Robert Bosch Corporation
Contents
1. Hasper Page 2 of 14 Robert Bosch Corporation Project Leader Ref GDS Section 1 GDS P A F A Comments Test Results Date General Procedure Other Yes Yes No or N A Needed 1 1 Has supplier agreed to 1 2 2 9 conform to Robert Bosch General Delivery Specification dated Are all documentation drawings service manuals alls etc available and in English Are the quoted conditions achieved OOOO OO OO Production Rate Pieces Hr Tool Life OOL OOL Facility Utilities 1 e power steam air etc Section 2 N A Ref GDS Section 3 GDS P A F A Comments Test Results Date Safety amp Health Standards Other Yes Yes No or N A Needed Emergency Stop Are Emergency Stop buttons OSHA for electrical pneumatic and 1910 212 hydraulic systems accessible and properly labeled Does Emergency Stop OSHA e R additional movement Does Emergency Stop OSHA require Manual Release and 1910 212 pushing the Start Button for the machine to restart CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 3 of 14 Robert Bosch Corporation Ref GDS Section 3 Comments Test Results Safety amp Health Standards Other Yes Yes or N A Is Emergency Stop located OSHA within close reach of 1910 212 operator and or technician near point of operation Machine Guarding Are all hazard areas guarded OSHA push stroke capture 1910 212 retract2. 1 phase 60 Hz Are controls designed so that 5 loss of power electrical pneumatic hydraulic does not present a hazard to personnel or damage to equipment or damage to work in process Are manual controls provided and interlocked to prevent damage to machine or work in process Are separate control systems used for each individual machine Do machine controls include diagnostic indication for all machine states Are abnormal continuous consecutive machine cycles prevented Do passwords limit access to 5 4 6 parameters Do out of tolerance process plant specific requirements values cause the machine to stop 5 4 6 Do field bus systems meet 5 4 7 5 521 Is control voltage regulated on 24 VDC Are receptacles for 115 5 5 1 VAC standard US grounded 3 prong CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 8 of 14 Robert Bosch Corporation Ref Epp e ae Electrical Desion Other Yes Yes No or N A Needed Do machine voltages comply 5 5 1 with plant specific tolerances Is equipment built with plant 5 5 2 a specific Preferred Electrical Components Are control transformers and 5 5 2 b power supplies sized 30 above maximum load Are functional and electrical components permanently labeled with their corresponding schematic designation Do controller output circuits have individual circuit protection lll lial E 20 expansion 5 24
3. 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 5 5 5 d that are not mounted on the machine have connectors 5 28 Are plugs and sockets 5 5 5 d permanently labeled per plant specific requirement io oe mm 3 75 off floor Are the control enclosures positioned so the machine can be observed while working in the enclosures CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 9 of 14 Robert Bosch Corporation Ref GDS Section 5 GDS P A F A Comments Test Results Date Electrical Design Other Yes Yes No or N A Needed 5 31 Are control cabinet working 5 5 space clearances maintained Note Depth l Im Width the greater of either 750 mm or cabinet width Are control cabinet doors 55 5 removable or able to open at least 90 degrees Are AC motors High Energy Efficient TEFC 480 VAC 30 60 Hz Do motors 25hp and above have continuous conductors between control enclosure and motor Do motors 25hp and above have power factor corrected to above 90 Are all transformer neutral conductors and power supply common conductors grounded at the source Does all control and power
4. Robert Bosch Corporation SECTION 7 PRE FINAL ACCEPTANCE CHECKLIST TABLE OF CONTENTS Page 7 1 ETE a ER ener tere E E er nT der serene ee NOS EEA Ree Tee RE 7 2 7 2 COORG TNS Gar ee et es 7 3 CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 1 of 14 Robert Bosch Corporation Bosch General Delivery Specifications for Machinery and Equipment 7 1 General 7 1 1 ey 7 1 4 Instructions All tests conducted at equipment supplier are preliminary acceptance tests Final acceptance will always be conducted at Bosch Bosch will provide qualified components for acceptance Provision for gauges measurement equipment and personnel to be coordinated with the project engineer Evaluation of quality will be done with statistical method when applicable described in Section 6 Acceptance shall be based on the production result Performance data and process time to be verified and documented Bosch Project Engineer Leader is responsible for the completion of the Machinery amp 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 authorized the No column require corrective action unless deviations have been CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W
5. ange per tool using equipment supplier set up procedure accomplished during run off trial Are all modes and features of software operation and data output demonstrated Test plan available Calculations verified Remote access verified Data transmission to Bosch network Section 7 N A GDS Section 8 Documentation and Shipping Comments Test Results Date Instructions Needed Is machine documentation provided as per Section 8 1 of the GDS Does service manual format meet Appendix 8 1 guidelines of the GDS Section 9 N A Section 10 Plant Specific Additional Requirements CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 14 of 14
6. clip and squeeze areas sharp edges hot cold surfaces Rotating shafts are enclosed 1910 212 Belts chains etc are OSHA enclosed 1910 212 All pinch points OSHA guarded 1910 212 Date Needed Are guards for setup interlocked and not easy to defeat Are protective barriers installed to protect other associates from flying objects e g milling grinding Two hand control Is check function anti tie down anti 1910 217 repeat distance acceptable Are manual controls inoperative in automatic Are light barriers light curtains safety mats etc verified for proper operation CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 4 of 14 Robert Bosch Corporation Ref Teele Lee Safety amp Health Standards Other Yes Yes No or N A Needed 3 14 Do all safety switches protective gates operate properly l ald verified to operate properly Does the exhaust system operate properly must stop must not stop if emergency stop is activated Are machine controls accessible and away from revolving spindle moving tools or other hazards Are general operating controls configured for safe operation 3 20 Are there interlocks for point of operation guarding Labeling Are the following labels posted in a Hazardous Maternal Utilities Fluids and Lubricants Lockout Tagout LO TO Are lock out devices provided for all utility shutoff
7. er Page 6 of 14 Robert Bosch Corporation Ref GDS Section 4 GDS P A F A Comments Test Results Date Mechanica Design Ergonomics Other Yes Yes No or N A Needed 4 3 Are workplace dimensions 4 3 2 according to the Bosch Workplace Measurement specifications ancl baal elie S S glare 4 3 3 Are all secondary tasks at 4 3 4 proper working heights actuating or reading controls handling parts bins etc Are all lifting tasks within NIOSH limits changing of tools fixtures bins etc Is the SE assessed z a aaa Is accessibility for a handling adjusting maintenance and cleaning adequate Ref GDS Section 5 GDS P A F A Comments Test Results Date _ Design Other Yes Yes No or N A Needed Are electrical drawings created with CAD and provided in plant specific format and also in Adobe Acrobat pdf format Are electrical drawings provided on paper in A B DIN A4 or DIN A3 size CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 7 of 14 Robert Bosch Corporation Ref Ele Electrical Design Other Yes Yes No or N A Needed PP dave ee LE e S all software nr nr rn U U O OO ON Nn 5 10 5 12 Nn pd pd 3 nin D N N N ON 5 4 Is a functional plan 5 4 provided 4 1 Are cycle counters present Can all lamps be tested 548 TEN 15 Is input power 480 VAC 3 5 5
8. ivided equally among work piece locations CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 12 of 14 Robert Bosch Corporation GDS Section 6 Quality Standards and Run off Comments Test Results Conditions or N A Are Gage Machine and Process capability studies conducted per paragraph 6 3 and Plant Specific Requirements Do results meet the following acceptance criteria Gage Capability Test Results a lt 10 of tolerance or b Alternatively Test Results ISOPlot Discrimination Ratio DR gt 12 5 Machine Capability Test Results Cmk gt 1 67 Process Capability I Test Results Is gage scale least count or least division lt 10 of smallest part tolerance Do gages display variable data unless otherwise specified Is technical availability gt 95 as per Appendix 6 2 Does changeover time meet BPS guidelines lt 10 min for equipment lt 5 min for assembly Is dry cycle run for 6 5 3 durability conducted Are process data or set up O sheets available Set up parameters included Tool change adjustment 6 procedures included 6 11 Are frequency of operational 6 6 2 adjustments adequate CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 13 of 14 Robert Bosch Corporation GDS Section 6 Quality Standards and Run off Comments Test Results Date Conditions or N A Needed Is at least one ch
9. s Pneumatic hydraulic and electrical systems CFO6790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 5 of 14 Robert Bosch Corporation Ref GDS Section 3 GDS P A F A Comments Test Results Date Safety amp Health Standards Other Yes Yes No or N A Needed HAZCOM eee 3 23 Are MSDS s available and in English for all associated hazardous materials eer Om T all hazardous materials 3 25 Are flammable liquids in OSHA metal OSHA approved 1910 106 safety containers Is grounding provided General pm iekagecmmoteas a LT leakage controlled 3 27 Have all operational hazards OSHA been identified Job Safety 1910 119 Hazard Analysis 3 28 Have special requirements OSHA for Division I Class I areas 1910 307 been addressed le E Division I Class I areas 1910 307 Sound 3 30 Does sound level not exceed 3 3 80 dB A under normal operating conditions Lasers 3 31 Does laser comply with all 3 2 6 requirements of ANSI Z136 1 Sate Use of Lasers Is laser labeled classified 3 2 6 and certified Robotic Operations 3 33 Do robotic operations 3 2 4 R15 06 dated 3 34 Are all power disconnects R15 06 and interlocks installed as required Have all mechanical stops R15 06 and range of motion stops been verified Is there full envelope R15 06 4 guarding CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasp
10. uter hardware and operating system meet plant specific requirement 5 54 Does computer software l meet plant specific requirement Nn DA P N O CF06790006 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 11 of 14 Robert Bosch Corporation Ref Teele ae Electrical Design Other Yes Yes No or N A Needed 5 55 Do program printouts and 5 7 remarks meet plant specific requirement Does use of software 5 modules meet plant specific requirement Al a connected to the BCN 5 8 1 5 58 Is all 3 party software 5 8 4 properly licensed Proof of ownership and original media are required Have virus protection 8 2 measures be considered implemented Please explain Is CATS UTP cabling used for all data network connections 5 61 Ts TCPAP protocol used 58 1 O O gaa 5 62 Have security measures been implemented to protect against loss or theft of data Please explain Will the machinery be integrated into an existing data collection system 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 Ref Quality Standards and Run off GDS P A F A Comments Test Results Date Conditions Other Yes Yes No or N A m 6 1 Are sample sizes selected 23 per Appendix 6 1 6 2 Are production samples d
11. wiring have readily accessible test points in electrical enclosures Where screw or screw clamp termination systems are used are all wires fitted with either ferrules or crimp connectors Are all wires labeled 5 6 terminated and identified in the electrical prints Are all enclosure outgoing 5 6 control conductors except conductors from controller I O terminated at terminal blocks or attachment plugs with receptacles eS eS CF4 02 619 doc Revision 1 4 1 05 Originator ChW BPS LS W Hasper Page 10 of 14 Robert Bosch Corporation Ref ele ome es Electrical Design Other Yes Yes No or N A Needed fe egress see O 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 Jal D without wire splices Do wireways outside enclosures have 15 spare wire ee ce A conductors used 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 a el a specific requirements allele ll length one meter 5 53 Does comp
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