AZ Automotive Weld Tooling & Assembly Equipment Standards
PRINTED COPIES ARE UNCONTROLLED
(UPDATED 5-3-07)
SECTION 1
1. General Requirements
All equipment and auxiliary equipment shall comply with the latest version of the applicable federal, state or province, and local codes and laws, where the equipment is to be used. It shall be the Suppliers responsibility to acquire any necessary copies. These shall include, but are not limited to, the following:
1. The National Electrical Code (NEC) NFPA 70
2. Occupational Safety & Health Act (O.S.H.A.) Standards
3. The Canadian Electrical Code
4.
5. Ministry of Labor Regulations
6. Canadian Standards Association (C.S.A.) Approved Auxiliary Equipment
7. Ontario Hydro Electrical Safety Code (21st edition)
8. Ministry of Consumer & Commercial Relations (M.C.C.R.)
9. SAE Electrical Standard for Industrial Machinery - Supplement to NFPA 79 SAE HS-1738
10. Work-place Hazardous Matter Information System (W.H.M.I.S.)
11. Special Publication SPE-1000-94 Model Code for the Field valuation of Electrical Equipment, Canadian Electrical Code
All industrial equipment, systems and components shall be under warranty for parts and labor for a minimum period of twelve (12) months from start of production as defined in the statement of requirements.
If the Supplier wishes to use any item that is not approved by the applicable federal, state or province, and local codes and laws, it will be the Supplier’s, not AZ’s responsibility to submit and gain approval. Non-approved items will NOT be accepted unless written proof of acceptance by the applicable agency is given to AZ.
The integrator shall supply two (2) books containing copies of all installation instructions and service data for each component.
Operation/Maintenance Service manuals shall be provided for each system 15 days prior to the shipment of the equipment. In addition, the supplier is responsible to update these manuals through the start of production at AZ Automotive Corporation.
Operation/Maintenance Service Manual description:
INTRODUCTION
System Description
Reference/Manufacturers' Literature
Equipment Layout
SAFETY
Basic Safety Recommendations
Safety Pin Locations - Drawing
Emergency Stop Push Buttons Cycle Stop Push Buttons Safety Mats, Light
Screens, Operators, etc. Locations - Drawing
SYSTEM AND MACHINE OPERATION
Systems Modes of Operation
Complete Start-Up Sequence
Individual Station Start-Up Procedure including Parts Loading and Unloading.
Shut Down Procedure
E-Stop Recovery Procedure
Sequence Of Operation
Manual Back-up Procedure
MAINTENANCE AND SERVICE
AZ Automotive has a planned maintenance manual. The Supplier shall provide planned maintenance inserts for any and all equipment they are providing for which AZ Automotive does not already have in their planned maintenance manual.
The planned maintenance schedules shall clearly define daily, weekly, monthly, yearly and all other maintenance required.
Cycle time and net run rate shall be based on AZ supplied statement of requirements. The supplier must provide estimated times for standard maintenance procedures, based on estimated uptime percentage.
The Supplier must provide a timeline with all critical milestones. This timeline will be updated weekly and distributed to the AZ Manufacturing Engineer.
The Supplier shall calculate the power, air volume, water and gas requirements of ALL equipment. These requirements shall be supplied to the AZ Automotive Manufacturing Engineer.
All designs are to be given the fullest consideration to:
A. Operator and maintenance personnel safety.
B. Simplicity in operator part loading without restrictions or interferences.
C. Free accessibility to all components for ease of maintenance and replacement with particular emphasis on hosing, secondary weld cables and transformer removal, where applicable.
D. Rigidity of construction for operation endurance.
E. Provide maximum robot working envelope to minimize robot repositioning and cycle time.
F. Compliance
with all
All commercial components shall be selected from the AZ Automotive Approved Standards Components List. This list is available on the sidebar.
All drawings shall be originals and become AZ Automotive property.
A complete new design is required.
Reference drawings are furnished for reference only. These drawings are not to be interpreted as design instructions.
Status reports are required on a weekly basis.
Where parallel part processing is done, such as multiple GEO stations or a parallel process, particularly welding operations, part marking is required to provide traceability to which path or station the part was processed in.
Multi-station operations will be numbered starting with "10" (or "5") and incrementing up to "99", the number of the last station. Typically the numbers would be "10, 20, 30," etc, with the last operation being "99". All system numbering to be reviewed by the AZ Manufacturing Engineer.
Design Supplier shall be responsible to update all designs including shop changes made during construction and launch.
The supplier shall conduct and document a Controls Process Review for each tool/system. The timing of the reviews shall be shown on the project time lines.
The Supplier shall not make changes to basic process or design without authorization from the AZ Automotive Manufacturing Engineer
Supplier is advised to print the current version of the AZ Tooling Standards in effect at time of design in case changes are made to the Tooling Standards after design has started.
All components or materials used in equipment or fixture manufacture or assembly shall be NEW, except for AZ Automotive supplied reconditioned equipment. It is the supplier’s responsibility to fully integrate any AZ supplied, re-condition equipment.
The machine (or system) contractor/supplier shall provide as part of the contractual requirement, a complete preventative maintenance/spare parts listing. The listing created is to be a compilation of information of the parts of the machine (or system) the contractor/supplier feels are of a preventative maintenance/spare parts nature and should be maintained for adequate repair or preventative maintenance capability at the AZ site.
The listings will provide the specified information on Machine/System parts of a "spare-part nature," that is, for all readily perishable, frictional wear, Preventive Maintenance, and operation "insurance" quality spare parts. This list will be broken down by sub station as well as full system and provided to the AZ Manufacturing Engineer.
If any disassembly is required, all break points or areas must be identified with station number, letters, and flow direction for reassembly.
All air, hydraulic, and water connections and manifolds shall be thoroughly drained, blown out, and plugged before shipping.
Adequate guards, shielding and protective safety devices shall be provided for protection of personnel and equipment.