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1. Title

Resistance seam welding machine.

Seam welding tooling for Honda MY16

Manufacturing Engineer – First Contact Site E - mail Phone

Piotr Gałan BWI TCK piotr.galan@bwigroup.com

+48 881 824 225

Engineering Contacts Site E - mail Phone

Roman Bielski BWI TCK – ME Team Leader roman.bielski@bwigroup.com +48 600 304 459

Olga Leśniak BWI TCK – Industrial Engineer olga.lesniak@bwigroup.com +48 883 350 316

Zhou Yanli BWI Fangshan - ME yanli.zhou@bwigroup.com

Baoshuai Huang BWI Fangshan - Purchasing baoshuai.huang@bwigroup.com +86 10 57 98 21 83

1. Title 1

2. Introduction 3

3. Intend of the specification 3

4. General construction requirements 4

5. Specific Requirements 6

6. Process information 14

7. Safety and Ergonomics 15

8. Environmental 15

9. Control requirements 15

10. Quality requirements 16

11. Maintenance requirements 16

12. Approval requirements 17

13. Documentation requirements 17

14. Training/Support Requirements 20

15. Quote requirements 20

16. Requirements for valuation 21

17. Special shipping requirements 21

18. Start-up and approval 22

19. Requirements for the monitoring of the process of constructing 23

20. BWI Group Run at Rate / Approval process 23

21. Special shipping requirements 23

22. Installation 24

23. Explanation of abbreviations used in the specification: 24

24. Attachments 24

2. Introduction

2.1 Specification concerns the order of:

2.1.1 Resistance seam welding machine .

2.1.2 Seam welding tooling.

2.2 The project include design, build, start, tests and qualification of machine and tooling at the supplier plant.

2.3 This process joins base cup and reservoir tube using resistance weldingmethod.Base cup is pressed in previous operation.

Resistance welding - is a group of welding processes which produces coalescence of metals with the heat obtained from resistance of the work to electric current in a circuit of which the work is a part, and by the application of pressure

2.4 This process occurs in the reservoir assembly cell and is performed in a manual load, manual unload operation.

2.5 This is high volume machine. It will work in industrial environment.

2.6 Welding toolingis dedicated for project with the following drawing numbers:

- 22293890 Reservoir tube with base cup pressed

Fig.1. Reservoir tube with base cup pressed, after seam welding.

2.7 Machine should be designed according to the ideas of the BF-0035– Appendix no.:1.

2.8 Documentation of the BF-0035is only a database to complete project, BWI is not responsible for lack in documentation.

2.9 Documentation of the products for which the machine is being built – Appendix no.: 2

2.10 If it will be presented other concept, it should be valuated as an alternative.

Before sending the alternative proposal, the supplier should contact the BWI engineer for approval of a new concept.

2.11 Deadline for readiness to receive the item - according to the plan:

Qualification Plan Date Place

MQ1 CW 36september2014 Supplier site

MQ2 CW 40 october 2014 BWI Fangshan plant

Table 1. Machine qualification dates

3. Intend of the specification

This equipment technical specification is intended as a guide for quoting purposes. All items specified are intended as a minimum standard acceptable to BWI Group. In no case is the successful contractor to assume the specification relieves them of the responsibility for the proper function of the equipment. The supplier, in submitting the bid, guarantees the functionality of the equipment. Any changes to the specifications that are initiated by BWI Group will be issued in writing, in the form of an addendum.

All information, documentation and appendix included in this specification are confidential and cannot be communicated to other company without BWI Corporate representative authorization.

4. General construction requirements

If applicable the vendor shall utilize the following prints or specifications are included in this packet for quotation purposes:

4.1 Water, air, bus bar connections must met requirement from attachment “utility connection”

4.2 BWI specifications (see section 24):

• Technical Specifications – General assumption for China OCT2009

• Equipment Preferred Components List for China APRIL2010

• General Equipment Specification for International Operations, Version #2 dated March 2000.

• Common Controls Specification for International Operations, Version #3 dated August 2003.

• BWI Automotive Lean Equipment Design Manual, 2nd Print – Dated October 22, 1998

4.3 Other applicable standards and specifications:

• IEC International Electro technical Commission

• ISO International Organization for Standards

• Hydraulic Fluid Power – General Rules Relating to Systems (Addendum to ISO 4413, 1998 Edition) DA-2002, September 1998, Version 1.0

• Pneumatic Fluid Power – General Rules Relating to Systems (Addendum to ISO 4414, 1998 Edition) DA-2003, September 1998, Version 1.0

• Guideline for Safety Circuits DA2001_Rev2_1_ Mar2003

• BWI Automotive Systems Electrical Specification for Industrial Equipment dated March 1997, DA 2004 (Addendum to NFPA 79)

• The required standard for gas fired equipment is NFPA 86, including conformance to IRI requirements.

• Design in Ergonomic Guideline_V-Sep2005_updated_July06

• BWI Sound Level Specification for the Purchase of Machinery and Equipment SL 1.0

• Design In Health and Safety Specification_DA 2006_Ver 2.1_Sep 1_2006 for NEW or RECONTROLLED MACHINES

• BWI Machine Control Logic Specification (DC-2005)

4.4 Label each lubrication point with tag and number of points on the machine (i.e. 2 of 4) and the generic ASME lubrication type (no brand names) for the noted point. Lubrication points will be centrally located and accessible without removing guarding at back of machine. Use one lube line per lube point.

4.5 All guards will be fastened through keyholes for ease of removal (one minute to remove max, with one person). Fasteners shall be the same size for all guarding on the machine. Guarding shall have (2) handles or thumb holes, for ease of removal.

4.6 All equipment will be supplied with an FR air supply. FR identified as Filter & Regulator. Pressure regulators shall be labeled with metal tags and correct setting information. Use a particulate filter and a coalescent filter at each machine. Dial faces shall be marked with acceptable operating range.

4.7 Equipment color is to be international standard RAL #1013 – White Urethane Alkyd Gloss Enamel. Exceptions to this requirement are to be noted by the vendor at the time of quotation. Note that if the existing equipment is already painted with the RAL #1013, the vendor will then need to clean and touch up the equipment with the above mentioned paint color.

4.8 All tooling must have an easily accessible storage location on the machine or part changeover cart, to facilitate model changeovers (if changeover is required).

4.9 The equipment design must contain all spilled fluid from reaching the plant floor. Design may accomplish this with either an angled drip pan mounted at a minimum of 8” off of the floor which drains to the back of the machine or by building a plate with a minimum 2” sealed lip. Splash runoff from guarding must also drain into this containment system.

4.10 All sensors that can be damaged during load/unload & changeover due to operator error or dropped parts must be protected. A consistent design approach should be used, allowing easy sensor adjustment and visibility of indicator lights.

4.11 All stations requiring reject chutes or reject boxes must be painted red, locked with and appropriate keyed lock and will include sensors to detect that the rejected component has been properly loaded into the reject box. Reject boxes and chutes must be designed such that the operator cannot remove parts previously loaded past the sensor, but not released or which can be fooled by broom sticks, parts on a string, etc.

4.12 In addition to any standard fault codes or monitor signals, the machine should include an Andon light to readily notify the operator that a fault has occurred and that action is necessary. This Andon light should be of the Stack Light type, with 3 separate colors and is to be located in prominent view of the operator. Color and functional definition are in App. 32.

4.13 Vendor is to include separate machine leveling feet and wheeled casters for ease of leveling and relocation. Fork lift channels, should be oriented front to back. Preventive maintenance access should be allowed from front or rear of machine.

4.14 Pneumatic valves, regulators, flow controls and gages are to be located in back of machine, below table top and behind hinged and interlocked electrical panel. Regulator gage faces to be oriented toward back of machine, so as to be visible with electrical panel opened.

4.15 Where possible, guarding above the machine tabletop is to be constructed of aluminum extrusions (reference manufacturer “Item, 80/20 or similar”) with removable Lexan panels for improved visibility and lighting. Guarding below machine tabletop can be constructed of sheet metal with square mesh steel panels.

4.16 If a light curtain is used, it must comply with the BWI – Specification for the Application of Light Curtains – dated December 1994. Contact BWI Controls Engineer for approval on selection and mounting of light curtains.

4.17 Each machine is to include a fixed tag noting the machine drawing number, tooling drawing number, manufacturer’s name, machine serial number, manufacturer’s shop order number and date of manufacture.

4.18 Each machine is to includetwo LED light source.

4.18.1 One directed to the work surface with a minimum illumination of 1500 LUX and a switch source allowing the operator to disable the light source – inside the machine for process control.

4.18.2 Second – with a minimum illumination of 1500 LUX and a switch source allowing the operator to disable the light source - area in front of machine should be light up to perform visual control by operator after operation.

4.18.3 Light source cannot interrupt operator – can’t emit heat or make him blind.

4.19 Drawings, service documentation and manuals, push buttons, tags etc. must be in English and Chinese.

4.20 All messages, errors and the diagnostic programs will be in English and Chinese language.

4.21 Software will be in English and Chinese version. It will be possible to choose one of the versions by one button or icon on touch screen.

4.22 The quick wearing out elements will be replaced easily. Deviations from this and other specifications identified in this technical specification must be identified in writing by the vendor at the time of quotation. Acceptance of any deviations must be made by the appropriate BWI Engineering personnel.

5. SpecificRequirements

This specification is not intended to dictate design or stifle the initiative of a supplier. If a different concept or component is proposed it must be done as an alternate proposal in a quote. Prior to submitting the alternate proposal, the supplier must contact the author of the specification to confirm the preliminary acceptability of the alternate concept. Any exceptions taken to these specifications must be fully detailed in the proposal.

5.1 General assumptions.

5.1.1 Machine must weld different diameters and length of reservoirs with base cups, as in table below:

Dimmensions Min [mm] Max [mm]

Reservoir tube external diameter 25 60

Reservoir length (tube only) 120 600

Reservoir wall thickness 0.7 3

Base cup wall thickness 1 4,5

Table2.Approximate dimension range of reservoir tube and base cup.

5.1.2 Machine must also weld different materials, examples in table below:

Feature Name Material - thickness

Base cup S355MC – 4,1±0,25[mm]

S420MC – 4,1±0,25[mm]

DC01 – 3,0±0,15[mm]

Reservoir tube PS24095176 – 1,2±0,08[mm]

E235+C – 1,2±0,05[mm]

24093843 – 1,2±0,05[mm]

22272611 – 1,2±0,05[mm]

S235JR+BK – 1,0±0,05[mm]

Table 3. Types of low-carbon steel alloys,that need to be weld.

5.1.3 Machine must weld different Base cup shapes – see App.33

5.1.4 Cycle time cannot exceed 9[s].

5.1.5 Dimension of station (with scrap separator, hydraulic power, tank, pups) can’t be bigger than 2500 x 2500 x 3500[mm] (width x depth x height).

5.1.6 Machine Up-time cannot be lower than 100% during MQ. During normal production 98%.

5.1.7 Required FTQ for this station must be 0 PPM during MQ. During normal production 250 PPM.

5.1.8 The tooling necessary to weld components must be delivered with machine - please show the tooling as the separate position in offer.

5.2 Main parts of station

5.2.1 Welding station

5.2.2 Welding controller, supervising system of rotary speed, clamp force, coolant level and pressure

5.2.3 Three water coolant circles

5.2.4 Box for toolings

Picture 1. General view of existing resistance seam welding machine.

Picture 2. Workspace area

Picture 3. Support tooling ( poliamid prism)

Picture 4. Regeneration cutting tool – see App. 3.

5.3 Specific construction requirements

5.3.1 Machine rated power must be at least 200 [kVA](lower power can be accepted after BWI engineer confirmation). It must be alternating current.

5.3.2 Maximal welding current can’t be lower than 26 [kA].

5.3.3 Station must have possibility to set electrode clamping force in range 100 to 800 [daN] (hydraulic actuators).

5.3.4 Resistance on disc electrodescannot be bigger than 5 [µΩ].

5.3.5 The coaxiality of upper tooling and mandrel cannot exceed 0.1 [mm].

5.3.6 Welding transformer must be protected against overheating – by water coolant system – third circle.

5.3.7 Electric cabinet must be equipped with air conditioner.

5.3.8 Whole station, in particular transformer must be protected against connecting power supply wrong way.

5.3.9 Machine must have protective system acc to China standards (CCC procedures).

5.3.10 Machine must control and display on operator panel:

5.3.11.1 Resistance welding parameters ( parameters tolerances and exceeding tolerances)

5.3.11.2 Reservoir tube presence

5.3.11.3 Reservoir tube rotary speed

5.3.11.4 Disc electrodes rotary speed in time

5.3.11.5 Contact pressure force ( each disc electrodes actuators controlled by proportional valve from operator panel )

5.3.11.6 Mandrel position

5.3.11.7 Welding time

5.3.11.8 Pressure of coolant, and coolant level in tank ( quote as option #1)

5.3.11 On machine there must be possibility of welding all combinations of components from points 5.1.1, 5.1.2.

5.3.12 Station must meet ergonomic requirements for Asia area (see Design in Ergonomic).

5.3.13 Mandrel must be deflected (by actuator) toward to the operator, for convenient loading and unloading of reservoir tube. Mandrel must when moved into position must be pressed into disc electrodes level

5.3.14 There must be possibility to read off position of lower base on mandrel.

5.3.15 Clamp must be equipped with encoder, for seam weld length control . 198dgr assures completed weld.

5.3.16 There must be possibility to read off position of upper clamp.

5.3.17 Actuator clamp must be equipped with position sensors..

Picture 6. Sample of actuator sensor

5.3.18 Both disc electrodes must be turned on during welding cycle.

5.3.19 Both disc electrodes must be cooled ( details in App.3 – disc electrodes)

5.3.20 Drive must be transferred directly to the electrodes. Each disc electrode drive must be controlled by encoder – assures disc electrodes speed control.

5.3.21 Contact force transfer of disc electrodes must take place through the actuator ( force transfer through thread is not acceptable).

5.3.22 Contact force value must be regulated by valve, and shown on operator panel (quote as option #2).

5.3.23 Rotary speed of disc electrodes must be controlled by encoders.

There must be independent speed control of both disc electrodes.

Any program must have setting parameters as:

- Rotary speed of left disc electrode

- Rotary speed of right disc electrode

- Acceptable value of speed difference between left and right disc electrodes (speed difference quote as option #3)

5.3.24 Disc electrodes control system, based on information from two encoders - may have automatic adjustment of rotary speed during welding cycle operation. (quote as option #4)

5.3.25 Angular position (inclination) of disc electrodes adjusted in the range 0÷15°can be:

5.3.26.1 Movable by actuators controlled from operator panel – protractor on the side (quote as option #5).

5.3.26.2 Movable manually by setting screw ( quote as option #6)

Picture 7. Inclination of disc electrodes ( 0 ̊ )

Picture 8. Inclination of disc electrodes ( 15 ̊ )

5.3.26 Cutting tool. Both disc electrodes must have the same diameter. Regeneration of contact surfaces of disc electrodes must be performed by regeneration cutting tool ( knife).

5.3.27 After regeneration of one disc electrode, it diameter must be measured – than the second disc electrode must be regenerated into the same diameter.

5.3.28 If vendor will develop automatic diameter measuring system, it might be implemented after BWI engineer approval ( quoted as option).

5.3.29 Vendor may quote described below solution as option #7:

- Two laser gauges, measures disc electrodes.

- Value of disc electrodes diameter is displayed on operator panel

- BWI engineer may define acceptable diameter difference between electrodes.

- When acceptable diameter difference is exceded, machine must perform regeneration program – operator is regenerating disc electrodes on machine by cutting tools manually.

- When operator finish regeneration, laser gauges are checking again both electrodes diameter.

- Measuring program may start before every cycle, or every “X” pcs welded.

5.3.30 Machine must be equipped with two regeneration tools, one for each disc electrodes. – App.3.

5.3.31 Position of cutting tool must be stable and be assured by shape of tool.

5.3.32 There must be knurling tool as on Picture 9.

Picture 9. Knurling weld

Picture 10. Not knurled weld

5.3.33 Machine must be equipped with container for catching chips from electrodes regeneration process.

5.3.34 Station msut automatically inform operator when disc electrodes must be changed(when diameter of disc electrodes is too small to perform cycle correctly) due to wear.

Wear off diameter ≤280[mm].

5.3.35 Change of both electrodes can’t take more than 5 minutes for one person. It is recommended not to use any tool to change it. If tool is required, it must be supplied with machine. Every tool must have dedicated place on machine.

5.3.36 There must be possibility to read off position of electrodes, and to reproduce this position after changeover for other application.

5.3.37 Machine must have cooling system intree cooling circuits.

5.3.38 First cooling circut has to consists container, pump, filter and heat exchanger. Purpose of this circle is to cool down outer contact surface of disc electrode, and reservoir tube being welded ( Picture 2.)

5.3.39 Both electrodes must be cooled during welding.

5.3.40 Coolant circulation must be closed.

5.3.41 Coolant outlet from work area must be protected with filter.(3/4”-192-020)

5.3.42 Pumps delivery must allow for continuous work (3 shifts).

5.3.43 Machine must automatically inform operator about low level of cooling liquid in tank.

5.3.44 Tank must be equipped with pipe with valve and connector – to allow connection to water pipe.

5.3.45 Operator must have easy access to tank and valve. It can’t take more than 3 minutes to refill coolant in tank.

5.3.46 Cooling system must be adept to work with water mixed with anti-corrosion substance (substance – CHEMETALLWEDOLIT C105).

5.3.47 Second cooling circuit must cool down welding transformer.

5.3.48 Third circle must cool down disc electrode through internal channels.

5.3.49 Second and third cooling circle must be supplied from factory water line – see App.31.

5.3.50 All coolant circles pressure must be controlled to detect lack of cooling.

5.3.51 Working area must be protected. It is recommended to use cage(Bosch-Rexroth profiles and polycarbonate glass as a safety curtain) and sliding doors.

5.3.52 Shield will be closed automatically after operator start cycle and automatically opened when process is finished (after finishing all movements).

5.3.53 Light curtains must be used for cycle time reduction.

5.3.54 All shields must be equipped with Schmersal safety switching rail. Pad must fit to

shape of sliding doors. All doors edges must be protected(especially for doors with C-shape)

5.3.55 There must be all from listed below Error-proofing conditions:

5.3.55.1 Checking for presence of the reservoir,

5.3.55.2 Checking position of both side-actuator (no pressure - information),

5.3.55.3 Checking position of clamp actuator (no pressure - information),

5.3.55.4 The absence of any component, poor loading of any component and also the selection of defective components must prevent machine cycle start.

5.3.56 PLC must allow to create minimum 99 different program.

5.3.57 Every program may have different:

• name;

• no.;

• tube diameter,

• welding speed;

• overlap;

• welding characteristic(welding current, number of impulse, curve of current rising and falling);

• electrode clamping pressure(pre-load, load, during welding and finish load);

• tolerance for welding current, welding time, electrode clamping pressure, cooling liquid pressure;

5.3.58 All parameters must be secured with 3lvl password system.

• 1st level must be available for operator (changing program number, reset errors, part counter reset, …) – no password required.

• 2nd level must be available for process engineer (1st level + process set up) – password is required.

• 3rd level must be available for service – password is required.

5.3.59 Machine must be equipped with panel as interface between control system and operator. In case of any action required on the machine the appropriate info must be displayed on the control panel screen for operator.

5.3.60 Machine must be equipped with continuous parameter supervising system.

5.3.61 Option: Supervising system must be able to storage production data:

• Date(day-month-year),

• Shift No,

• Program No,

• Part following No,

• Real current,

• Welding time.

5.3.62 Loading/unloading position must fulfill Design in ergonomics standards.

5.3.63 The panel high must meet design in ergonomic standards.

5.3.64 Station must have possibility to work in automatic and manual mode. Switch to change mode must be placed on operator panel

5.3.65 The sequence of movements in manual mode must be the same as in automatic mode.

5.3.66 There must be the possibility of attaching the operator panel on both the left and right side of the machine.

5.3.67 Machine must be equipped with emergency buttons (red button with yellow background). Emergency button must be installed in every place where operator needs to work, perform changeover, set some parameters.

5.3.68 Machine cycle starting should be realized through 360º whisker switch. Switch must be placed on the right side, and emergency stop button on the left side of machine. Cable must be long enough to change position of buttons(emergency button – right side, start – left side).

5.3.69 Position of both switch and emergency button must meet design in ergonomic standards.

5.3.70 The buttons cannot stick out of the machine.

5.3.71 The station must detect if components were loaded to the fixture and not allowed to perform operation without part loaded or loaded incorrect. The status of sensor must be checked every cycle.

5.3.72 The machine must have scrap separator equipped with sensor logically connected with machine control system to protect against bad parts going to the further process. For example if the result of the operation is NOK the operator is obligated to put the bad part to the scrap separator. Otherwise machine cannot start the next cycle. The scrap separator should be in red color and it must be placed in work area of the operator. Sensor must be located in place which protects it from handle induction. Scrap container should be equipped with kind of protection (with key). Operator cannot take NOK parts from container. Scraps must be place in scrap box which allow to visually evaluating scraps and quantity. When 3 failures occurs one by one machine stop and alarm about reaping failure. Will not start until problem is removed. Also there should be possibility to assembly scrap container on the both sides of machine (connectors, terminals, grips must be on the both sides of machine). It is recommended to plan place for scrap separator in that way that it does not protrude beyond machine block.

5.3.73 The cell should have light system to inform of actual work status acc to specification.

5.3.74 In case of any action required on the machine the appropriate info must be displayed on the control panel screen for operator.

5.3.75 All names on labels, descriptions, descriptions of buttons, joysticks, all warnings, operator panel and control system should be written in English and Chinese.

5.3.76 System should inform in case of failure on the front panel.

5.3.77 After end of cycle operator should get message if part was good or bad.

5.3.78 If the part was bad, starting new cycle should be possible after placing part in scrap separator and machine must inform operator what is the reason of qualifying parts as a NOK one.

5.3.79 Program must show number of good parts and scraps during the shift, and should be stored in memory.

5.3.80 It must be possibility to reset the counter after reached the maximum value

5.3.81 Real machine time must be displayed on the control panel.

5.3.82 Machine time ( cycle initiation – door open), and cycle time ( cycle initiation – cycle initiation) must be shown on operator panel for last part.

5.3.83 Program number and name must be displayed on the control panel.

5.3.84 Position of all sensors on machine must be unequivocal.

5.3.85 All sensors must be easy to change. It is recommended to use only sensors equipped with connectors, or cables with connectors.

5.3.86 There must be two pipes attached to machine. Both should be 2.5 m high from floor level. With first of them the electric cable must go out of the machine. With the second one rest of media(air if required, water if required….).

5.3.87 All machine elements must be protected against corrosion.

5.3.88 All sharp edges must be eliminated, to avoid any injuries.

5.3.89 Control cabinet must be placed on machine back.

5.3.90 Supplier must provide with machine proper certificate as for sound level.

5.4 Specific tooling requirements

5.4.1 Tooling should ensure exact dimensions according to drawing requirements and ensure output capability Cpk>= 2,0.

5.4.2 Tooling weight must meet Design in ergonomic standards. Moreover tooling weight must be accepted by BWI engineer. If weight exceeds acceptable standards there must be special trolley for changeover supplied with machine.

5.4.3 Design of the tooling should not make it difficult for the operator to load and unload components. Loading height and deep is specified in process documentation.

5.4.4 Tooling design must allow to changing used elements in max 5 min without any added tools. If tools are required supplier must supply it with machine.

5.4.5 All tooling elements must be permanently marked. Labels, paint marking, adhesive plates are not allowed.

5.4.6 Mandrel can’t contact with sliding doors.

5.4.7 Mandrel must be isolated from rest of station

5.4.8 Support tooling – polyamide prism ( showed on Picture 3.) distance to reservoir axis must be regulated by operator.

5.4.9 Adjustment range of support tooling must enable to operate with all ranges of reservoirs from Table 2.

5.4.10 Tooling cannot have any impact on machine cycle time.

5.4.11 Tooling design should ensure correct error-proofing in order to protect form incorrect placement and clamp components during loading.

5.4.12 Tooling cannot damage part in any way. Scratches, dents, crack, tube deformations are not allowed.

5.4.13 On the tooling there must be 100 % tube correct loading error proofing.

5.4.14 All working elements must be made with hard material. It is recommended to use sintered carbides or protective coatings. Minimal hardness – 60 HRC.

5.4.15 All working elements must be protected from sparks, splinters etc.

5.4.16 Tooling must assure proper dimensions after welding operation.

6. Process information

Sequence of operations

6.1 Operator loads reservoir tube on mandrel.

6.2 The operator starts the cycle by the hitting whisker switch

6.3 The shield is closed

6.4 The machine initiates the seam welding process

6.4.1 Mandrel move to working position

6.4.2 Base cup is secured between mandrel and pressing tool (upper clamp)

6.4.3 Disc electrode move to contact position with tube and rotate the tube with transmitting the energy

6.5 When the cycle ends – machine elements go to start position, give the information about OK or NOK parts, operator unloads the part and transfers it on slide (OK part) or scrap (NOK part)

7. Safety and Ergonomics

Reference:

Design-In Health and Safety Specification Version 2.1 September 2006

General Equipment Specification for International Operations DC-2001 Version 2, dated March 2000 (pages 1 through 4) Sections 2 & 3

98/37/EC Directive, Essential requirements for machines and safety components

73/23/EWG Directive, Essential requirements for electric equipment

Automotive Manufacturing Engineering Ergonomic Guidelines, Sept 2006

7.1 Safety for the process and equipment shall comply with requirements as specified in the BWI Design-In Health and Safety Specification (DA-2006) and Design-In Ergonomics. Also, the vendor may be required to be involved in a formal risk assessment process during the equipment design phase as a function of the Design-In Health and Safety Specification.

7.2 The equipment shall be designed so that the operator is not subjected to hazardous motions.

7.3 All equipment must include the ability to independently lock out all energy sources for safety during maintenance, clean up, and machine shutdown

7.4 Ergonomics: Reference - BWI Automotive Lean Equipment Design Manual, 2nd Print – Sept 2005. (According to Asia Pacific Ergonomic Checklist)

8. Environmental

8.1 All indirect materials to be used in support of normal machine operations, which can affect the ISO 14001 plant certification, must be listed in details and included in the quotation.

8.2 The equipment must meet BWI Environmental Standard number 10949001 - “Material Specification” Substances of Concern and Recycled Content.

8.3 BWI Corporation Sound Level Specification SL 1.0, July 2002

8.4 Sound level must not exceed 85 dB.

9. Control requirements

9.1 Reference:

General Equipment Specification for International Operations (Revised 02/03/03)DC-2001 Version 2, dated March 2000 (pages 1 through 4) Sections 2

Common Controls Specifications for International Operations (Revised 03/06/00) DC-2002 Version 3, dated August 2003 including Appendix A in specification

9.1.1 In some areas of the plant might reach 45C. Heat exchanger or air conditioning should be used in the PC console. The hydraulic system shall be sized to adequately cool the fluid using 32oC at 2.5 – 4 bars.

9.1.2 Software & its documentation are to be in English (Chinese optional). All schematics, construction diagrams, & stock lists are to be in English (Chinese optional). This applies to all documents that would be used by Maintenance personnel for troubleshooting

9.1.3 Preferred for new machine is PLC processors Control Logix

9.1.4 Outlet is to be mounted on the door of each control panel.

9.1.5 The vendor shall provide (1) copy each of A.B. RSLogix and the Panelview Plus (RSView Studio Machine Edition) programming software at the time that the programs are submitted to ME for approval. The software will be registered to BWI Group. Supply (1) copy for total project, not per machine

9.1.6 Some control panels will have to be larger than existing panels due to lack of sufficient space now, addition of Control Reliable devices, 230 volt hardware, etc. Spare terminals, PLC I/O, and panel space are required. Alternative wiring methods will be considered to conserve panel space.

9.1.7 BWI Grouup reserves the right to make changes to general construction of the equipment, including location and method of mounting panels, boxes, H.M.I., valves, guards, etc. These would be no-cost changes that would be mutually agreed upon between BWI Group and the Vendor. BWI Group and the Vendor will agree on these items during design or during equipment construction. With adequate notice from the Vendor, BWI Group will not cause delay of the project or added costs with these changes.

9.1.8 Cables that move or flex shall be high flex style cable.

All elements used to perform the above work must be in accordance with the standards required by the BWI Group:

9.2 BWI.: Technical specification. General Assumption.

9.3 General Equipment Specification for International Operations (Revised 02/03/03)

9.4 DC-2002: Common Controls Specification for International Operations (Revised 03/06/00)

9.5 DC-2005: Machine Control Logic Specification (A-B Format) (Released 06/98)

9.6 DC-2008: Application Guideline for Common Design of Human/Machine Interface Screens (Revised 03/01/00)

9.7 DA-2001: Specification for the Application of Safety Circuits (Revised 12/02)

9.8 DA-2003: Pneumatic Fluid Power – General Rules Relating to Systems (Released 09/98)

Any exceptions should be discussed with the persons mentioned in this specification, and any approved changes must be in writing.

Tooling must be delivered to BWI Group ready to be connected to the existing mains network [electricity, air etc.]

10. Quality requirements

10.1 All requirements about generating capacity proces (Cp, Cpk) must be complied according to drawing requirements by point 15.

10.2 The production capability of the tooling have to fulfill requirements of Cp, Cpk>= 2,0 on all Key Product Characteristics (KPC) and Quality/Customer Interface (QCI) dimensions is required.

10.3 Cpk less than 1.67 is not acceptable.

10.4 All surfaces marked on the complete reservoir assembly should be protected from spatters

10.5 Design of tooling should provide proper error-proofing to protect against starting the process without placing components, components confusion between the sides and misplaced components.

11. Maintenance requirements

Reference:

BWI Lean Equipment Design Manual dated October 22, 1998 pages 1 through 65.

Technical Specifications – General Assumption for China SEPT2009

Equipment Preferred Components List for China APRIL2010

11.1 Incorporate simple designs. Consider ease of maintenance for perishable tooling and parts.

11.2 All switches and sensors must be mounted using brackets and strikers that do not have slotted holes.

11.3 Design equipment to allow operator to perform routine maintenance.

11.4 At a minimum, equipment should be designed so that operator can identify problems such as noises, vibrations, oil leaks, and low fluid levels.

11.5 The spare parts and routine maintenance must be clearly noted in the machine documentation linked to a visual indicator on machine.

11.6 Hydraulic valves, switches, etc. must be positioned and designed to allow easy access for maintenance personnel.

12. Approval requirements

On the approval of all documentation must be provided two weeks time. Approval of the drawings by the two people mentioned in the specification does not relieve the supplier of the machine from requirements contained in the above specifications. Purchase any of the components before making approval of the project is the risk borne by the supplier.

Reference:

General Equipment Specification for International Operations DC-2001

Version 2, dated March 2000 (pages 1 through 4) Section 5.4

12.1 All drawings must be approved by the appropriate Manufacturing Engineer prior to the purchase of any components by the supplier. The approval of drawings by Manufacturing Engineer does not constitute a waiver of the supplier’s responsibility for meeting the specifications, or for providing functional, capable equipment. Drawings, or any other documents, marked confidential or proprietary will not be accepted.

12.2 Approval drawings

12.2.1 Submit approval drawings to the Manufacturing Engineer. Allow 2 weeks for drawing approval.

12.2.2 The supplier shall not purchase components prior to approval.

12.2.3 Approval drawings must include a machine layout drawing showing overall machine dimensions, electrical panel location, and all utility requirements and connection sizes along with their approximate locations.

12.3 BWI Group approval of drawings does not constitute a waiver of supplier’s responsibility for meeting the specification, or for providing functionally capable equipment.

12.4 Invoice approval

12.5 The BWI Purchasing Department will handle all commercial aspects.

12.6 The final invoice will be approved only after successful completion of the following:

12.6.1 MQ1 at the Vendor (documentation requirements)

12.6.2 MQ2 at BWI plant

12.6.3 Completion of all documentation requirements.

12.6.4 Completion of any outstanding punch list items.

13. Documentation requirements

The full documentation sent to the buyer will allow BWI Group to duplicate the system plus support day-to-day operation and maintenance. Supplier must deliver all the documentation (3 copies – one before MQ1, two before MQ2) to manufacturing engineer. Provide all documentation listed in section 4.1 and 4.2 of General Equipment Specification for International Operations, Version #2 dated March 2000.

All the final, approved and updated documentation (technical drawings, PLC programs, work instructions etc.) must be delivered to the buyer in 3 paper and 2 electronic (CD) copies. Technical documentation must be written in English.

The following items must be included:

13.1 Maintenance manuals

• Preventive maintenance procedures (include safe handling procedures).

• Timeline displaying recommended preventive maintenance procedures.

• Calibration procedures and timing.

• Special maintenance instructions.

• Planned maintenance recommendations.

• Lubrication chart with instructions and schedule.

13.2 Installation instructions

• Installation procedures.

• Installation requirements.

• Required special tools.

13.3 Troubleshooting guide and procedures

13.4 Software

• All software must be licensed to BWI Group.

• Source code on CD with detailed comments on program lines

• Original source code program files are to be provided in hard copy format with comments.

13.5 Operations manual

• Set-up procedure with initial set-up instruction (hardware and software).

• Startup procedure (hardware and software).

• Shutdown procedure (hardware and software).

• An explanation of operational modes.

• Operating instructions.

• Theory of operation and general description.

• Change over procedures.

• Sequence of operation.

• Lockout information (actions performed to de-energize each energy source, and the verifications required to ensure the energy sources are isolated and neutralized).

13.6 Critical spare parts list

13.7 Recommended spare parts list

• Original manufacturer’s catalog and ordering information for all purchased items.

• Illustrated spare parts list with descriptive information, purchasing source and current pricing.

• Warranty information.

• Recommended list of perishable tools, and necessary supplies, with suggested initial stock level.

13.8 One complete set of prints, per BWI format, (3.5” or CD Disk is acceptable) that must include applicable prints from the following:

• Electrical

• Mechanical ( .dwg, and 3D)

• Pneumatic

• Hydraulic

• Software

ALL DOCUMENTS MUST NOT BE MARKED PROPRIETARY

13.9 All tools and control drawings must be supplied to BWI Group inAutoCAD 2000 format.

Documentation will allow BWI Group to duplicate the system plus support day-to-day operation.

13.10 Machine Documentation to include a complete set of machine and controls drawings, with drawing numbers specified by BWI Group Manufacturing Engineering. These drawings to be similar to existing machine drawings, a disc copy of which will be provided at the time of order.

• All mechanical drawings must be in metric. All gages must be in metric.

• Allcontrols drawings must be completed using IEC symbols.

• Service and manuals, push buttons, tags etc. must be in English and Chinese

13.11 Provide a documentation holder mounted to the side of the machine to hold documentation.

13.12 A tool layout will be included in the machine drawing package. This layout is to include views and part numbers for the tooling as required to support the production operation.

13.13 All machine drawings must be updated to represent the as-built condition of the machine or invoice approval will not be granted. The drawing numbering system will be common among all machines in the complete cell. Detail number callbacks and stock lists need to be complete. Drawing number format is:

13.14 Numbered according to the instructions contained in the annex (section 16.12 in the instruction). More information about the numbering will be forwarded at the first meeting with the vendor..

13.15 CD backup copies of all the PLC programs.

13.16 In PLC programs supplier is obliged to use the clear method of commenting the line-by-line actions, variables etc. to facilitate the day-by-day service and maintenance. The method of marking and commenting the programs must be agreed between supplier and ME prior to the installation.

13.17 Exceptions for off-the-shelf equipment or components will be considered.

13.18 A tool layout will be included in the machine drawing package. This layout is to include views and part numbers for the collet chuck, collet, tool holders, inserts, tool blocks, special risers, etc. as required for supporting the production operation. Where applicable this tool layout is also to include a tool path plot with pertinent information such as tool radius, feeds and speeds between end points, etc.

13.19 For each machine the supplier must deliver the full PFMEA. The PFMEA will be reviewed with ME before concept approval design

Provide all documentation in accordance with Section 4.1 and 4.2 specification „General Equipment Specification for International Operations”, version 2.0 , March 2000.

The documentation provided must be in English.

The design of all elements of the machine should be provided in electronic form as:

- 3D model of machine

- Autocad drawings version 2000 or lower in dwg format,

- in paper form in duplicate.

Drawing tables will comply with the standard of BWI Group FangShan.

Special attention should be paid to provide the following documents:

• Spareparts list,

• List of expendableparts

• Wiringdiagrams,

• The drawings of mechanical parts,

• Pneumatic and hydraulicdiagrams,

• Instruction switching on and off,

• The Tooling Manual

• FMEA analysistool

14. Training/Support Requirements

Performer above mentioned activities is obliged to provide the person who will be responsible for the training of operation and maintenance of the tooling and provide technical assistance as needed. Training can take place at the same time as installation or a later date agreed in advance with those listed in this specification. Term training, however, cannot be later than the date MQ2.

15. Quote requirements

15.1 Quote requirements are listed in the following specification. If there is a need to make some exceptions by the vendor, these exceptions must be stated clearly as an exception. Supplier quotations that restate or limit the scope of the specification without clearly noting the exception will not be honored. In case the vendor makes no exception it means he/she fulfils all specification’s requirements.. The vendor is welcomed to add alternatives to the specification.

15.2 The vendor must supply the following information for the Request for Quotation package:

• Base bid of mechanical design, mechanical build, control system design and control system build

• Exceptions to the Technical Equipment Specification or any referenced specifications

• Allspecialinstallationrequirements

• Physical size and weight of the equipment

• Equipment utility requirements (voltage, full load current, air PSI)

• Allspecialenvironmentalrequirements

• Quantity and timing for debug parts

• Quantity and timing for machine qualification parts

• Pricing and availability of spare parts/components

• Shipping equipment to destination localization

• Training cost shall be listed as a separate line item

• Allequipmentmusthaveguarantee

• Options, if they are applicable

15.3 The selected vendor(s) will participate in and complete a review and update of the Design in Health & Safety documentation for this equipment, prior to the start of design.

15.4 The selected vendor(s) shall quote the original specification as well as additional options if desired to reduce cost and improve performance. If an option is accepted, it will be included in a revised specification.

15.5 All machine drawings will include a specific tool layout for station error proofing. This layout will include a pictorial representation of and or a description of all error proofing occurring in the station. The error proofing registration number for all error proofing occurring in the station will also be included. The layout will also include the dimension or characteristic being verified and the tooling datum from which the verification occurs. For those error-proofing checks made by physical or optic measurement, drawings for set-up (calibration) and boundary reject (High & Low Limit Rejects) masters will be included, with all pertinent dimensions. It is possible to make boundary rejects from component sub-assemblies, but the alteration and dimension to be modified must be identified. Where possible, the goal should be to have a maximum of 1 set-up and 1 common low reject boundary and high reject boundary master for all applicable error-proofing checks completed in a station.

Quote has to be sent back to TCK engineers. If any terms regarding timing are not acceptable, please submit the acceptable date in quotation.

THE INTENT OF THIS QUOTE IS TO SELECT SUPLIER.

WITH THE OFFER SUPPLIER MUST PROVIDE THE DETALIED TIMING SCHEDULE FOR EACH PROJECT REALIZATION STEP

16. Requirements for valuation

Valuation should be performed according to Section 4 of the specificationGeneral Equipment Specification for International Operations, version 2.0, March 2000.

The supplier shall provide pricing based on this specification and present measurement solutions optional and alternatives, which will allow to reduce costs and/or will improve machine performance and product quality. If the options are approved, they will be included in an updated specification or included as an attachment to the original.

The Supplier shall provide a detailed valuation in pressing equipment, measurement must include the following information:

16.1 number of hours expected to complete technical documentation and operating cost

16.2 number of hours expected to complete the necessary parts in metal and with the average cost of operating hours

16.3 total cost of materials used in the construction of toolings without labor costs mentioned in section above

16.4 number of hours expected at the final assembly of the tooling along with the price of operating hours

16.5 the total cost of the trade

16.6 the expected number of hours to complete start-up and pressingtooling settings in the target location BWI FangShan along with the cost of one operating hour.

17. Special shipping requirements

17.1 The supplier will be responsible for preparing the equipment package for shipment to the specified BWI Group facility at no cost to BWI Group.

17.2 Tooling must be packed in accordance with the requirements of air shipment in wooden box.

17.3 Provide well-marked lifting lugs on the equipment.

17.4 The equipment must be wrapped in plastic during shipment to reduce contamination.

17.5 All moveable components must be tied down so they do not move during transit.

18. Start-up and approval

18.1 Establish machine capabilities according to Qualification Plan. This must be done at the supplier’s plant (MQ1) and during MQ2 at FangShan plant in China after installation.

18.2 BWI Group will confirm the supplier detailed Qualification Plans not later than two weeks before the Qualification date (for each MQ1 and MQ2). The plans may differ between MQ1 and MQ2.

18.3 BWI Group will provide all component parts to the vendor for purposes of setup, debug, machine capability tests, and a one-hour runoff at the vendor's plant.

18.4 BWI Group engineering personnel will assist during runoff to analyze efficiency and assign causes for any downtime.

18.5 The operator cycle time and the machine cycle time must not exceed the times specified in the Process Requirements section of this specification.

18.6 The supplier has the responsibility to supply labor for runoff in their plant. The runoff process will consist of the demonstrations listed below:

18.7 Equipment Acceptance Criteria will be:

18.7.1 MQ1 qualificationcompleted

18.7.2 Overallworkmanship

18.7.3 Functionality of all error proofing devices

18.7.4 Machine safety devices and interlocks

18.7.5 Preventivemaintenancerecommendationrequirements

18.7.6 Requirements for machinemanuals

18.7.7 Equipment documentation including mechanical, electrical, fluid power

18.7.8 Spareparts list review

18.7.9 Duration of run required to qualify machine

18.7.10 Delivery timerequirements

18.7.11 Baselinenoiselevel

18.7.12 Baselinevibrationlevel

18.7.13 Ergonomicanalysis

18.7.14 Lockout procedure including posted placards (written in English and Chinese)

18.8 In the event of a special cause of variation, based on the nature and extent of this variation, the run-off will berestarted.

Start-up Proces and Approvals –

The release condition of tooling on the factory is to meet the requirements of the specification. The adequacy of the recipient must be made after the unit is installed in Fangshan BWI. Fangshan BWI will provide all the necessary components that will be used to set up and start-up of the tool and to perform the necessary tests. Persons authorized from BWI will assist in the start-up in order to analyze capacity and identify the reasons for any outages and failures. The supplier is obligated to provide support during the start-up of the target location. Technical acceptance will be after setting the dimensions. During acceptance required is minimum of 4hours tooling work without jamming the tooling(up time 99,5%).The start-up will include: Capability&Capacity Studies - examine the capacity of the manufacturing process by measuring the repeatability coefficient Cp and Cpk process, checking the efficiency of the production process.

Acceptance date of the MQ1 - September 2014, in case the tools will return to the supplier after receiving tooling in order to perform corrections, they must be delivered to the BWI Fangshan two weeks before the planned reception in order to make adjustments to the pressing program

19. Requirements for the monitoring of the process of constructing

Supplier is obliged to deliver with valuation detailed work schedule.Schedule shouldcontain:

17.1 The time needed to create construction drawings, and electric scheme

17.2 Time for approval of drawings and electrical

17.3 Time to buycomponents

17.4 Time for performance of mechanical components

17.5 Time for performance electrical connection, pneumatics

17.6 MQ1 date of receipt no later than specified by the client

Any reports on the work of the toolings should be sent to:

Piotr Galan:mailto:piotr.galan@bwigroup.com

Quotation without tooling timing won’t be considered.

20. BWI Group Run at Rate / Approval process

After elimination of the failures but no earlier than one week after acceptance a technical tool at the destination process will continue testing the ability of the BWI FangShan. Final approval of tool will basically rely on the repetition of an activity carried out in MQ1 but the minimal required time is 8hours.

Date of the final acceptance MQ2 October of 2014 year, if the tools will back to supplier after reception in order to perform corrections of toolings, they must be delivered to BWI FangShanfor two weeks before planned collection in order to make corrections the pressing program.

During MQ1 and MQ2 will be prepared documents:

• MQ form

• Data sheet

• List of Open Points

MQ2 possitive must be without Open points

Possitive result of MQ2 allows tooling to work in BWI Fangshan.

21. Special shipping requirements

Prior the shipment of the machines all the shipment requirements must be agreed between ME and the supplier.

21.1 The equipment must be shipped using metal skids, or fumigated wood.

21.2 Provide well-marked lifting lugs on the equipment.

21.3 The equipment must be wrapped in plastic during shipment to reduce contamination.

21.4 All moveable components must be tied down so they do not move during transit.

21.5 All software and manuals should be shipped separately from the machine in labeled binders.

21.6 Notify the Project Engineer a minimum of two days prior to equipment arrival at the plant in FangShan, China.

21.7 Ensure that all items necessary for proper reassembly of the disassembled machine are packaged and shipped with machine, (i.e. dowels, leveling screws, etc.) Identify all disassembled members of machines or equipment with simple codes to expedite reassembly efforts. Provide prints marked with coded points to aid reassembly. Pictures are also acceptable.

21.8 The vendor will be responsible for preparing the equipment for shipment to the specified BWI Group facility at no cost to BWI Group.

21.9 Invoicing – the following payment schedule will be followed unless otherwise specified in the purchase order:

21.9.1 Partial invoice after Machine Qualification at the vendor plant if all documentation due at this time has been supplied and capability documented.

21.9.2 Final invoice approval will be granted after successful completion of all runoff requirements at BWI Group plant in FangShan, China.

22. Installation

It is expected from the vendor posting a person who will support the installation of the tooling in FangShan BWI and, if necessary, will provide support and technical.

23. Explanation of abbreviations used in the specification:

20.1 MQ – technical acceptance machine/tool, 1 initial, 2 final

20.2 CpCpk – indicators of the capacity of the manufacturing process

24. Attachments

#No: Name File

App.1 BF-0035 existing machine general doc

App.2 22293890 - reservoir tube with base cup

App.3 Contact tooling part Quantity -

Lower Tool

Couner electrode 2

Disk electrodes 2

Electrode knife 2

App.12 BWI Fangshan equipment and tooling design guidelines

App.4 Design-In Health and Safety Specification

App.5 Material Specification. Substances of Concern and Recycled Content

App.6 Common controls specification for international operation

App.7 Specification for the Application of Safety Circuits

App.8 Hydraulic fluid power – general rules relating to systems

App.9 Pneumatic fluid power – general rules relating to systems

App.10 Electrical specification for industrial machinery

App.11 Sound level specification SL 1.0

App.12 Manufacturing engineering ergonomics guidelines 1.0

App.13 General equipment specification for international operations

App.14 Lean equipment design

App.15 Common controls specification for international operations

App.16 Lean equipment controls design

App.17 Design in health and safety specification

App.18 Equipment preferred components list in China

App.19 ISO4413 Hydraulic fluid power – General rules relating to systems

App.20 ISO4414 Pneumatic fluid power – general rules relating to system

App.21 Machine qualification plan

App.22 Tooling building timing

App.23 Technical specification – General assumption for China

App.24 Design-In Ergonomics checklist – step2 – product design

App.25 Design-In Ergonomics checklist – step4 – hand tools

App.26 Design-In Ergonomics checklist – step5 – material handling

App.27 Design-In Ergonomics checklist – step1 - information gathering

App.28 Design-In Ergonomics checklist – summary 2

App.29 Design-In Ergonomics checklist – step3 - asiapacific

App.30 Design-In Ergonomics checklist – step3 - asiapacific

App.31 Utility connections

App.32 Light tower

App.33 Tear away test

App.34 Different shapes of base cup

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