................... 6-5
SECTION 7 - PRE/FINAL ACCEPTANCE
*
7.1
7.2
General.......................................................................................................... 7-2
Pre/Final Acceptance Checklist ................................................................... 7-3
Table of Contents
-
ii
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
Page
SECTION 8 - DOCUMENTATION & SHIPPING INSTRUCTIONS
8.1
8.2
8.3
8.4
8.5
8.6
Machine Documents .................................................................................... 8-2
Shipping Instructions .................................................................................. 8-3
Ocean Freight Shipping . ............................................................................ 8-3
Package Identification ................................................................................. 8-4
Shipping Documentation............................................................................. 8-4
Invoicing....................................................................................................... 8-5
SECTION 9 - APPENDICES
• Appendix 1.1
General Terms and Conditions for the Purchase of Capital
Equipment
* • Appendix 2.1
Machine Data Sheet
* • Appendix 2.2
Design Review Checklist
* • Appendix 2.3
Investment Assessment
* • Appendix 4.1
US Contacts for Bosch Products
• Appendix 4.2
Workplace Measurements
• Appendix 5.1
Control Systems Overview form
* • Appendix 5.2
• Appendix 6.1
* • Appendix 6.2
• Appendix 8.1
Special Attention Points for Equipment Suppliers
Parts to Produce for Total Test, Sample Size
Technical Availability
Documentation
SECTION 10 - ATTACHMENTS (PLANT SPECIFIC)
(See Section for details)
Table of Contents
-
iii
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 1 - GENERAL PROCEDURES
TABLE OF CONTENTS
Page
1.1
Preface. ...................................................................................................................1-2
1.2
Formal Quotation Requirements ...........................................................................1-2
1.2.1...... General.......................................................................................................1-2
1.2.2...... Parameters of Quote for Machinery and Equipment ...................................1-3
1.2.3...... Itemized Prices...........................................................................................1-4
1.2.4...... Proposal Description ..................................................................................1-5
1.2.5...... Project Completion.....................................................................................1-5
1.3
Order and Alterations ............................................................................................1-6
1.4
Work at Buyer’s Facility ........................................................................................1-6
1.5
Payment Schedule...................................................................................................1-7
General Procedures
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1 - 1
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 1 - GENERAL PROCEDURES
1.1
Preface
This specification has been written to present Robert Bosch Corporation/Affiliate’s
(hereinafter referred to as ‘Bosch’) requirements for industrial equipment in an orderly
manner.
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).
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.
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.
Deviations to specifications provided herein may be allowed when necessary, and agreed
upon in writing by Project Engineer. Copy to Purchasing.
Individual locations may have plant specific requirements which can be found in
Section 10.
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.
General Procedures
-
1 - 2
BOSCH General Delivery Specifications for Machinery and Equipment
1.2.2
Apr. 1, 2005
Parameters of Quote for Machinery & Equipment
a)
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.
b)
The following information to be included:
• Bosch RFQ Number
• Part name(s), number(s), and/or identification number.
• Name of Project Engineer requesting the quote.
• Machine tool equipment supplier’s quotation number and date.
c)
The quotation shall include firm delivery dated from the date of purchase
order.
d)
Document requirements:
All drawings, documentation, etc., as per Section 8 shall be supplied in
English.
e)
Must provide special foundation or other site requirements in quote.
f)
A basic timeline containing critical milestones is to be provided with the
quote.
General Procedures
-
1 - 3
BOSCH General Delivery Specifications for Machinery and Equipment
1.2.3
Apr. 1, 2005
Itemized Prices
The following shall be itemized and separately priced on the quote:
a)
Basic machine
b)
Special Machine Options
c)
Fixtures/Workholding
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 gaging 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.
General Procedures
-
1 - 4
BOSCH General Delivery Specifications for Machinery and Equipment
1.2.4
1.2.5
Apr. 1, 2005
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%
utilization), estimated power consumption, 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. Estimated 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 (Appendix 5.1) 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
The supplier shall inform the Project Engineer of any known or suspected
by-products of machine fluids used which may be hazardous to health.
Project Completion
At the completion of each project, parts, drawings and support documentation
belonging to Bosch to be entirely returned.
General Procedures
-
1 - 5
BOSCH General Delivery Specifications for Machinery and Equipment
1.3
1.4
Apr. 1, 2005
Order and 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.
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.
Work at Buyer’s Facility (See also Section 9: General Terms and Conditions for the
Purchase of Capital Equipment (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 facilities’ 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.
General Procedures
-
1 - 6
BOSCH General Delivery Specifications for Machinery and Equipment
1.5
Apr. 1, 2005
Payment Schedule (See also Section 5 and 7.3 of General Terms and Conditions for the
Purchase of Capital Equipment (Appendix 1.1)).
1.5.1
Robert Bosch Corporation payment schedule for the Purchase of Capital Equipment
is as follows:
80% Net 30 of complete purchase price upon Delivery of equipment to specified
Bosch Facility.
20% Net 30 of complete purchase price upon Final Acceptance at specified Bosch
Facility.
(See Section 7 for Pre-Final Acceptance Checklist.)
General Procedures
-
1 - 7
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 2 - PROJECT MANAGEMENT
TABLE OF CONTENTS
Page
2.1
Project Timing ........................................................................................................2-2
2.2
*
*
*
Design Review Requirements.................................................................................2-3
2.2.1...... Design Reviews .........................................................................................2-3
2.2.2...... First Design Review...................................................................................2-3
2.2.3...... Final Design Review ..................................................................................2-4
Project Management - 2 - 5
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 2 - PROJECT MANAGEMENT
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 time line is to be provided with the quotation.
The final time line 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)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
Kick-off meeting
Process flow chart
Process FMEA review
Preliminary design (mechanical and electrical)
Preliminary design review
Purchase of critical long lead-time components
Final design (mechanical and electrical)
Final design review
Purchase of remaining material
Equipment control programming
Equipment control program review
Receipt of purchased/produced components
Floor plan layout and foundation requirement
Equipment build/assembly
Tryout part availability
System tryout and debug
- manual mode
- automatic mode
Measurement system calibration
Preliminary gage capability study
Preliminary process capability study
Documentation review
Project Management - 2 - 2
BOSCH General Delivery Specifications for Machinery and Equipment
u)
v)
w)
x)
y)
z)
2.1.4
2.2
Pre-acceptance at supplier
Package & ship
Installation at Bosch
Tryout and debug at Bosch
Final capability studies
Final acceptance sign-off
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.
Design Review Requirements
2.2.1
*
*
Apr. 1, 2005
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
The first design review will be a comprehensive concept design review and
preliminary PFMEA (Process Failure Mode and Effect Analysis) review.
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,
Appendix 2.3.
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.
Project Management - 2 - 3
BOSCH General Delivery Specifications for Machinery and Equipment
*
*
2.2.3
Apr. 1, 2005
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 Special Attention Points, Appendix 5.2.
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.
Final Design Review
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
Project Management - 2 - 4
BOSCH General Delivery Specifications for Machinery and Equipment
2.2.4
g)
Updated Machine Data Sheet
h)
Hazardous Material List
i)
Foundation Drawing
j)
Approval Prints
k)
Anticipated PM Requirements (Labor, Material, & Frequency)
Apr. 1, 2005
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 followup review may be required to evaluate modifications.
Project Management - 2 - 5
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 3 - SAFETY AND HEALTH STANDARDS
TABLE OF CONTENTS
Page
3.1
General ...................................................................................................................3-2
3.2
General Standards ..................................................................................................3-2
3.3
Noise Standard........................................................................................................3-3
3.4
Environmental Considerations ..............................................................................3-3
Safety and Health Standards - 3 - 1
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 3 - SAFETY AND HEALTH STANDARDS
3.1
General
Equipment must meet the requirements of the Occupational Safety and Health Act (latest
amended edition). The OSHA standards are to be interpreted as minimum requirements.
3.2
General Standards
3.2.1
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) Occupational Safety and Health Administration, Department of Labor, General
Industry Standards, Series 1910 (latest revision).
b) American National Standards Institute Codes.
c) National Fire Protection Association (NFPA) Regulations.
d) National Fluid Power Association “Systems Standard for Industrial Machinery”.
3.2.2
Equipment must be designed to accept lockout devices on all energy sources (i.e.
pneumatic, hydraulic, electric) and must be labeled.
3.2.3
Additional safety requirements are included in the specific sections for electrical,
hydraulic, pneumatic, and machine design.
3.2.4
A written risk assessment as per latest ANSI/RIA R15.06 is required for all robots
prior to final acceptance.
3.2.5
No asbestos containing materials (ACM) shall be used.
3.2.6
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).
Safety and Health Standards - 3 - 2
BOSCH General Delivery Specifications for Machinery and Equipment
3.3
Apr. 1, 2005
Noise Standard
All steady state or cyclical noise levels produced by machinery or equipment shall not exceed
80dB(A), when running under all anticipated operating conditions while producing parts.
The noise measurement shall be made along the perimeter of the machine at a 3 foot distance
and also at the operator(s) position(s).
3.4
Environmental Considerations
(Gases, Fluids, Coolants, Cleaning Solutions, Paints, etc.)
3.4.1
In response to increasingly stringent controls on the use and disposal of waste
materials, the supplier shall conform to the following provisions:
a) ISO 14000 Environmental Management System.
b) Material Safety Data Sheet in English must be submitted to the Project Engineer
for approval of all material to be used in the machine prior to Preliminary Design
Review. Usage rates of environmentally sensitive chemicals need to be indexed
to some criteria such as production rates.
c) Materials containing PCB (polychlorinated biphenyl) are not allowed
(e.g. capacitors, oil in transformers, and certain hydraulic fluids).
Mercury containing switches/devices are not permitted.
Use of leaded paint is not permitted.
d) The supplier shall notify the Project Engineer of any anticipated levels of
emission from radiation, gases, vapors, fumes, dusts, and mists.
e) All chemicals must be recertified to be on the EPA TSCA inventory.
f)
Equipment shall be designed to contain all process fluids (oil, coolant, etc.) with
no leaks or splashing onto the operator or floor.
3.4.2
An approved material list is available from the Project Engineer upon request.
3.4.3
All equipment that requires ventilation for oil/coolant MUST use filtration
equipment. The mist density must not exceed 0.2 mg/m3 at the equipment exhaust.
Equipment manufacturers must utilize the filtration technology specified by Bosch.
(See plant specific requirements, Section 10 - Attachments)
(See Section 7 for Pre-Final Acceptance Checklist.)
Safety and Health Standards - 3 - 3
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 4 - MECHANICAL DESIGN
TABLE OF CONTENTS
Page
4.1
*
Mechanical Design Guidelines ...............................................................................4-2
4.1.1...... Components ...............................................................................................4-2
4.1.2...... Drawing Standards.....................................................................................4-3
4.2
Floor Plan Layout...................................................................................................4-5
4.2.1...... General Requirements ................................................................................4-5
4.2.2...... Floor Layout Drawings...............................................................................4-5
4.2.3...... Machine Leveling.......................................................................................4-5
4.3
Ergonomic Guidelines ............................................................................................4-6
4.3.1...... Workstations ..............................................................................................4-6
4.3.2...... Workplace Measurement............................................................................4-6
4.3.3...... Task Lighting .............................................................................................4-6
4.3.4...... Controls and Indicators...............................................................................4-6
4.3.5...... Lifting ........................................................................................................4-6
4.3.6...... Access........................................................................................................4-6
*
4.4
Pneumatic Controls ................................................................................................4-7
4.4.1...... General.......................................................................................................4-7
4.4.2...... Equipment Requirements ...........................................................................4-7
4.4.3...... Safety.........................................................................................................4-7
4.5
Lubrication..............................................................................................................4-9
4.6
Paint .... ...................................................................................................................4-9
Mechanical Design - 4 - 1
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 4 - MECHANICAL DESIGN
4.1
Mechanical Design Guidelines
4.1.1
Components
a) Use of BOSCH Products:
The use of BOSCH products is required for special purpose machines. For
Information and Service, contact responsible BOSCH group (see Appendix 4.1)
for product overview and addresses. If the use of BOSCH products is not
possible, exceptions must be noted at the time of quotation, in exceptional cases
at latest during preliminary design review.
b) Preferred Mechanical/Pneumatic Components:
The use of components readily available within U.S. is required.
(See plant specific requirements, Section 10 - Attachments)
c) Measurement Instruments:
Selection of measurement instruments and systems has to include consideration
of calibration requirements. Prior to final selection, the equipment supplier must
communicate to the Project Engineer the necessary procedures, equipment and
masters. For masters and gages, a certification of calibration and traceability to
a standard has to be supplied by the equipment supplier. Masters must be
delivered with the equipment.
(See plant specific requirements, Section 10 - Attachments)
d) Metric Hardware is required. Deviations require approval by the project
engineer.
Mechanical Design - 4 - 2
BOSCH General Delivery Specifications for Machinery and Equipment
4.1.2
*
Apr. 1, 2005
Drawing Standards
See plant specific requirements, Section 10 – Attachments.
a) Language:
All documentation, including drawing remarks, schematic diagrams, parts lists,
PLC programs, etc., must be in English.
b) Dimensions:
To insure uniformity of machine and tool design, details should conform to the
International System of Units (SI). English equivalent may be shown in
parenthesis adjacent to the metric dimension. Geometric Dimensioning and
Tolerancing is preferred.
c) Sizes:
• Mechanical Drawings:
Assembly and detail drawings should be drawn on ANSI D or DIN A1.
Multiple detail drawings should be placed on one sheet.
• Parts List (Bill of Materials):
Separate parts lists should be on A size.
d) Drawings Numbers:
Drawings shall contain a BOSCH assigned drawing number in the title block.
Contact Project Engineer for numbers.
e) CAD-Drawings:
CAD-drawings are preferred over hardcopy originals. For format of CAD files
see plant specific requirements, Section 10 - Attachments.
f)
Content:
• Mechanical Drawings - consist of the following:
- Main Assembly Drawing
- Assembly Drawings
- Subassembly Drawings
- Detail Drawings
- Parts Lists
Mechanical Design - 4 - 3
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
• Pneumatic & Hydraulic Drawings - consist of the following:
- Schematic Diagrams
- Parts List
• Main Assembly Drawing
The main assembly drawing should show the overall completed machine or
assembly. It should have at least two views: plan or top view, and one
elevation or side view. Sufficient detail is required on these drawings to
convey the overall completed appearance of the machine, including control
panels. It is mandatory that these drawings 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 of
index travel, and operator location.
• Assembly and Subassembly Drawings
It is essential that equipment and machine drawings be broken down into
logical assembly and subassembly drawings for clarity. Each detail shown on
an assembly drawing should have a position number assigned and a leader
line pointing to it. The position number corresponds to the same number in
the bill of material/parts list.
• Detail Drawings
Detail drawings show all dimensions and tolerances necessary to manufacture
the part. Materials must be designated as per standard designations such as
AISI, SAE, etc. Heat treatment and surface finish requirements need to be
shown in universally accepted designations.
• Parts Lists (Bill of Materials)
All assembly, subassembly, schematic, and panel layout drawings, have a
corresponding bill of materials or parts list. The parts list is a list of all
manufactured and purchased parts required to complete the “assembly”.
The name and part number of the original manufacturer must be shown on
the parts list.
Mechanical Design - 4 - 4
BOSCH General Delivery Specifications for Machinery and Equipment
4.2
Apr. 1, 2005
Floor Plan Layout
4.2.1
General Requirements
The supplier shall be required to furnish preliminary and final layout drawings that
define the overall equipment/machinery configuration which shall include but not
limited to the following considerations:
4.2.2
•
Overall dimensional size of equipment/machinery (L x W x H)
•
Location, size, range of movement, and direction of movement of doors for all
• Electrical panels
• Access areas
•
Access to the required lubrication points (fluid tanks fill and drain points, etc.)
•
All necessary clearance dimensions shall be shown.
•
Location and size of support equipment (e.g. filters, pumps, chip carts, mist
collectors, drip pan, etc.).
•
Location and size of part loading and unloading devices.
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 - Attachments.
4.2.3
Machine Leveling
Machine leveling devices must be supplied with equipment.
Mechanical Design - 4 - 5
BOSCH General Delivery Specifications for Machinery and Equipment
4.3
Apr. 1, 2005
Ergonomic Guidelines
4.3.1
Workstations
a) If feasible both technically and based on the scope of work, operators should be
given the option of either sitting or standing while performing their work.
b) Workstations which accommodate a sitting operator should be equipped with an
adjustable chair and adjustable footrest.
c) 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 4.2.
4.3.3
Task Lighting
a) The following light intensities are required:
• 1,000 lux for testing and adjusting delicate components.
• 1,500 lux for assembling delicate parts and electronics.
b) Reflecting workstation surfaces should be avoided.
4.3.4
Controls and Indicators
Placement of Controls and Indicators should be within operator’s normal reach and
field of vision. See also Appendix 4.2.
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
a) 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.
b) The layout of the workstation should provide easy access for maintenance,
cleaning, housekeeping, material handling, etc.
Mechanical Design - 4 - 6
BOSCH General Delivery Specifications for Machinery and Equipment
4.4
Apr. 1, 2005
Pneumatic Controls
4.4.1
General
4.4.1.1
Non lubricated compressed air shall be used wherever possible.
4.4.1.2
All types of pneumatic control logic are subject to approval by Project
Engineer. Electrical logic controls are preferred.
4.4.1.3
Pneumatic circuit should be designed to function at minimum 4.5 bar.
6 bar (85 PSI) is standard plant pressure.
Control voltage for solenoid air valves shall be 24V DC.
4.4.2
Equipment Requirements
4.4.2.1
4.4.3
Components
a)
Filters, separators, pressure regulators, and dryers must be part
of the pneumatic circuit. Automatic water dump traps shall be
used to drain air line filters and lubricators.
b)
All air cylinders that bottom in rapid travel must be cushioned
to prevent pounding. Deceleration valve shall be used when
cylinder does not bottom in either direction.
c)
Lubricators shall be used only when approved by project
engineer. If lubricators must be used, they shall be so mounted
as to assure ample downstream lubrication to those parts being
served by the lubricator.
d)
Air discharge to atmosphere shall be provided with mufflers of
sufficient capacity to reduce noise readings to 80 dBA or less
at point of discharge.
Safety
4.4.3.1
The main air and hydraulic inlet valves should provide a quick means
of shutting off the supply and exhausting the downstream system. It
must be in easy reach of the operator and designed to be locked out in
the closed position.
Mechanical Design - 4 - 7
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
4.4.3.2
Independent of the energy (e.g. electric or pneumatic) used to control
the pneumatic system, no danger shall result from switching on or off
the energy supply, from energy breakdown as well as resumption of
energy (unexpected or intended).
4.4.3.3
To avoid rapid, uncontrolled movements when switching on systems
that employ 3 position valves, a filling circuit/valve shall be used.
4.4.3.4
Construction: Air receivers and surge tanks shall be designed:
• To conform to the ASME Unfired Pressure Vessel Code and to
applicable governmental pressure vessel codes.
• So that they cannot be dismantled while containing pressure.
• With a separate port of adequate size for a safety relief valve.
4.4.3.5
Receivers and Surge Tanks shall be permanently marked with
outstanding words reading “CAUTION PRESSURE VESSEL”.
4.4.3.6
Safe Working Range of Adjustable Controls:
Pressure and flow control components shall be constructed in a
manner that prevents adjustment outside their safe working range. The
manufacturer’s information plate on pressure control components shall
be marked to indicate their minimum and maximum pressure limits.
4.4.3.7
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.
4.4.3.8
Cycle Restart:
The equipment cycle may be manually restarted after an emergency
operation, provided resumption does not create a hazard or cause
damage to the equipment or to the work in process. Where continuing
the cycle is not feasible, manual controls shall be provided for
returning the actuators affected by the emergency control to their cycle
start or other preset position.
4.4.3.9
Emergency Controls:
Emergency controls shall be provided at each operator’s work station.
Mechanical Design - 4 - 8
BOSCH General Delivery Specifications for Machinery and Equipment
4.5
Apr. 1, 2005
Lubrication
If technically possible, maintenance-free components shall be used. If not possible, lubrication
points have to be easily accessible (without removing guards) and permanently tagged.
Type of fluid and grease should be approved by Bosch. Attempts should be made to use
lubricants stocked at Bosch sites.
4.6
Paint
4.6.1
Paint being used must be resistant to oil and test fluid and also to synthetic coolants
and any other consumable liquids with which the equipment may come in contact
with during regular operation.
4.6.2
Machine tool surfaces which come in contact with the workpiece, or surfaces which
might be source of contamination shall not be painted. They might be constructed
by using e.g. stainless steel, chromating, etc., in order to avoid rust or other
degradation.
4.6.3
All heat treat equipment surfaces exposed to high temperature shall be painted with
heat resistant paint. Aluminum paint may be required.
4.6.4
Colors:
USE
Equipment
COLOR
(See plant specific requirements, Section 10 - Attachments)
Installations: Sprinkler Lines
Gas Lines
4.6.5
STANDARD
Red
Yellow
All paints shall be lead-free.
(See Section 7 for Pre-Final Acceptance Checklist.)
Mechanical Design - 4 - 9
OSHA Red
OSHA Yellow
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 5 - ELECTRICAL DESIGN
TABLE OF CONTENTS
5.1
Page
Standards ................................................................................................................5-2
5.2
Control Systems Overview .....................................................................................5-2
5.3
Documentation ........................................................................................................5-2
5.3.1...... Drawings....................................................................................................5-2
5.3.2...... Software.....................................................................................................5-2
5.4
Functional ...............................................................................................................5-2
5.4.1...... Safety.........................................................................................................5-2
5.4.2...... Manual Control ..........................................................................................5-2
5.4.3...... Independent Control ...................................................................................5-3
5.4.4...... Diagnostics ................................................................................................5-3
5.4.5...... Anti-Repeat................................................................................................5-3
5.4.6...... Control Parameters/Values .........................................................................5-3
5.4.7...... Bus Systems...............................................................................................5-3
5.4.8...... Lamp Test ..................................................................................................5-3
5.4.9...... Cycle Counters...........................................................................................5-3
5.5
Equipment...............................................................................................................5-3
5.5.1...... Machine Voltage ........................................................................................5-3
5.5.2...... Components ...............................................................................................5-3
5.5.3...... Component Labeling ..................................................................................5-4
5.5.4...... Controller Outputs......................................................................................5-4
5.5.5...... Enclosures..................................................................................................5-4
5.5.6...... Motors........................................................................................................5-5
5.6
Wiring Methods ......................................................................................................5-5
5.6.1...... Grounding ..................................................................................................5-5
5.6.2...... Test Points .................................................................................................5-5
5.6.3...... Wire Termination, Labeling .......................................................................5-5
5.6.4...... Splicing......................................................................................................5-6
5.6.5...... Spare Wire .................................................................................................5-6
5.6.6...... Wire Type ..................................................................................................5-6
5.6.7...... Wire Colors................................................................................................5-6
5.6.8...... Flexible Conduit.........................................................................................5-6
5.7
Programmable Logic Controllers and Computers ...............................................5-6
* 5.8
Data Management and Networking.......................................................................5-6
5.8.1...... Infrastructure and Interfaces .......................................................................5-6
5.8.2...... Virus Protection .........................................................................................5-7
5.8.3...... Physical and Data Security .........................................................................5-7
5.8.4...... Software.....................................................................................................5-7
*
*
*
*
*
*
*
Electrical Design - 5 - 1
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 5 - ELECTRICAL DESIGN
5.1
Standards
All equipment shall conform to the latest NFPA 70 (National Electric Code) and NFPA 79
(Electrical Standard for Industrial Machinery) unless otherwise stated in these specifications.
5.2
Control Systems Overview
A Control Systems Overview form shall be completed when the job is quoted.
(See Appendix 5.1)
5.3
*
Documentation
5.3.1
Drawings
All drawings shall be drawn with CAD and drawing files shall be provided in plant
specific format (See plant specific requirements, Section 10 - Attachments). In
addition, drawings shall also be provided in Adobe Acrobat pdf format.
Electrical Drawings shall be “A” or “B” size (DIN Size A4 or A3).
*
5.3.2
Software
All software needed to use or modify any component of the machine shall be licensed
and provided. All software shall be in English. Source code of all software developed
under this purchase order shall be provided and becomes the property of Bosch.
5.4
Functional
A functional plan describing sequential operation shall be provided for all machines.
5.4.1
Safety
Control of all devices shall be designed such that loss of power in any form
(electrical, pneumatic, hydraulic) shall not present a hazard to personnel or damage
the equipment or work in process. No automatic restart shall occur when power is
resumed.
5.4.2
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.
Electrical Design - 5 - 2
BOSCH General Delivery Specifications for Machinery and Equipment
5.4.3
Apr. 1, 2005
Independent Control
Separate control systems shall be used for each individual machine.
5.4.4
Diagnostics
Diagnostic indication shall be provided for each possible state of the machine.
5.4.5
Anti-Repeat
On equipment where continuous consecutive cycling is not a normal condition, the
controls shall be designed to prevent such operation.
5.4.6
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.
5.4.7
Field Bus Systems
See plant specific requirements, Section 10 - Attachments.
5.4.8
Lamp Test
All lamps shall have a method of testing for defective bulbs.
5.4.9
Cycle Counters
Both a non-resettable and a resettable cycle counter shall be included.
5.5
Equipment
5.5.1
Machine Voltage
The primary voltage for machines shall be 480 VAC, 3φ, 60 Hz. Control voltage
shall be regulated 24 VDC. Receptacles for 115 VAC shall be standard US
grounded 3 prong (Some plants have specific requirements for machine voltage
tolerances, see Section 10 - Attachments).
5.5.2
Components
a) Equipment shall be constructed utilizing Bosch “Preferred Electrical
Components” (See plant specific requirements, Section 10 - Attachments).
*
b) Transformers and power supplies shall have 30% excess capacity.
Electrical Design - 5 - 3
BOSCH General Delivery Specifications for Machinery and Equipment
5.5.3
Apr. 1, 2005
Component Labeling
All functional and electrical components shall be permanently labeled with their
corresponding schematic designation.
5.5.4
Controller Outputs
Controller outputs shall have individual over current protection for each circuit.
5.5.5
Enclosures
a)
Expansion:
Enclosures shall be designed with 20% expansion capability. This shall include
but not be limited to space for terminal blocks, relays, breakers, starters,
wireways, and controller I/O.
b)
Lighting:
Lighting controlled by a door switch shall be provided on enclosures over 0.425
m3 (15 cu. ft.).
c)
Programmable Devices:
*
All enclosures containing a programmable device shall have a 115 VAC GFCI,
receptacle labeled “For programming device only”.
A programming interface shall be readily accessible.
d)
Connectors:
Wiring to enclosures not mounted on the machine shall have connectors. Plugs
and sockets must be permanently labeled (See plant specific requirements,
Section 10 - Attachments).
e)
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.
*
f)
Safety:
Minimum working space in front of electrical enclosures shall be maintained.
See Section 9 - Appendix 5.2 for more detail.
Electrical cabinet doors shall be removable or able to open at least 90 degrees.
Electrical Design - 5 - 4
BOSCH General Delivery Specifications for Machinery and Equipment
5.5.6
Apr. 1, 2005
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%.
5.6
Wiring Methods
5.6.1
Grounding
Transformers and power supplies shall have their neutral or common conductors
grounded at the source. If special earth grounds are necessary, this shall be specified
by the supplier during initial design review and detailed in the installation
specifications.
5.6.2
Test Points
All control and power wiring shall have readily accessible test points in the control
enclosures.
5.6.3
*
Wire Termination, Labeling
For screw or screw clamp terminations, all wire ends shall be fitted with ferrules or
crimp connectors. All wires shall be labeled, terminated and identified in the
electrical prints. Multiple-device control panels shall be equipped with terminal
blocks or attachment plugs and receptacles for all outgoing control conductors.
Wiring directly to the terminal connection points on input or output modules of
programmable electronic systems shall be permitted.
Wire labeling method shall be specified by the customer. The machine builder is
responsible for determining customer preference. Wires shall be labeled at each end
either with wire numbers or termination labels. Wire numbers or termination
labels shall be used exclusively.
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, dropping any
punctuation and adding leading zeros as appropriate. For example, the wire
that connects to output Q2.4 should be labeled "Q024".
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
Electrical Design - 5 - 5
BOSCH General Delivery Specifications for Machinery and Equipment
5.6.4
Apr. 1, 2005
Splicing
Splicing is prohibited. Wiring shall run uninterrupted from terminal to terminal.
5.6.5
Spare Wire
A minimum of 15% spare wire shall exist in each wireway that is external to an
enclosure.
*
*
5.6.6
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:
- Type PUR: for areas with coolant, oil and diesel/gasoline calibration type fluids
(e.g. VISCOR™)
- Type PVC: for brake fluid areas
5.6.7
Wire Colors
See plant specific requirements, Section 10 - Attachments.
5.6.8
Flexible Conduit
Each section of flexible conduit shall be kept to a maximum of 1 meter.
5.7
Programmable Logic Controllers and Computers
See plant specific requirements, Section 10 - Attachments.
*
5.8
Data Management and Networking
The Bosch Corporate Network (BCN) is a private, global data network which interconnects
all Robert Bosch GmbH sites throughout the world. The network has been designed to
provide fast, secure, and reliable data transmission to all sites. To this end, it is requested
that all vendors adhere to the BCN standards wherever possible.
5.8.1
Infrastructure and Interfaces
The physical connection to the BCN is generally provided via RJ-45 jacks installed
as required near the equipment. These network drops will be terminated external to
the equipment such that cable infrastructure troubleshooting or rewiring can be done
without requiring access into the machine enclosures.
Managed Cisco routers and switches comprise the backbone of the corporate
network. To ensure network integrity and monitoring down to each networked
device, manageable Cisco switches should be used rather than simple network hubs.
Your Bosch representative should be able to obtain recommended equipment model
numbers.
Electrical Design - 5 - 6
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
TCP/IP over Ethernet is the standard protocol. Some sites may require specific
subnetting or support for other management protocols for manufacturing devices, so
be sure to check with your Bosch representative. Site-specific static IP addresses can
be assigned by the local information technology group or equivalent responsible
group.
5.8.2
Virus Protection
One of the greatest network security threats are viruses. The BCN has multi-layered
anti-virus protection starting at company firewalls cascading down to each desktop
computer. Anti-virus engines on desktop computers are updated daily with the latest
virus definition files and anti-virus scans are scheduled to run automatically on these
computers. Bosch requires that vendors evaluate the vulnerability of their equipment
to computer viruses and worms. Reasonable safeguards and/or software updates
should be part of the preventative maintenance recommendations for the equipment.
Due to throughput and performance requirements of some manufacturing computing
systems, real-time anti-virus scanning may not be possible. In this case,
manufacturing computing systems may be isolated from the general-use BCN using
Virtual Local Area Networks (VLANs). VLANs allow specific traffic flow from
manufacturing lines’ data concentrators through to other systems located on the
general-use BCN. In the event of a virus outbreak emanating from a manufacturing
computer system, all traffic flow from that manufacturing system to the general-use
BCN can be quickly stopped until the source of the virus is located and eradicated.
5.8.3
Physical and Data Security
Data confidentiality is extremely important to Bosch. Company policy states that
unauthorized data transmission of any nature to external parties is strictly forbidden.
To protect that policy, modems are not permitted on any computer connected to the
BCN. If remote dial-up access is required, alternate techniques will be employed
using existing Bosch standards and safeguards.
Removable data storage devices (i.e., external hard drives, USB memory sticks, etc.)
are not normally permitted on computers connected to the BCN because these
devices can be used to transport sensitive data off the premises. Specific exceptions
to the removable storage restrictions can be made when alternate procedures are
instituted to ensure the security of Bosch corporate data.
5.8.4
Software
It is also the vendor’s responsibility to ensure that any third-party software, included
as part of the finished equipment, is properly and legally licensed. Bosch may
request physical proof of proper licensing or transferability.
Any third-party software support agreements must be clearly documented so that all
parties understand the terms. Where applicable, all software components and their
interactions should be documented thoroughly and included as part of the operating
and maintenance instructions for the equipment.
(See Section 7 for Pre-Final Acceptance Checklist.)
Electrical Design - 5 - 7
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 6 - QUALITY STANDARDS & RUN-OFF CONDITIONS
TABLE OF CONTENTS
Page
6.1
General ...................................................................................................................6-2
6.2
Guidelines for Statistical Evaluation.....................................................................6-2
* 6.3
Gage, Process and Machine Capability ................................................................6-3
6.4
Gage Scale and Signal Output...............................................................................6-3
* 6.5
Equipment Effectiveness and Durability Demonstrations...................................6-4
6.6
Run-off Conditions ................................................................................................6-4
6.6.1 Process Data or Set-up Sheet .......................................................................6-4
6.6.2 Adjustment Frequency Limitation................................................................6-4
* 6.7
Software Validation ...............................................................................................6-5
Quality Standards & Run-Off Conditions - 6 - 1
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 6 - QUALITY STANDARDS & RUN-OFF CONDITIONS
6.1
6.2
General
6.1.1
It is the policy of the Robert Bosch Corporation 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 Appendices 6.
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.
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. Non-standard
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.
Quality Standards & Run-Off Conditions - 6 - 2
BOSCH General Delivery Specifications for Machinery and Equipment
6.3
*
Apr. 1, 2005
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 - Attachments).
6.3.2
The following capability requirements apply unless otherwise agreed upon in the
Purchase Order:
(a) Gage Capability:
(i) If a standard gage Repeatability and Reproducibility (R&R) test is used,
Study Variation / Tolerance shall be <10%
(ii) 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.
(b) Machine capability: Cmk shall be >1.67; and
(c) Process capability: Cpk shall be > 1.33.
Note:
6.4
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.
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
Quality Standards & Run-Off Conditions - 6 - 3
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
be resolved prior to design approval. In general, all parameters useful in analyzing
machine performance and quality of operation should be monitored.
6.5
*
6.6
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.
Run-off Conditions
6.6.1
6.6.2
Process Data or Set-up Sheet
a)
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.
b)
The set-up sheet should quantitatively define set-up parameters, cycle time, tool
change and adjustment procedures, relevant specifications (e.g., warm-up
period, feeds, speeds, dressing frequencies, strokes, cylinder pressures,
sequence diagrams/timing charts), masters, test parameters, control settings and
alignment/calibration procedures.
c)
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.
Adjustment Frequency Limitation
a)
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.
Quality Standards & Run-Off Conditions - 6 - 4
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
b)
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.
c)
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.
d)
A minimum of one change per tool, following the established set up procedure,
should occur during the run-off.
6.7
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 5.8, 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.
(See Section 7 for Pre-Final Acceptance Checklist.)
Quality Standards & Run-Off Conditions - 6 - 5
Robert Bosch Corporation
SECTION 7 – PRE / FINAL ACCEPTANCE CHECKLIST
TABLE OF CONTENTS
Page
7.1
General....................................................................................................................7-2
7.2
Checklist..................................................................................................................7-3
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Page 1 of 14
Robert Bosch Corporation
Bosch General Delivery Specifications for Machinery and Equipment
7.1 General
7.1.1
All tests conducted at equipment supplier are preliminary acceptance tests.
Final acceptance will always be conducted at Bosch.
7.1.2
Bosch will provide qualified components for acceptance. Provision for
gauges/measurement equipment and personnel to be coordinated with the
project engineer.
7.1.3
Evaluation of quality will be done with statistical method, when applicable,
described in Section 6.
7.1.4
Acceptance shall be based on the production result. Performance data and
process time to be verified and documented.
Instructions:
Bosch Project Engineer/Leader is responsible for the completion of the Machinery & Equipment
pre-acceptance checklist.
The first “Yes” column P/A is for Pre-Acceptance; the second “Yes” column F/A is for Final
Acceptance.
Items that are Not Applicable shall be recorded as N/A in the comments section. All items that
have checks in the “No” column require corrective action unless deviations have been
authorized.
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Page 2 of 14
Robert Bosch Corporation
Project:
Project Leader:
Date:
Ref.
GDS/
Other
GDS Section 1:
General Procedure
1.1
Has supplier agreed to
conform to “Robert Bosch
General Delivery
Specification” dated:
?
1.2
Are all documentation,
(drawings, service manuals,
etc.) available and in
English?
1.3
Are the quoted conditions
achieved
1.3.1
! Cycle Time?
1.3.2
! Machine Utilization?
1.3.3
! Changeover Time Min.?
1.3.4
! Production Rate
Pieces/Hr.?
1.3.5
! Tool Life?
1.3.6
! Gage Capability?
1.3.7
! Process Capability?
1.3.8
! Facility Utilities (i.e.
power, steam, air, etc.)?
P/
A
Yes
F/
A
Yes
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
No
Comments/Test Results
or N/A
Date
Needed
1.2.2.9
1.2.2.d
8.1.1
1.2.1
Quote
6.5.1
6.5.2
Quote
Quote
6.3.2
6.3.2
2.2.3.e
Section 2: N/A
GDS Section 3:
Safety & Health Standards
Emergency Stop
3.1
Are Emergency Stop buttons
for electrical, pneumatic and
hydraulic systems accessible
and properly labeled?
3.2
Does Emergency Stop
function and prevent
additional movement?
3.3
Does Emergency Stop
require Manual Release and
pushing the Start Button for
the machine to restart?
CF06790006 .doc
Ref.
GDS/
Other
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
Revision: 1, 4/1/05
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Page 3 of 14
Robert Bosch Corporation
GDS Section 3
Safety & Health Standards
3.4
Is Emergency Stop located
within close reach of
operator and/or technician
near point of operation?
Machine Guarding
3.5
Are all hazard areas guarded
(push, stroke, capture,
retract, clip and squeeze
areas, sharp edges, hot/cold
surfaces):
3.5.1
! Rotating shafts are
enclosed?
3.5.2
! Belts, chains, etc., are
enclosed?
3.5.3
! All pinch points
guarded?
3.6
Are guards clear where
viewing is required?
3.7
Are guards not easily
removable by operator?
3.8
Are guards for setup
interlocked and not easy to
defeat?
3.9
Are protective barriers
installed to protect other
associates from flying
objects (e.g. milling,
grinding)?
Controls
3.10
Two hand control: Is check
function, anti tie-down, anti
repeat, distance acceptable?
3.11
Are manual controls
inoperative in automatic
cycle?
3.12
Are all instructions/labels in
English?
3.13
Are light barriers, light
curtains, safety mats, etc.,
verified for proper
operation?
CF06790006 .doc
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
OSHA
1910.212
OSHA
1910.217
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Page 4 of 14
Robert Bosch Corporation
GDS Section 3
Safety & Health Standards
3.14
Do all safety switches/
protective gates operate
properly?
3.15
Are all safety door interlocks
verified to operate properly?
3.16
Does the exhaust system
operate properly (must stop/
must not stop) if emergency
stop is activated?
3.17
Are machine controls
accessible and away from
revolving spindle, moving
tools or other hazards?
3.18
Is control panel access
adequate with no blockage?
3.19
Are general operating
controls configured for safe
operation?
3.20
Are there interlocks for point
of operation guarding?
Labeling
3.21
Are the following labels
posted (in English):
3.21.1
3.21.2
3.21.3
3.21.4
3.21.5
3.21.6
3.21.7
3.21.8
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
3.4.3
OSHA
1910.212
OSHA
1910.212
Danger Signs?
Caution Signs?
Confined Space?
Notice Signs?
Safety Instructions?
Hazardous Materials?
Utilities?
Fluids and Lubricants?
Lockout/Tagout (LO/TO)
3.22
Are lock-out devices
provided for all utility
shutoffs (Pneumatic,
hydraulic and electrical
systems)?
OSHA
1910.
1200
!
!
!
!
!
!
!
!
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3.2.2
Originator: ChW/BPS-LS W.Hasper
Page 5 of 14
Robert Bosch Corporation
GDS Section 3
Safety & Health Standards
HAZCOM
3.23
Are MSDS’s available and
in English for all associated
hazardous materials?
3.24
Is safe storage provided for
all hazardous materials?
3.25
Are flammable liquids in
metal (OSHA approved)
safety containers? Is
grounding provided?
General
3.26
Is potential oil & coolant
leakage controlled?
3.27
Have all operational hazards
been identified (Job Safety
Hazard Analysis)?
3.28
Have special requirements
for Division I Class I areas
been addressed?
3.29
Are sensors provided for
Division I Class I areas?
Sound
3.30
Does sound level not exceed
80 dB(A) under normal
operating conditions?
Lasers
3.31
Does laser comply with all
requirements of ANSI
Z136.1 Safe Use of Lasers?
3.32
Is laser labeled, classified
and certified?
Robotic Operations:
3.33
Do robotic operations
comply with ANSI/RIA
R15.06 dated
?
3.34
Are all power disconnects
and interlocks installed as
required?
3.35
Have all mechanical stops
and range of motion stops
been verified?
3.36
Is there full envelope
guarding?
CF06790006 .doc
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
3.4.1
OSHA
1910.106
3.4.1.f
OSHA
1910.119
OSHA
1910.307
OSHA
1910.307
3.3
3.2.6
3.2.6
3.2.4
R15.06
R15.06
R15.06
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Page 6 of 14
Robert Bosch Corporation
GDS Section 4 –
Mechanical Design Ergonomics
4.1
Are workplace dimensions
according to the Bosch
Workplace Measurement
specifications?
4.2
Is task lighting adequate, no
glare?
4.3
Are all secondary tasks at
proper working heights
(actuating or reading
controls, handling parts bins,
etc.)?
4.4
Are all lifting tasks within
NIOSH limits (changing of
tools, fixtures, bins, etc.)?
4.5
Are lifting aids provided for
heavy items?
4.6
Is maximum lifting weight
30 lbs.?
4.7
Is the following assessed:
4.7.1
! Improper/unnecessary
lifting?
4.7.2
! Repetitive motions?
4.7.3
! Operator posture?
4.8
Is accessibility for material
handling, adjusting,
maintenance, and cleaning
adequate?
GDS Section 5:
Electrical Design
5.1
Are electrical drawings
created with CAD and
provided in plant specific
format and also in Adobe
Acrobat pdf format?
5.2
Are electrical drawings
provided on paper in “A”,
“B”, “DIN A4” or “DIN A3”
size?
CF06790006 .doc
Revision: 1, 4/1/05
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
No
Comments/Test Results
or N/A
Date
Needed
4.3.2
4.3.3
4.3.4
4.3.5
4.3.5
4.3.5
4.3.6.b
Ref.
GDS/
Other
5.3.1
5.3.1
Originator: ChW/BPS-LS W.Hasper
Page 7 of 14
Robert Bosch Corporation
GDS Section 5:
Electrical Design
5.3
Can Bosch make changes to
all software?
5.4
Is a functional plan
provided?
5.5
Are controls designed so that
loss of power (electrical,
pneumatic, hydraulic) does
not present a hazard to
personnel or damage to
equipment or damage to
work in process?
5.6
Are manual controls
provided and interlocked to
prevent damage to machine
or work in process?
5.7
Are separate control systems
used for each individual
machine?
5.8
Do machine controls include
diagnostic indication for all
machine states?
5.9
Are abnormal continuous
consecutive machine cycles
prevented?
5.10
Do passwords limit access to
parameters?
5.11
Do out of tolerance process
values cause the machine to
stop?
5.12
Do field bus systems meet
plant specific requirements?
5.13
Can all lamps be tested?
5.14
Are cycle counters present?
5.15
Is input power 480 VAC, 3
phase 60 Hz.?
5.16
Is control voltage regulated
24 VDC?
5.17
Are receptacles for 115 VAC
standard US grounded 3
prong?
CF06790006 .doc
Revision: 1, 4/1/05
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
5.3.2
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.4.6
5.4.7
5.4.8
5.4.9
5.5.1
5.5.1
5.5.1
Originator: ChW/BPS-LS W.Hasper
Page 8 of 14
Robert Bosch Corporation
GDS Section 5:
Electrical Design
5.18
Do machine voltages comply
with plant specific
tolerances?
5.19
Is equipment built with plant
specific "Preferred Electrical
Components"?
5.20
Are control transformers and
power supplies sized 30%
above maximum load?
5.21
Are functional and electrical
components permanently
labeled with their
corresponding schematic
designation?
5.22
Do controller output circuits
have individual circuit
protection?
5.23
Do enclosures have room for
20% expansion?
5.24
Do enclosures larger than
0.425 cu. m (15 cu. ft.) have
lighting controlled by a door
switch?
5.25
Do enclosures with
programmable devices have
a 115 VAC GFCI receptacle
labeled "For programming
device only"?
5.26
Do programmable devices
have a readily accessible
programming interface?
5.27
Does wiring to enclosures
that are not mounted on the
machine have connectors?
5.28
Are plugs and sockets
permanently labeled per
plant specific requirement?
5.29
Are enclosures at least 100
mm (3.75") off floor?
5.30
Are the control enclosures
positioned so the machine
can be observed while
working in the enclosures?
CF06790006 .doc
Revision: 1, 4/1/05
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
5.5.1
5.5.2.a
5.5.2.b
5.5.3
5.5.4
5.5.5.a
5.5.5.b
5.5.5.c
5.5.5.c
5.5.5.d
5.5.5.d
5.5.5.e
5.5.5.e
Originator: ChW/BPS-LS W.Hasper
Page 9 of 14
Robert Bosch Corporation
GDS Section 5:
Electrical Design
5.31
Are control cabinet working
space clearances
maintained? Note! Depth –
1m, Width – the greater of
either 750 mm or cabinet
width.
5.32
Are control cabinet doors
removable or able to open at
least 90 degrees?
5.33
Are AC motors High Energy
Efficient TEFC, 480 VAC,
3Φ, 60 Hz?
5.34
Do motors 25hp and above
have continuous conductors
between control enclosure
and motor?
5.35
Do motors 25hp and above
have power factor corrected
to above 90%?
5.36
Are all transformer neutral
conductors and power
supply common conductors
grounded at the source?
5.37
Does all control and power
wiring have readily
accessible test points in
electrical enclosures?
5.38
Where screw or screw clamp
termination systems are
used, are all wires fitted with
either ferrules or crimp
connectors?
5.39
Are all wires labeled,
terminated and identified in
the electrical prints?
5.40
Are all enclosure outgoing
control conductors except
conductors from controller
I/O terminated at terminal
blocks or attachment plugs
with receptacles?
CF4.02.619.doc
Revision: 1, 4/1/05
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
5.5.5.f,
Sec 9
Appen.
5.2
5.5.5.f
5.5.6
5.5.6
5.5.6
5.6.1
5.6.2
5.6.3
5.6.3
5.6.3
Originator: ChW/BPS-LS W.Hasper
Page 10 of 14
Robert Bosch Corporation
GDS Section 5:
Electrical Design
5.41
Are all wires labeled at each
end?
5.42
Are 'wire numbers' or
'termination labels' used
exclusively?
5.43
Where 'wire numbers' are
used, does each wire have
the same number at all
termination points?
5.44
Where 'wire numbers' are
used, are wires connecting to
controller I/O labeled Ixxx
for inputs or Qxxx for
outputs?
5.45
Where 'termination labels'
are used, are wires labeled
with the terminal name?
5.46
Are all conductors installed
without wire splices?
5.47
Do wireways outside
enclosures have 15% spare
wire?
5.48
Are only stranded copper
conductors used?
5.49
Is MTW wire jacketing used
on wires not leaving control
enclosures?
5.50
Is PUR cable used in oil,
coolant or VISCOR
splash/mist areas, and PVC
cable used in brake fluid
splash/mist areas?
5.51
Do wire colors meet plant
specific requirements?
5.52
Is maximum flexible conduit
length one meter?
5.53
Does computer hardware
and operating system meet
plant specific requirement?
5.54
Does computer software
meet plant specific
requirement?
CF06790006 .doc
Revision: 1, 4/1/05
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
5.6.3
5.6.3
5.6.3
5.6.3
5.6.3
5.6.4
5.6.5
5.6.6
5.6.6
5.6.6
5.6.7
5.6.8
5.7
5.7
Originator: ChW/BPS-LS W.Hasper
Page 11 of 14
Robert Bosch Corporation
GDS Section 5:
Electrical Design
5.55
Do program printouts and
remarks meet plant specific
requirement?
5.56
Does use of software
modules meet plant specific
requirement?
Data Management and Networking
5.57
Will the machinery be
connected to the BCN?
5.58
Is all 3rd party software
properly licensed? (Proof of
ownership and original
media are required.)
5.59
Have virus protection
measures be
considered/implemented?
(Please explain.)
5.60
Is CAT5 UTP cabling used
for all data network
connections?
5.61
Is TCP/IP protocol used?
5.62
Have security measures been
implemented to protect
against loss or theft of data?
(Please explain.)
5.63
Will the machinery be
integrated into an existing
data collection system?
5.64
Is there a contingency plan
that will provide for
“continuous production” in
the event of hardware/
software failure or virus
infection? (Please explain.)
GDS Section 6:
Quality Standards and Run-off
Conditions
6.1
Are sample sizes selected
per Appendix 6.1?
6.2
Are production samples
divided equally among work
piece locations?
CF06790006 .doc
Revision: 1, 4/1/05
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
No
Comments/Test Results
or N/A
Date
Needed
5.7
5.7
5.8
5.8.1
5.8.4
5.8.2
5.8.1
5.8.1
5.8.3
5.8.1
5.8.3
5.8.1
5.8.2
5.8.3
5.8.4
Ref.
GDS/
Other
6.2.3
6.2.4
Originator: ChW/BPS-LS W.Hasper
Page 12 of 14
Robert Bosch Corporation
GDS Section 6:
Quality Standards and Run-off
Conditions
6.3
Are Gage, Machine and
Process capability studies
conducted per paragraph 6.3
and Plant Specific
Requirements?
6.4
Do results meet the
following acceptance
criteria:
! Gage Capability:
a) <10% of tolerance;
or
b) Alternatively,
ISOPlot(sm)
Discrimination Ratio
DR>12.5?
6.4.1
! Machine Capability:
(Cmk > 1.67)?
6.4.2
! Process Capability:
(Cpk > 1.33)?
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?
6.7
Is technical availability >
95% as per Appendix 6.2?
6.8
Does changeover time meet
BPS guidelines (<10 min.
for equipment, <5 min. for
assembly)?
6.9
Is dry-cycle run for durability
conducted?
6.10
Are process data or set-up
sheets available:
6.10.1
6.10.2
6.11
Set-up parameters
included?
! Tool change/ adjustment
procedures included?
Are frequency of operational
adjustments adequate?
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
6.3
6.3
Test Results:
Test Results:
6.3
Test Results:
6.3
Test Results:
6.4
6.4.2
6.5.1
6.5.2
6.5.3
6.6.1
!
CF06790006 .doc
6.6.2
6.6.2
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Page 13 of 14
Robert Bosch Corporation
GDS Section 6:
Quality Standards and Run-off
Conditions
6.12
Is at least one change per
tool, using equipment
supplier set up procedure,
accomplished during run-off
trial?
6.13
Are all modes and features
of software operation and
data output demonstrated:
6.13.1 ! Test plan available?
6.13.2 ! Calculations verified?
6.13.3 ! Remote access verified?
6.13.4 ! Data transmission to
Bosch network?
Ref.
GDS/
Other
P/
A
Yes
F/
A
Yes
P/
A
Yes
F/
A
Yes
No
Comments/Test Results
or N/A
Date
Needed
No
Comments/Test Results
or N/A
Date
Needed
6.6.2
6.7
6.7
6.7
6.7
Section 7: N/A
GDS 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?
Ref.
GDS/
Other
8.1.2
8.1.2.b
Section 9: N/A
Section 10: Plant Specific Additional Requirements
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Page 14 of 14
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 8 - DOCUMENTATION & SHIPPING INSTRUCTIONS
TABLE OF CONTENTS
Page
8.1
Machine Documents ...............................................................................................8-2
8.2
Shipping Instructions .............................................................................................8-3
8.3
Ocean Freight Shipping..........................................................................................8-3
8.4
Package Identification ............................................................................................8-4
8.5
Shipping Documentation ........................................................................................8-4
8.6
Invoicing..................................................................................................................8-5
Documentation and Shipping Instructions
-
8 - 1
BOSCH General Delivery Specifications for Machinery and Equipment
Apr. 1, 2005
SECTION 8 - DOCUMENTATION AND SHIPPING INSTRUCTIONS
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 (i.e. measuring
devices, dressing attachments).
8.1.2
Three (3) sets of hardcopy documents and, if available, CAD drawings in electronic
format should be submitted to the Project Engineer along with the machine:
The following documents are to be included, if applicable:
a)
h)
Operation, Set-up, and Maintenance Instruction (See Appendix 8.1 for format
guidelines)
Service Manual (See Appendix 8.1 for format guidelines)
Hydraulic Diagram, with parts list
Pneumatic Diagram, with parts list
Layout - Including location of switches, motors, solenoid valves, etc.
Electrical Diagram - Including internal circuit diagrams, KVA ratings, fuse
amperages, parts lists, general diagram on installation Position and panel
layout diagram.
PLC Program - program printout, symbol table and cross reference table in that
order.
Software diskettes, including source codes
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
Function Plans
Computer Program Listings
Computer Program Flowcharts
Preventative Maintenance Schedule
Assembly and Detail Drawings
Spare Parts List with manufacturer’s name & stock number
Tooling List
Certificates of Compliance (pressure vessel, calibration, high freq. etc.)
Robotic Risk Assessment
Laser Product Report and accession number from CDRH
Safety Instructions
Component Manuals
b)
c)
d)
e)
f)
g)
8.1.3
The above documents have to be updated within thirty (30) days after final
acceptance and sent to the Project Engineer.
Documentation and Shipping Instructions
-
8 - 2
BOSCH General Delivery Specifications for Machinery and Equipment
8.2
8.3
Apr. 1, 2005
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.
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 instructions must be visible to handlers, i.e. lift points, labels such
as “This End Up”, “Protect From Rain”, etc.
Ocean Freight Shipping
8.3.1
The Purchase Order Number, BOSCH Part Number and Release Number must
appear on:
• Packing List
• Certification
• Outside Container
• Bill of Lading
If applicable, Freight Authorization Number must appear on:
• Consignee's copy of the Air Bill/Bill of Lading
• and Invoice
Documentation and Shipping Instructions
-
8 - 3
BOSCH General Delivery Specifications for Machinery and Equipment
8.3.2
Apr. 1, 2005
All freight should be shipped collect, unless it is:
a)
b)
c)
reshipment due to defective goods,
shipment via Premium freight due to late delivery,
shipment via non-designated carrier.
THESE SHIPMENTS HAVE TO BE PREPAID AT EQUIPMENT SUPPLIER’S EXPENSE.
8.4
Package Identification
Mark each package or separate piece as below:
Robert Bosch Corporation 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
To be air mailed directly to Robert Bosch Corporation or it’s Affiliates.
Five (5) copies of Commercial Invoice
Three (3) copies of original Bill of Lading
Three (3) copies of the Packing List stating contents of each package or case.
8.5.1
Documentation for U.S. Customs Clearance
To enable U.S. Customs to clear the shipment three (3) commercial invoices have to
accompany the shipment:
• 1 copy in package
• 1 copy in envelope attached to the outside of the package
• 1 copy attached to the Air Way Bill (AWB).
Documentation and Shipping Instructions
-
8 - 4
BOSCH General Delivery Specifications for Machinery and Equipment
8.6
Apr. 1, 2005
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 Corporation 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)
b)
c)
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.
Total gross, tare and net weight.
Costs of packing.
For International Orders only:
d)
e)
f)
g)
h)
8.6.4
Cost of freight from manufacturer to dock shipping agent.
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”.
Kilowatt rating for electric motors (For Customs purpose only).
Return shipment of repairs must show the value of the part and the cost of
repair, including repair materials.
Signature.
Commercial invoice quantities and values must match exactly to shipping
documents. Reference to specific page and line item from Purchase Order required.
Documentation and Shipping Instructions
-
8 - 5
BOSCH General Delivery Specifications for Machinery and Equipment
SECTION 9 - APPENDICES
TABLE OF CONTENTS
SECTION 9 - APPENDICES
•
Appendix 1.1
General Terms and Conditions for the Purchase of
Capital Equipment
* •
Appendix 2.1
Machine Data Sheet
* •
Appendix 2.2
Design Review Checklist
* •
Appendix 2.3
Investment Assessment
* •
Appendix 4.1
US Contacts for Bosch Products
•
Appendix 4.2
Workplace Measurements
•
Appendix 5.1
Control Systems Overview form
* •
Appendix 5.2
Special Attention Points for Equipment Suppliers
•
Appendix 6.1
Parts to Produce for Total Test, Sample Size
* •
Appendix 6.2
Technical Availability
•
Appendix 8.1
Documentation
Appendices
-
Section 9, Page 1
Apr. 1, 2005
APPENDIX 1.1
GENERAL TERMS AND CONDITIONS FOR THE
PURCHASE OF CAPITAL EQUIPMENT
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 Corporation ("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
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 1 of 10
APPENDIX 1.1
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.
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.
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 2 of 10
APPENDIX 1.1
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.
7.5
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
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 3 of 10
APPENDIX 1.1
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 pre-acceptance 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
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
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
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 4 of 10
APPENDIX 1.1
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.
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.
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 5 of 10
APPENDIX 1.1
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 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.
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 6 of 10
APPENDIX 1.1
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 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.
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 7 of 10
APPENDIX 1.1
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.
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 8 of 10
APPENDIX 1.1
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
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.
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 9 of 10
APPENDIX 1.1
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.
RBUS/LEG\Legal Library\Drafting...Appen11.DOC
Final Version LEG05012000
Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment
Issued April 1, 2005, Page 10 of 10
APPENDIX 2.1
MACHINE DATA SHEET
BOSCH DATA
SC No:
Investment No:
PO No:
Description:
For Component:
Production Rate:
Qty./Day
Requested by:
Name
Dept.
Date
SUPPLIER DATA
Supplier:
Model No:
Supplier Proj. Engr:
Dim. :
Serial No:
L
W
H
Weight:
Utility Usage
Elect. Main Breaker:
Motors
Amps
Volts
Yes
No
Chilled Water
GPM
BTU/H
DI Water
GPM
Potable Water
GPM
Function
Qty
KW
RPM
Volt
Amp
PH
Elect. Full Load Current
Elect. Panel attached
Gas SCFM
Pressure
Steam lb/hr.
Pressure
Air SCFM
Pressure
Coolant System
System Capacity:
gals.
Environmental
Pump Cap.:
Sys. Type:
Exhaust SCFM Vol.
Temp.
Solid Waste Type
External Tank Cap:
Size:
Type of Filter Media:
Contaminants:
Mist
Vol.
Smoke
VOC
Treatment
Drip Pan Req.:
Yes
No
Chip System
Waste Water Discharge
GPM:
Chip Material:
Waste Oil Discharge
GPD:
System Type:
Other Systems
Cranes:
Dust
Volume:
Special Foundation Requirements
Max. Weight:
Special Hazards:
OSHA Req.
Communication Requirements
Number of Network Jacks Required:
CF06790005 .xls
Originator: ChW/BPS-LS W.Hasper
Section 9, Appendix 2.1 - Machine Data Sheet
Issued April 1, 2005, Page 1 of 1
Revision:
1, 4/1/05
APPENDIX 2.2
DESIGN REVIEW CHECKLIST
Project:
Date:
Project Engineer:
Vendor Representative:
1.0
2.0
Yes
Reviewed?
No
N/A
Yes
Acceptable?
No
N/A
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 special design concerns:
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
Updated Machine Data Sheet
2.8
Hazardous Material List
2.9
2.10 Foundation Drawing
2.11 Approval Prints
2.12 Anticipated PM Requirements (Labor, Material, & Frequency)
2.13 Other:
CF06790004 .xls
Originator:
ChW /BPS-LS W.Hasper
Section 9, Appendix 2.2 - Design Review Checklist
Issued April 1, 2005, Page 1 of 1
Rev. 1, 4/1/05
APPENDIX 2.3
Investment Assessment
Attachment 2 to the supplementary manual for the ZI Central Directive Investment Assessments
BPS-Assessment with qualitative criteria
BPS-Principle
Value
Criteria
0
1
2
Comment
3
4
Process Orientation
1
The equipment layout is according to the sequence of operations (routing). There are no
batch processes.
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 equipment is systematically designed according to TPM Pillar 4
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)
4 FIFO (First-In-First-Out) is maintained by internal transportation of products
Flexibility
1
Short changeover time (<10 min for equipment, < 5 for assembly) allow for small lot sizes, 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 Variations of ±10 % in demand are covered with self regulating systems (Pull system)
Standardization
The material transportation processes are repetitive in a defined rhythm, material foot
1
prints and quantity of material are defined.
2 A packaging concept exists with standardized containers (dunnage)
3
Deviations for the standard are quickly recognized, escalation levels are defined, there is a
structured process to eliminate deviations from the standard
Transparency
1 The material flow is clearly oriented and easy to understand
2
The preventative maintenance actions are visualized, Goal and Actual values is displayed
as a key indicator 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 observable
Measurement Scale
4
3
2
1
0
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
For update and further information see http://www.intranet.bosch.com/ZI11/Investment_assessments/
Section 9, Appendix 2.3 - Investment Assessment
Issued April 1, 2005, Page 1 of 1
APPENDIX 4.1
US Contacts for Bosch Products
Bosch Rexroth Corporation
Contact:
Kim Huff
Bosch Rexroth Corporation
2810 Premiere Parkway – Suite 500
Duluth, GA 30097
Phone:
Mobile:
Fax:
E-mail:
Web site:
Industrial Hydraulics\
Linear Motion and Assembly
▪
▪
▪
▪
▪
▪ Linear Motion Technology
• Linear Motion Guides (standard and
miniature series, roller and ball elements)
• Ball Screws
• Linear Ball Bushings and precision
ground round shafting
• Linear Actuators (belt, ball screw, lead
screw, pneumatic drives)
• Ball Transfers
▪ Assembly and Material Flow Technology
• FMS Aluminum extrusion – full line of
sizes, shapes and accessories.
• Workstations (adjustable, powered, air
supply, lighting)
• Lean Manufacturing technology
• Transfer Systems and non-synchronous
conveyors (TS palletized systems)
• Single strand material handling and
product flow conveyors, (VarioFlow)
Valves and controls\
Compact hydraulics\
Pumps\
Power units / accessories
Hydraulic cylinders
Electric Drives and Controls
▪
▪
▪
▪
▪
Motion controllers and PLCs
Servo drives and motors
Frequency converters
Fastening and press-fit technology
Resistance welding
Pneumatics
▪
▪
▪
▪
Valves and actuators
Cylinders
Fieldbus valve manifolds
Electro-pneumatic valves and positioners
(678) 957-4055
(770) 310-1398
(678) 417-6637
kim.huff@boschrexroth-us.com
www.boschrexroth-us.com
Robert Bosch Tool Corporation (EW)
Power Tools
Contact: John A. Onik
Robert Bosch Tool Corporation
1800 West Central Road
Mount Prospect, Illinois 60056
Phone: (224) 232-2000
Section 9, Appendix 4.1 - US Contacts for Bosch Products
Issued April 1, 2005, Page 1 of 1
Issued April 1, 2005
Section 9, APPENDIX 4.2
Page 1 of 2
BOSCH
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
s
s
d
s
Max. 1400
“Unobstructed”
View
s
Max. Positioning
Height d: 1500
e
c
c
H1
max.
300
A
b
k
e
max.
300
k
A
b
α
α
H2
A
H2
600
BOSCH FMS-Worktable
i
BOSCH FMS-Worktable
i
t1
Fig. 1
t2
Fig. 2
Seating Workplace (Fig. 1)
Description
Distance to work area
Working height
e
i
t1
t2 2
t1
Fig. 3
Seating/Standing Workplace (Fig. 2)
Standing Workplace (Fig. 3)
Influence on:
0 to 325
Aim a minimum distance from the front edge
Pay attention to dimension c
H2
Reference values for working height see Fig. 5 & Table I. (the work area
of the fingers is decisive)
900 - 1080
min. 900
Influence on: Arm position
Above a = 90, k = 520 to 750 Dependent on: Body height
Visual distance s
is possible
Fixture height
Work piece 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. 5 and Table 1.)
A
From tabletop to work
area
c
Leg room depth
t1
min. 350
min. 80
Foot room depth
t2
min. 550 (for free movement)
min. 150
Leg room width
t3
min. 800, Getting up from chair must be possible by swiveling the chair
min. 600
Footrest:
Free room for knees
Inclination
k
α
Installed at workplace (platform continues to rear)
520-750 (adjustable height), at A = 900 only k = 520 to 700 possible
5º - 10º
Room for foot movement:
Clearance height
i
Also for chair legs
min. 120
Seating Height
b
Adjustment range min. 250, preferably 300, adapted to height of work area
s
s is almost independent from body height when
seated and can be adjusted via seating height
Visual distance
Arm position
Visual distance s
Head inclination
H1
Working Surface Height
1)
t2
1) Visual distance is dependent on
17
60
166
0
0
154
0
37 0
57
44
0
64
0
24
0
0
46
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).
0
720
Fig. 4
Top view of knee room, clearance in the
back, distance of persons and area of free
movement.
1 87
0
53
t3
several parameters.
Reference values can be
determined by comparing similar
workplaces or by experimenting.
The following parameters must be
comparable:
min.1000
min.
1000
Size and shape of recognizable
details
min. 1000
Type of activity
Contrasts (object/surroundings)
Illumination intensity
Area of free movement per workplace
min. 1.5 m 2 recommended.
Individual power of vision
s is heavily dependent on body height when standing
and can be influenced via working height (see Fig. 5)
1200
1100
1000
950
900
Fig. 5
Visual distances and underarm positions illustrated depending on body height and work height
© 1999 Robert Bosch GmbH
Responsible FV/PLP1
Issued April 1, 2005
Page 2 of 2
Section 9, APPENDIX 4.2
Table 1
Reference values for working heights H 1 and H 2 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
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
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
APPENDIX 5.1
Control Systems Overview
Controller Type
CF06790003 .xls
Manufacturer
Page 1 of 2
Model
Programming
Language
Originator:
Programming
Device
ChW/BPS-LS W. Hasper
Section 9, Appendix 5.1 - Control Systems Overview
Issued April 1, 2005, Page 1 of 2
Comments
(German translation, next page)
Revision: Original, 03/11/05
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.
CF06790003 .xls
Page 2 of 2
Originator:
ChW/BPS-LS W. Hasper
Section 9, Appendix 5.1 - Control Systems Overview
Issued April 1, 2005, Page 2 of 2
Revision: Original, 03/11/05
APPENDIX 5.2
Special Attention Points for Equipment Suppliers
Spaces around Control Cabinets and Compartments:
Electrical
Cabinet
1.
Working Space Depth and Width
As per:
NFPA 79
12.5.1
12.5.1.1 (Minimum depth requirement
for Bosch to be 1 meter.)
12.5.1.2 The width of the working space in
front of control cabinets and
compartments shall be the width of
the control cabinet or compartment,
or 750 mm (2-1/2 ft.), whichever is
greater.
2.
Recessed Control Cabinets and Compartments
Depth
of working space
min. 1 meter
Width
of working space
per 12.5.1.2
Fig. 1
Recess cannot be
more than 6 inches
As per:
NFPA 79
12.5.1.3
Electrical
Cabinet
Fig. 2
Fig.1 and Fig.2 are examples of many possibilities. For more details, see the entire NFPA 79 12.5.
Section 9, Appendix 5.2 - Special Attention Points for Equipment Suppliers
Issued April 1, 2005, Page 1 of 1
APPENDIX 6.1
Parts to Produce for Total Test
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.
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.
Calculation example:
Cycle time:
To be evaluated:
15 seconds (one part produced at a time)
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)
= A/(B-1)** = 1,920/(25-1)
= approx. every 80 Pcs.
** 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
Section 9, Appendix 6.1 - Parts to Produce for Total Test, Sample Size
Issued April 1, 2005, Page 1 of 1
APPENDIX 6.2
Technical Availability
VDI 3423 Draft Aug.1998 (excerpts, translated by Robert Bosch Corp. Charleston SC, USA. Jan. 2000)
For updated and complete information see latest German/English issue. It can be purchased via
http://www.beuth.de/index_en.php
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.
Defects, for example are:
• material defects
• design or construction defects
• defects in documentation
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
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).
Section 9, Appendix 6.2 - Technical Availability
Issued April 1, 2005, Page 1 of 1
APPENDIX 8.1
DOCUMENTATION
1.
Preferred format for Operation Instructions and Service Manual
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:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1.2
Title Page
Table of Contents
List of Tables
List of Illustrations
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)
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
Section 9, Appendix 8.1 - Documentation
Issued April 1, 2005, Page 1 of 3
APPENDIX 8.1
1.3
1.4
Pages numbering 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).
Section Content.
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. address, telephone numbers).
2. Section 2.0 General Description - Prepares the reader for the detailed description by
providing information regarding the components and nomenclature and define
terms.
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.)
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.
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.
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.
7. Section 7.0 Troubleshooting - Provides fault isolation steps that correspond to the steps
outlined in the Operation section.
Section 9, Appendix 8.1 - Documentation
Issued April 1, 2005, Page 2 of 3
APPENDIX 8.1
8. Section 8.0 Service and Maintenance - Provides recommended preventive maintenance
checks, procedures and schedule. Refers to third-party manuals as required.
9. Section 9.0 Recommend Spare Parts list (see paragraph 1.4)
1.5
Modifications to this format shall be agreed upon in writing by the Project Engineer and the
vendor.
1.6
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.
Section 9, Appendix 8.1 - Documentation
Issued April 1, 2005, Page 3 of 3