New Process Design and Installation Review Procedure Attachment #1
Health and Safety Requirement Checklist For New Programs
Health and Safety Review
SIGN OFF AND
VERIFICATION
WORKSHEET
Plant
Department
Project No
Equipment Manufacturer
Lead Engineer
Controls Engineer
Safety Engineer / Responsible Safety Representative
Design
Vendor Run-off
Stage of Review:
Operation
Description
Y
1.0
Acceptance
N
Date
Manufacturer Signature
Launch
Remarks
N/A
ELECTRICAL
1.1
Supply Termination /
Disconnects
1.2
Protection Against
Electrical Shock
1.3
Protection Of
Equipment
1.4
Control Circuits And
Their Functions
1.5
Start Circuits
1.6
Stop Circuits
Termination Of Incoming Supply Conductors
Termination Of Grounding (Protective Earth)
Conductors
Disconnect Switch Approved
Disconnect Handle Affixed with Captive Means.
Disconnect Switch Height From Working
Surface
Door to Disconnect Interlock
No Components Above Or Behind Disconnect
Protection Against Shock – Direct Contact
Overcurrent Protection
Protection Against Supply Interruption Or
Voltage Reduction And Subsequent
Restoration
Control Circuit Supply –
Isolated From Higher Voltages
Control Circuit Voltages – Max. Values
Connection Of Control Devices To Common
Side Of Circuit
Start Circuit Design - All Safeguards In Place
Start Circuit Design – Two Deliberate Acts To
Initiate Motion
Start Circuit Design – Audible/ Visible Warning
Start Buttons
Start Pushbuttons Guarded Against Inadvertent
Operation
START Above Or To The Left of Associated
STOP Pushbutton
Stop Circuit Design - Category 0, 1, and 2
This document and any of its contents shall be considered transient when printed.
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Page 1 of 10
New Process Design and Installation Review Procedure Attachment #1
Description
Y
1.7
Emergency Stop
Circuits
1.8
Operating Modes
1.9
Two Hand Control
1.10
Guard Interlocks
Acceptance
N
Remarks
N/A
Emergency Stop Circuit Design
Emergency Stop PB –
Red, Unguarded Mushroom Head, Latching In,
Manually Reset. Legend Plate Shall be Yellow
Emergency Stop PB - Located At Every
Operator Control Station
Emergency Stop Pullcord – Max. (2) 90 Deg.
Turns Per Switch
Emergency Stop Pullcord - Less Than 75 Feet
(22.9 m) Total Length
Emergency Stop Pullcord - Located 3 – 6 Feet
(.9 – 1.8 m) From Standing Surface
Pullcord Switch, Pull Cord,
E-Stop Pushbuttons, Safety Relays Approved
Main Console – Overall Machine Modes
Main Console – Machine Automatic / Manual
Mode Select
Station Operator Panels –
Manual Selector Switch and Pushbuttons
Provided
Station Operator Panels –
Station Mode Select
Station Operator Panels –
Normal / Bypass Mode Selection
Station Operator Panels –
Interlocking with Main Console
Station Operator Panels –
Jog Mode Only Operates in Manual Mode
Two Hand Control – Application Requirements
– Type IIIC System per EN 574
Palm Buttons Hardwired Safety Relays (Control
Reliable, Anti-Tie Down, Anti-Repeat) or
compliant with w-EL10 Programmable Safety
Systems
Palm Button Wiring Separate From Power
Wiring
Maintained Depression Throughout Cycle Or
Past Hazard
Located Sufficient Distance From Hazard For
Stopping (Minimum Safety Distance
Calculation)
Distance Between Palm Buttons
Palm Buttons Approved
Not Easily Bypassed
Guard Switches Hardwired Safety Relays
(Control Reliable) or compliant with
w-EL10 Programmable Safety Systems
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New Process Design and Installation Review Procedure Attachment #1
Description
Y
1.11
Operator Interface
1.12
Presence Sensing
Devices (Light
Curtains, Safety Mats,
Laser Scanners)
1.13
Programmable
Controller
1.14
Control Equipment
1.15
Conductors And
Cables
1.16
Wiring Methods and
Practices
1.17
Electric Motors
1.18
Accessories and
Lighting
1.19
Warning Signs And
Reference
Designation
1.20
Documentation
Acceptance
N
Remarks
N/A
Control Station Location
HMI Height
Push Buttons –
Proper Colors and Usage
Indicator Lights & Illuminated Pushbuttons –
Proper Colors and Usage
Durable Legend Plates For
Devices (PB's, PL's, SS's, etc.)
Emergency Return Pushbutton – Unguarded
Yellow Mushroom Head
Ground Connected Light
Presence Sensing Devices Hardwired (Control
Reliable) or compliant with
w-EL10 Programmable Safety Systems.
Located Sufficient Distance From Hazard For
Stopping (Minimum Safety Distance
Calculation)
Approved Components
Safety Circuits (E-Stop, Two-Hand Control,
Etc.) Operate Independently Of Logic
Location And Mounting
Adequate Clearance For Component
Maintenance
Approved Conductor Types
Conductor Sizing
Marking of Insulation (including mandatory
AWG marking in USA and Canada)
Proper Wire Colors
Connections And Routing
Wiring Inside Enclosures – (Panel Wiring)
Wiring Outside Enclosures – (Machine Wiring)
Motor Direction Arrow
Motor Mounting
Receptacles
Control Enclosure and Machine Lighting
Warning Signs
Component Identification – Tags Adjacent To
But Not On The Devices
Maintenance Manual
Drawings
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New Process Design and Installation Review Procedure Attachment #1
Description
Y
2.0 PNEUMATIC
2.1
Basic Design
Requirements
2.2 Documentation
Acceptance
N
Remarks
N/A
System Requirements
All Components Approved
Unintended Pressure –
(Over – Or Under – Pressure)
Main Shut-Off Valve Exhausts All Downstream
Pressure (No Trapped Air)
No Blocked Center Valves
No Uncontrolled Movement
Emergency Stop And Emergency Return
Functionality
System Restart After An Emergency Stop Or
Return
Two Hand Controls
Location Of Manual Controls
System Protection
Sequence Control
Control Systems With Servo Or Proportional
Valves
Leakage
Control Or Power Supply Failure
Accessibility Of Components And Piping For
Maintenance
Exhaust Air Protection –
Velocity, Contamination, And Noise Are
Minimized
Component Identification –
Tags Adjacent To But Not On The Devices
Vertical and Inclined Equipment
Counterbalanced
Air Blowoffs Limited to 30 PSI (2.1 Bar)
Surge Tanks / Air Receivers
Coupling Guards Covering Rotating Shafts and
Couplings
Flexible Hose Properly Restrained, Min. 4
Times Burst Strength
Drip Leg
Maintenance And Operating Data
Drawings
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New Process Design and Installation Review Procedure Attachment #1
Description
3.0 HYDRAULIC
3.2 Basic Design
Requirements
3.2 Documentation
Y
Acceptance
N
N/A
Y
Acceptance
N
N/A
System Requirements
All Components Approved
Unintended Pressure –
(Over – Or Under – Pressure)
No Uncontrolled Movement
Emergency Stop And Emergency Return
Functionality
System Restart After An Emergency Stop Or
Return
Two Hand Controls
System Protection
Sequence Control
Control Systems With Servo
Leakage
Operating Temperature
Control Or Power Supply Failure
Accessibility Of Components And Piping For
Maintenance
Component ID Tags – Adjacent To But Not On
The Devices
Flexible Hose Properly Restrained
Gas-Charged (Pressurized) Accumulators
Accumulator Warning Tags Placed and
Indicated On ECPL Tag
Maintenance And Operating Data
Drawings
Description
4.0 LUBRICATION
4.1
System
Requirements
4.2
Piping and Tubing
4.3
Reservoirs
4.4
Documentation
Remarks
Remarks
No External Leakage
Component Identification –
Tags Adjacent To But Not On The Devices
Accessibility Of Components And Piping For
Maintenance
Lubrication Service Diagram Present
All Components Approved
Pipe or Tube Sized Correctly
Pipe or Tube Properly Supported
Lube Fill Points Accessible, Outside of
Guarded Areas
Oil Lube Systems – Drain Plugs Accessible
Maintenance And Operating Data
Drawings
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Revision Date: 20070914
Page 5 of 10
New Process Design and Installation Review Procedure Attachment #1
Description
Acceptance
Y
N
N/A
5.0 ENERGY CONTROL AND POWER LOCKOUT / ENERGY CONTROL FOR SETUP AND PERMITTED MINOR TASKS
5.0
Placard for ECPL procedures
ECPL ./ ECSPMT
Isolation of Energy Sources
ECSPMT (where applicable)
Arc Flash warning labels installed (where
applicable)
Description
Y
6.0 MECHANICAL
6.1
Guarding
6.2
Risk Assessment
6.3
Process FMEA
6.4
Machine FMEA
6.5
Inclined Equipment
6.6
Lift Assists And
Hoists
6.7
Maintenance
Acceptance
N
Remarks
Remarks
N/A
General Requirements
Fixed / Removable Guards
Guard Design And Construction
Guard Material
Safety Interlock System
Safety Distances
Paint
Protective Material (Lexan) Thickness
Power Transmission Guards Fixed
Perimeter Or Barrier
Conduct a Risk Assessment, Personal
Protective Equipment (PPE) Requirements,
Material Handling, and Machines FAS08-036
Process FMEA Conducted To Identify Critical
Characteristics For The Process
Machine FMEA Conducted To Identify Critical
Machine Items
Vertical and Inclined Equipment
Counterbalanced
Secondary Safety Restraints for Overhead
Equipment
Controls
Working range
Machine Maintenance
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Revision Date: 20070914
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New Process Design and Installation Review Procedure Attachment #1
Description
Y
Acceptance
N
N/A
Remarks
Y
Acceptance
N
N/A
7.0 ROBOTS
7.0
Robots
Training Requirements
Guarding
Signs At Entry Points
Emergency Stop Requirements
Teach Mode –
Selection And Operation (Auto Mode Not
Allowed)
Teach Pendant - Requirements
Single Point Control
Control Reliable Circuitry
Stops – Limiting Devices General
Stops – Limiting Devices
Mechanical (Hardstops)
Stops – Limiting Devices
Non-Mechanical (Retractable Hardstops, etc.)
Description
8.0 WORK ENVIRONMENT
8.1 Work Place
Platforms Greater Than 4 Feet (1.2 m)
Stairs / Ladders
Floor
8.2
Surface Temperature
Temperature
Air Temperature
8.3
Sufficient For Task
Illumination
Lighting: Factory / Office
8.4
Licensed Ionizing Sources
Radiation
Non-Ionizing Radiation and Laser Equipment
8.5
Ford Toxicology Clearance (GMAP / Tox
Chemical
Numbers)
Restricted / Prohibited
Substances or Materials
Controls Sufficient To Prevent Employee
Exposure To Air Contamination
Process Safety Study For Anticipated
Quantities (Hazardous Chemicals)
Hazard Communication (HAZCOM / WHIMS)
8.6
CO2 Fire Protection Systems
Protection Against
Ingress and Egress –
Other Hazards
Clearance & Distance
Explosion
Combustion Equipment Safety
Emergency Lighting
High-Work – Activities Identified
High-Work – Anchorage Points
8.7
Signs
Accident Prevention Signs & Tags
8.8
Emergency Shower /
Placement / Installation
Eyewash
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Remarks
See FAS08-040 Attachment G for minimal requirements
See FAS08-040 Attachment G for minimal requirements
See FAS08-040 Attachment G for minimal requirements
Revision Date: 20070914
Page 7 of 10
New Process Design and Installation Review Procedure Attachment #1
Description
Acceptance
N
N/A
Remarks
Y
Acceptance
N
N/A
Remarks
Y
Acceptance
N
N/A
Remarks
Y
Acceptance
N
N/A
Remarks
Y
9.0 CERTIFICATIONS
9.0
CDRH – FDA (Laser Product Certification)
Certifications
Electrical Safety Authority (ESA) – Canadian
Plants Only
Pre-Start Health and Safety Review (PSR) –
Canadian Plants Only
Factory Mutual (FM)
Technical Standards and Safety Authority
(TSSA) – Canadian Plants Only
Canadian Standards Association (CSA) –
Canadian Plants Only
Underwriters Laboratory (UL)
CE
Crane & Hoist / Lifting Equipment Certification
Other Applicable Certifications
(i.e., Pressure Vessels)
Description
10.0 MISCELLANEOUS
10.1
Labor Relations
Local Contractual Obligations
Description
11.0 ERGONOMICS
11.0
Ergonomics
Refer to DFE (Design for Ergonomics) CPEM
Description
12.0 NOISE AND VIBRATION
12.1
77 dBA or Less TWA (Use w-SX1 Measurement
Equipment Noise
Criteria)
Level
Greater Than 77 dBA and Less Than 80 dBA
TWA (Use w-SX1 Measurement Criteria and wSX1 Request for Deviation Form)
Greater Than 80 dBA TWA (Use w-SX1
Measurement Criteria and w-SX1 Request for
Deviation Form)
Impact Less Than 140 dB
12.2
FoE Noise and Vibration Policy
Vibration
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Revision Date: 20070914
Page 8 of 10
New Process Design and Installation Review Procedure Attachment #1
Description
Y
Acceptance
N
N/A
Remarks
FUNCTIONAL TESTS
If a warning horn is part of the safety plan, will it achieve an approximate
10 dB differential over the expected ambient noise level at the machine's
extremities without exceeding the Health & Safety maximum at 3 feet from
the horn?
If a warning horn is part of the safety plan, are all machine motions held in
abeyance on start-up until after the delay time for the warning horn has
expired?
Does the tool relief timer (if used) function properly during an E-stop?
(Maximum adjustable stop delay: 1 second)
Is the "master" relay de-energized if the machine is E-stopped?
Does the control system offer sufficient information and degree of
manual control to allow an operator to return the machine or any of its
stations to its initial state to begin automatic cycle after an E-stop during
any point in the cycle?
Are the manual buttons interlocked to prevent destructive or otherwise
non-permissible machine actions or sequences? (i.e., what damage
may result if pushbuttons are depressed out of sequence?)
Are the manual functions sufficient to support maintenance needs?
(Opposing motions should be easily exercised in rapid sequence except
where destructive or otherwise non-permissible conditions may result.)
Do motions or actions initiated by an HMI screen button begin and end
crisply relative to the buttons actuation?
Do the automation interlocks function correctly in conformance to the
interlock strategy.
Test machine reaction to loss of air pressure. Close the main air shutoff
valve. Machine should react as agreed upon by Ford and the OEM.
Test machine for reaction to lube fault. Simulate a lube fault. The
machine should stop at the end of its current cycle, annunciate the fault,
and prevent another cycle from starting.
Test the machine Auto / Manual interlock. While running an automatic
cycle, put a station in Manual and press a manual button (ie, if the slide is
advancing, press return). Nothing should happen.
Test machine for loss of hydraulic pressure. Close the ball valve on the
hydraulic unit. Machine should react as agreed upon by Ford and the
OEM.
Test machine for loss of coolant pressure. Close the coolant supply
valve. Machine should react as agreed upon by Ford and the OEM.
Verify all E-Stop buttons and E-Stop pull cords are readily accessible.
Test the operation of the gate interlock at the load station
Test the operation of the gate interlock at the unload station
Test the pull cord on the right hand side of machine (when applicable).
Machine should E-Stop the machine.
Test the pull cord on the left hand side of machine (when applicable).
Machine should E-Stop the machine.
Ensure gate access timers are set correctly and zero speed monitors are
operational (if used).
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New Process Design and Installation Review Procedure Attachment #1
Description
Y
Acceptance
N
N/A
Remarks
Acceptance
N
N/A
Remarks
Acceptance
N
N/A
Remarks
Manually disconnect the wiring of one of the two 24 VDC input channels to
the Safety Relay. The equipment within the guarded area, or the entire
machine if required by the design, shall safely be de-energized and come
to a stop. Reset shall not be possible until the input channel is
reconnected and the reset or start button is pressed.
Verify that all hydraulic pressure is relieved when an interlocked guard is
opened or when pushing any E-Stop button or pulling any E-Stop pull cord
Verify that all air pressure is relieved when an interlocked guard is opened
or when pushing any E-Stop button or pulling any E-Stop pull cord
Description
Y
14.0 RISK ASSESSMENT
14.1
Review at Design,
Procedures Referenced in
Build, Modification &
Global Standard FAS08-036
Commissioning
Description
Y
NEW PROCESS DESIGN AND INSTALLATION REVIEW ROCEDURE
15.0
15.1
Review at Design,
Runoff, Launch
Transmittal Fax Sent
Refer to FAS08-035
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Revision Date: 20070914
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