General Audit

1. Documentation

  • Is there documentation complete and compliance with TST 000138? (All mandatory manuals, drawings and lists according to Embraco mandatory templates, submission format and file extension)

  • All documentation is writen in English? (mandatory language)

  • All documentation is also translated to local site language? (if agreed in the contract)

  • Is the machine ledge available according to Embraco template?

  • Are the technical and commercial specifications of components completely described in the diagrams/schemes and in the parts lists?

  • Were program backups considered and delivered?

  • Are the manuals/diagrams in an easily accessible place and available for use?

  • Are all electrical panels provided with consoles to keep manuals and diagrams?

  • Are the Electrical Drawings “As Built” updated?

  • Is it necessary to update documentation before shipment to Embraco regarding tryout results?

2. Identification, Tags and Labels

  • Is the nameplate mounted on the door next to the main disconnect / isolator?
    NOTE: Items on the nameplate include: Manufacturer's name and address; Year of manufacture; Embraco code and Op. numbers; Electrical, lube, pneumatic, and hydraulic drawing numbers; Line Voltage; Control Voltage, Max Interrupting Capacity, Main Fuse or Breaker, Installed Load; and Measured Full Load Current.

  • Has the supplier installed equipment within EMC guidelines and has EMC declaration available in addition to CE certificate and RISK Assessment?

  • Has the panel the description of the rated current (A), machine/equipment power factor (%), frequency (Hz), number of phases, power (kW), power supply voltage (V) and consumption (kWh), as necessary?

  • Are all components marked with diagram reference numbers?

  • Are all electrical connections identified and labeled according to the standard?

  • Are the components (electrical components external to the panel, hydraulic, pneumatic, lubrication components) identified according to the schematic diagram and as close as possible to the component with aluminum plates, fastened with rivets or screwed to the machine?
    Note: It is important that the identification of the electrical components is in such a way that in case of its replacement the identification remains in place.

  • Are all cables and terminals (including terminal style connectors) labeled? Are the labels and tags made of either laminated plastic or non-corrodible metal? Are the indetification black lettering upon either a white or metallic background?

  • Are the connection cables between the machine/equipment and control cabinet properly identified with markers resistant to chemical action due to contact with oils, water and other solvents found in our production process?

  • Are cables identified and tagged on both ends with a unique number (this includes machine networking I/O cables)? Are the mating sockets tagged with the same number?

  • Do all adjustable devices such as regulators include the target setting on the identification tag?

  • Is there identification of the wire tips fitted with insulated terminals? The terminal blocks are also identified? Are all identification protected against oil and grease?

  • Are there rotation direction indicators for air motors?

  • Are there motion indicators for airflows?

  • Are the photocell switches with status and correct alignment indicator?

  • Are the proximity switches with indicator status?

  • Are the I/O modules physically and clearly identified according to their function, separating digital and analogic signals and grouped by input and output?

3. Design, Maintenance, Interchangeability and Standardization

  • Are all the components being selected and specified under all intended uses of the system (ISO 4414 – clause 5.2.1)? Are all the components installed and used according to the Component Manufacturer's recommendations to operate reliably under all intended uses of the system (ISO 4414 – clause 5.2.1)?

  • Is the list of installed materials and brands in accordance with TST 000138?
    Note: Any nonconformity must be reported.

  • Does the machine/equipment has any obsolete component or in the obsolescence phase, recognized by their manufacturers?
    NOTE: Only for overhauling/retrofitting of machine/equipments

  • Are the Modularity concepts applied, easy to swap in modules level?

  • Is there interchangeability of parts so that they can be replaced quickly without adjustments?
    NOTE: Interchangeability can be functional,physical, universal or local.

  • Have all the required spare parts been delivered according to contract agreement?

  • Are all elements (ex. bolts, connectors, cylinders, motors) grouped to give the minimum number of sizes and types for spare part reduction?

  • Are the necessary maintenance gages standard?

  • Does the design of machine applied standard components wherever possible in order to reduce spare parts lead time?

  • Are all major items easily accessible and easy to maintain and replace (ex. motors, gear boxes, electrical panels, shafts, rollers, bearings)?

  • Are the maintenance space enough for servicing and removal of equipments (no points to slip / trip / hit / fall)?

  • Are there any devices hidden by other devices?

  • Are there good access and easy visibility to all panel doors, inspection and maintenance points?

  • Are there PokaYoke systems to indicate wrong operation?

  • Does the machine/equipment have protections such as gutter (runway) guards to prevent the accumulation of oil (lubricant, hydraulic fluid, coolant) on the factory floor?

  • Are the components with a safety function designed within the fail-safe concept to prevent uncontrolled movement of power components?

  • Are filter elements that may be part of routine inspection and replacement by the operator in an easily accessible location?

  • Components such as solenoid valves, pressure switches, gages, sensors with digital readout, I/O blocks, and terminal boxes are mounted outside of the machine guarding?

  • Do all components that have either LED indication or other (analog/digital type) are clearly visible to the operator?

  • Has devices been mounted to protect components from harsh environments such as coolants and fluids, heat, and excessive vibrations?

  • Are cable connection and routing into devices been protected such that liquids are drained away from the device?

  • Is it easy to perform Thermograph maintenance activities?

  • Is it easy to perform predictive maintenance activities?

  • Are the fast fitting elements with FIXING AND CONNECTION RAPIDITY (quick change concept) applied all over?

Mechanical Audit

1.COMPONENTS

1.1. Valves

  • Are Manual valves with open closed indicators?

  • Are there installed windows on distributing valves in the machine/equipment's front panel?

1.2. Gauges

  • Do all control instruments present a collared dial with indication of normal working range and with the central value of the normal range positioned at 12:00?

1.3. Rollers

  • Is the rotation direction of all rollers shown?

  • Are rollers fixed for easy alignment?

1.4. Belts and chains

  • Are belt tensions easy to check?

  • Is the normal position of the belt tension systems clearly identified?

  • Is there easy access for changing belts and chains and other items needing frequent maintenance?

1.5. Bolts

  • Are the numbers of bolts reduced to a minimum?

  • Are all bolts located where they can be reached by wrenches?

  • Are the critical bolts marked to check tightness?

1.6. Pipes

  • Are pipes set at pitches that allow additional tightening?

  • Is the flow direction shown on all piping?

1.7. Transmission and mechanical power

  • In special cases, is the sensing of the temperature of the oil in the gearbox provided?

  • Are the motors with pulley´s and belt mounted on adjustable bases that allow for the sharing and adjusting of the belt tension?
    NOTE: Applicated on Motors that are used to drive gear boxes

  • Are the gear boxes fitted with two bearings on the input shaft?

  • Is the rotation direction marked on gears and shafts?

  • Do the Maximum diameters of sprocket hole pulleys follow the manufacturer's recommendations?

  • Are all the gear boxes provided with a display of the lubricant level that is easily visibility after installation?
    Note: May be required for sensing temperature in gear boxes in special applications.

  • Are the flexible couplings aligned to 50% or less of the coupling manufacturer's specifications for the parallel and angular misalignment?

1.8. Traction units

  • Are all turnbuckles only actuated pneumatically? Note: Systems that use a screw or spring should not be used without the prior written approval from Embraco Engineering.

  • Does the compressed air supply for the turnbuckles comply to the pressure pipes standards?

  • Are the traction units the Caterpillar type with a RC160 chain?

1.9. Ramps

  • All ramps have a radius curve of 3 meters? Note: Other alternatives should be validated with written approval.

  • All ramps have a 30° slope to the horizontal? Note: Other alternatives should be validated with written approval.

1.10. Troley

  • Is there an automatic lubrication system for trolley and chain pins?

1.11. Pumps

  • Are the hazardous materials transfer pumps compatible with the material being handled?

  • Are the pumps driven by electric motors coupled with C type flanges?

1.12. Motors

  • Does the installation location of the motor have direct ventilation from outside the machine/equipment?

  • Is the installation location of the motor protected from any source of dirt, splinters, etc..? Note: There should be no opening of any kind between the motor compartment and another compartment of the machine/equipment.

  • Are the motor flanges type "D"? Note: Flanged motors do not need to be fixed on the base; otherwise the alignment must be guaranteed.

  • Are the motors and/or pump/transmission devices mounted on a common, rigid base?

  • Is the assembly of a motor carried out in a way that all the fixing screws can be easily removed and replaced and the electrical connection boxes easily reached?

1.13. Transfer systems

  • Are the transfer systems protected against overload?

  • Is the machine operation visible from the outside of the machine when the unit is at full travel?

  • Do the products have their fixing ensured during the entire transfer? Note: The fixation using clamps in critical applications can be used.

  • Are there knockers planned at work-stations where location is critical?

  • Is the handling/transfer system robust enough allowing for the easy attachment of the product?

  • Parts located on idle work-stations must remain in the positive position, as long as they don’t interfere with the subsequent transfer?

  • Does the movement of the transfer systems - fast forward movement to feed, stop or reverse have a controlled deceleration?

1.14. Tooling

  • Has enough space been reserved to facilitate tool change?

  • Has the quick change concept been applied for tools replacement?

1.15. Bearings

  • Are there any smooth and flat spots for fixing (with a magnet) the accelerometer on the bearings of rotating machinery/equipment with an "A" criticality? Note: Check with the ENGINEERING MAINTENANCE the criticality of the equipment being supplied.

  • Do the bearing housings have slots for the extraction, if the removal of the bearing is not possible in a normal way?

1.16. Guards and Covers

  • In the case of aggressive environment, shafts and bearing guides should have bellows or telescopic protection. Is it in compliance, if it’s the case?

  • Are there transparent covers for easy checking of mechanical drives (ex. belts, shafts)?

  • Do the guards have inspection windows, on the rotating bearings for the collection of vibration data?

  • Do the coupling guards contain an inspection window for monitoring by a stroboscope? Note: Construction practices requirements that meet the predictive maintenance carried out in EMBRACO.

  • Are there covers to prevent scattering of debris and coolant residue from cutters/grinders installed as close to the scatter source as possible?

2. DESIGN AND MAINTENANCE

  • Are quick disconnect and locking devices used instead of screws wherever possible?

  • Are there notches, colors, and references to make adjustment easier?

  • Is there a reference plane for measuring machine precision and was it already learned?

  • Can measurements of both static and dynamic precision be done quickly and easily?

  • Are measurement reference planes hidden behind pipes or covers?

  • Are there any straps, hooks, lifting lugs, eye bolts or special devices for lifting machinery/equipment? Note: critical points must be named and labeled

  • Are shielded cars used in environments with a high degree of contamination and with wheel retainer?

  • Are there Position indicators for important moving parts?

  • Are there any flat and accessible surfaces to check the level without removing any parts?

  • Are the contact surfaces smooth or flat as much as possible?

  • Are the vibration limits in accordance with the IEC 60034-14, NBR10.272 and ISO 1940 standards?

  • Are there no scatter chips, coolant, etc?

  • There is place suitable for the removal of splinters/chips or scrap?

  • Has the structure been designed to prevent accumulation of cutter and debris?

  • Are there any suitable places to drain the silencers?

  • Are non-metallic materials used for buses or guides? Note: if the use compulsory it should be approved by Embraco Engineering.

  • Are all points of wear that are part of the machine/equipment or fixed devices that directly contribute to the precision of the operation, are reinforced and easily replaceable?

  • The points of wear or fixed devices which contribute to the precision are protected against abrasive particles?

  • Are the chain guides/conveyor belts coated with wear strips?

  • Are all guides and pins hardened, ground and easy to replace?

  • Are the wear components standardized and interchangeable?

  • Does it have ease of change and adjustment for worn parts? (ex. Knifes, belts).

  • Is it thoroughly protected against sources of dust and grime?

  • Are the components subject to pressure or impact made of hardened tool steel?

  • Are all the bushes, flanges, caps, etc. designed to be accessible through threaded holes or notches to facilitate their extraction?

  • In the joints of rotating components are pins used for connections? NOTE: Except for protection (fuse point).

  • Are there any belt-like protections or cable holders for electrical cables, hydraulic and pneumatic hoses?

  • Is there a drain at the bottom of fans or blowers to remove any buildup of fluids?

  • Are cylindrical pins used in places that require precision? Note: these can only be used in places which do not require precision.

Hydraulic Audit

1. COMPONENTS

1.1. Motors and Pumps

  • Are the hydraulic pumps protected so as to avoid collision with parts carried in the vicinity?

  • Are the hydraulic pumps mounted on the outside of the hydraulic tank and designed to allow easy access for maintenance and disassembly?

  • Do the couplings of the motor and pump have a removable cover for inspections?

  • Are the motor and pump mounted on a rigid base which ensures alignment of the coupling?

  • Are the pumps fitted with filters in the suction line, which are a coarse mesh 100, to protect the pump from large particles or splinters? Are the filters provided with saturation control?

  • Is the interconnection of the motor-pump system with the hydraulic circuit through a flexible component?

  • Are Flexible hoses used for pump output.?

  • Is the replacement of submerged pump possible without the need of oil removal?

  • Do all the pumps have a label identifying the direction of rotation?

1.2. Hydraulic tanks

  • Are the tanks built in such a way as unleveled to allow liquid discharge from the bottom part of the tank to ease cleaning service?

  • Are the components in the hydraulic tank (motors, pumps, valves, etc.) mounted so that access for adjustments and maintenance is easy and requires little pipe disassembly?

  • Are all hydraulic oil tanks and refrigeration oil tanks containing windows to assist internal cleaning procedures?

  • Are the oil tanks mounted outside machines interior?

  • Are viewers, refilling and oil removal points located in such a way to allow easy access for inspection and fast oil change, in the least possible time?

  • Is the tank filling hole with a diameter not smaller than 50 mm?

  • Is there at least one opening for tank cleaning? If the tank has internal divisions, does it have one opening for each of them?

  • Are minimum level electric/mechanic controllers installed? Are all oil levels visible and vertical?

  • Is an oil temperature indicator provided?

  • Is the tank away from the floor at least 150 mm?

  • Is there some way to prevent oil spilling on the floor or returning to tank during maintenance and/or due to leakage?

1.3. Fliters

  • Do the installed filters have a saturation indicator; are they easily accessible for cleaning and changing?

  • Are there Drip trays located under filters.?

  • In the case of machines that use cutting oil coolants, or lubricants, are they equipped with filtration systems or another type of protection to prevent any kind of contamination?

  • Are filters installed in hydraulic units in such a way that is easy to be replaced without the need of oil removal?

1.4. Cylinders

  • Are all cylinder aligned with no side loads?

  • Are the cylinder cushions adjusted?

1.5. Accumulators

  • Are the Pre-charge pressure clearly marked at/near the accumulators?

1.6. Valves

  • The valves should preferably be mounted close together, by stage, on the same base, in modules and next to the actuators. Is this being considered in this machine/equipment?

  • Are the valves, preferably, installed next to each other, by stage, at the same frame, in modules and next to the actuators?

  • Are manifolds used to valves base montage?

2. MAINTENANCE

  • Is the fluid used in the system hydraulic oil with an ISO VG 68 viscosity class, petroleum-based?

  • Does the hydraulic system operate with oil at a temperature between 45 - 55 ° C?

  • Every hydraulic unit that heats up above 60º C must contain fin heat exchangers. Is this being considered in this equipment?

  • Is the noise levels generated by the hydraulic unit equal to or less than 78 dB?

  • Is the hydraulic system equipped with a discharge valve to relieve the pressure in the pumps in cases of over pressure?

  • Are Hydraulic Units separated by functionality?

  • For hydraulic components that perform safety functions (load lifting, fixing parts, indexing, transportation, etc.) is it equipped with monitoring systems to ensure a fail-safe operation?

  • How is done the switching speed by hydraulic actuators (should not be used when powered)?

  • Is the hydraulic system provided with sampling points before the return filter and after the pressure pump?

  • Were pressure test points installed in the hydraulic circuit after the valves and on the pump?

  • Are the component’s technical and commercial specification fully described in the hydraulic circuit diagrams and parts list?

  • Are gauge pressure connectors provided in the hydraulic pipeline after the valves and after the pump?

  • Are Hydraulic Gauges with normal operating ranges marked?

Pneumatic Audit

1. COMPONENTS

1.1.Valves

  • Do all electrically valves – solenoid have indicator lights?

  • Solenoids can operate at Nominal voltage preferably 24 VDC +10% -20%?

  • Do solenoid valves have manual overrides which can be operated without removing solenoid covers or enclosures?

  • Are piping of the exhaust into the machine/equipment frame or manifold?

  • Are muffler and a low point drain provided in the machine/equipment frame or manifold?

  • Are all spool type valves mounted with the spools horizontal?

  • Are there means/provisions to avoid incorrect mounting of valves, e.g. mounting-bolt pattern, port identification or other identification?

  • Do all the air exhausts have a silencer?

  • Do the exhaust ports face downward to avoid trapping any discharge?

  • Are valves protected from contamination?

1.2. Filters, Lubricators and Regulators

  • Is the pneumatic systems supplied with a line filter installed at the point of connection to the supply line?

  • Does the drip leg conform to Embraco Standard?

  • Are proper sized filters used for pre-filtering and general use filtering?

  • Are the main air pressure switch provided and properly set?

  • Do the spindle air purge circuits have a coalescing filter followed by a regulator and pressure switch?

  • Are all the lubricators (except recirculation and injection type) mounted at the same level or higher than the supplied components?

  • Does the lubricator line have a button for filling the oil?

  • Do the regulators have pressure gauges applied and rated pressure readily identified on it?

  • Are the regulators and valves located as close as possible to the power actuator?

1.3. Cylinders

  • Are the cylinders equipped with adjustable cushions (damping systems) on both ends to avoid mechanical shocks and excessive vibrations?

  • All cylinders aligned – no side/radial loads. Are the pneumatic cylinders installed in such a way so they don't receive a radial load on their shafts?

  • Are the cylinders equipped with adjustable flow control valves on both ends?

1.4. Tubing / Pipes / Hoses

  • Are the flexible lines, hoses, tubing protected from damage, if the weight of the hose assembly could cause undue strain or deflection?

  • Are reusable nylon ties used to bundle tubing together?

  • Tubing is in blue color?

  • Zinc dichromate piping are not painted?

  • Are pipes, fittings, hoses and connections conform to the DIN 2353/ISO 8434-1 standards?

  • When the threads of the pipes and fittings were sealed was only liquid type sealant used?

  • Are the Inlet pipes and passages boxes free of burrs, sharp edges and foreign matter?

  • Where the pipe work and hoses were installed and are subject to a lot of vibration, were isolators used to ensure the attaching?

  • Are there any flexible pipes (hoses) that have a sharp bend in them that may cause enough friction (rubbing) to cause premature wear?

1.5. Air Receivers / Surge Tanks

  • Are the air storage tanks equipped with a condensate dump valve / drain valve?

  • Are the air storage tanks equipped with a safety relief valve?

  • Are the air storage tanks in accordance with the ISO 16528 or local similar regulation? (In case of Brazil NR13 for pressure vessel)

  • Are the air storage tanks equipped with a device for measuring the air pressure?

  • Is the safety relief valve not adjustable over the maximum working pressure of the receiver?

  • Is the pressure gauge provided to show receiver pressure at all times (no isolation valve to be used for this)?

  • Is there a lockable, shutoff valve located downstream, as close as possible to the receiver, and accessible?

2. MAINTENANCE

  • Are pneumatic system modules distributed?

  • Is the pneumatic system dimensioned to operate at a pressure of 5 bars (73psi) or below?

  • Are the pneumatic equipments provided with a power line and maintenance unit in the supply?

  • Are pneumatic units installed in an easily accessible and visible place (no points to slip / trip / hit / fall)?

  • Are pneumatic panels with transparent cover for easy inspection?

  • Are all control pressure gages with glass and collared dial with indication of normal working range done internally and never in the protection glass cover, since it can turn around and defeat the purpose? (normal working range shall be colored green and superior and inferior limit values as red range with the central value of the normal range positioned at 12:00)

  • All exhaust ports fitted with silencers / reclassifies to deflect air downward and away from personnel?

  • Manual blow-off circuit time limited and less than 2 bar (30 psi)?

  • Continuous blow-off circuits should not be used. If required, is it controlled and activated by PLC logic?

  • Do all parts of the pneumatic system designed to operate or otherwise protected against pressures exceeding the maximum working pressure of a system or any part of the system or the rated pressure of any specific component?
    NOTE: The preferred means of protection against excessive pressure is one or more pressure-relief valves located to limit the pressure in all related parts of the system. Other means, such as pressure-regulators, provided these means satisfy the application requirements?

  • Is there only one source of air supply to the machine/equipment including a manually operated safety valve? If not, more than one source must be approved by EMBRACO Maintenance‘s representative in writing?

  • Are Gages, Displays, Pressostats and other devices for viewing and control in place for easy access to the operator? No higher than 1.5 meters off the mounting surface of the pneumatic system.

Lubrication Audit

1. COMPONENTS

1.1. Lubricant Tanks

  • Are the tanks installed at least 150 mm from the floor?

  • Do all lubricant tanks for automated systems have sufficient capacity to operate for 12 hours or more before it becomes necessary to refill them?

  • Do all lubricant tanks for manul and/or mist lubrication systems have sufficient capacity to operate for 24 hours or more before it becomes necessary to refill them?

  • Is the lubricant level gage (service oil, oil tank) easy to view from the inspection position? Is the oil topping up easy?

  • Do the lubricant level gages have minimum and maximum markings?

  • Can the lubricant level indicator be clearly seen from the lubricant supply area?

  • Can the lubrication tank be pulled out in order to obtain a more convenient lubrication process?

  • The diameter of the hole to supply the lubricant tank is not less than 50 mm?

  • Is there at least one opening for the purpose of cleaning the tank? If the tank has internal partitions, does each one have an opening?

  • To facilitate cleaning, were the tanks constructed in such a way that the output of lubricant is at the bottom and is tilted towards the output?

  • Do all the tanks for cooling oil contain hatches to assist in internal cleaning?

  • It is possible to change submersible lubricant pumps without the need for removing the oil?

  • Are lubricant temperature indicators provided?

  • Is there any protection against contamination for the fluid that returns to the tank?

1.2. Lubricant Filters

  • Does the lubrication system have display devices for indicating the saturation of the filter, minimum oil level and lack of oil?

  • Are all the filters equipped with electrical or mechanical visual indicators showing the degree of impurity found in the oil?

  • Do the lubrication units have filters installed in such a way that are easily replaced/cleaned without the need for the removal of the oil?

  • Are the filters single or double switchable installations that operate continuously?

1.3. Lubricant Pumps

  • Is there a manometer for measuring system pressure at the lubrication pump outlet?

  • Does this have a manual shutoff valve to close the compressed air to the lubrication pump? (If this is pneumatic).

  • Are the lubrication pumps pneumatic, manual or electric motor driven? (Except for the single line system where it is not recommended to use manual pumps)

  • Does this have a pressure switch to indicate a high pressure level?

  • If the machine/equipment is controlled by a PLC, is the pump pressure switch connected to this?

1.4. Grease systems

  • In individual grease lubrication points, the grease nipples that are used are the commercial line (Zerk standard) that has the written approval of Embraco for their use?

  • Does the manual greasing systems have a return to a centralized point and is it fully identified?

  • Are the grease nipples angled for easy greasing?

1.5. Lubrication Lines

  • Are the lubrication lines made from rigid tubes? (Except where there is vibration).

  • All pipe work has connections and wall thickness sufficient to withstand the maximum pressures of the systems.

  • Are the lubrication lines located in an area where one cannot use them as a ladder or support (handle)? When this is not possible, protective covers must be provided. The lines that go round corners of the machine/equipment that are exposed to possible damage from external sources, should have a protective cover on these corners.

  • Lubrication lines which are to pass into or through structural parts of the machine/equipment, ends at both sides, in a junction block or a connection box and have no seams in the inner part of the structure?

  • Are all lubrication lines (pipes) firmly fixed with clamps and bolted to structural parts of the machine/equipment?

  • Are the clamps removable?

  • Is the minimum diameter of the grease pipe system is 6mm?

  • The minimum diameter of the oil pipe lubrication system is 4mm?

  • Does the machine/equipment have any protection for cables and hoses, conveyor type or cable support mechanism?

1.6. Manual Lubrication Systems

  • Does the machine/equipment with a manual lubrication system have up to 6 lubrication points?

  • Are all the manual lubrication system lines brought into their respective blocks by a single distribution block, thereby facilitating the lubrication?

  • Is the single lubrication block isolated and clearly identified and referenced in the lubrication manual?

  • Is the single lubrication block installed in such a way that the operator standing on the floor can reach it?

  • With the manual lubrication process it is not necessary to remove components from the machinery/equipment, turning off the air supply, or stopping the operation?

1.7. Centralized Lubrication Systems - General

  • Does all the equipment have a centralized lubrication system?

  • In the case of centralized lubrication, the feeders have snap on connections on the inlet and outlet of lubricant to facilitate the assembly of the piping?

  • The diagram of the lubrication system has been improved in machinery/equipment with centralized lubrication system, with the aim of facilitating its understanding?

1.8. Centralized Lubrication Systems – Simple Line

  • Are the feeders mounted on bars with 1 to 10 outputs?

  • The simple line lubrication system, has feeds fixed directly to the lubrication point and is constituted by only a primary block and an appropriate number of secondary blocks that lead directly to the lubrication point?

  • In the bar feeders is there enough space to replace a single unit without the need to remove the other neighboring feeders?

  • Are all the discharge lines to the lubrication points of the simple line lubrication system having gages in the respective sections of the secondary blocks?

  • Are the feeders independent of the block? In the event of failure of a feeder can this be replaced without the requirement of replacing the whole block?

1.9. Centralized Lubrication Systems – Progressive Line

  • Is the cycle indicator connected to the PLC of the machine/equipment?

  • Are the feeder blocks made up of independent sections or slices of the block, i.e. in case of a failure of any slice this can be replaced without the requirement to replace the whole block?

  • Are the outputs of each feeder block section correctly identified with "O" for one output and "T" for two outputs?

  • All discharge lines to the lubrication points in the progressive system have gages in the respective sections of the secondary blocks?

  • Does the system have a cycle’s indicator in the master block?

1.10. Mist Lubrication Systems

  • Was the mist lubrication system duly authorized by Embraco?

  • Was the system specified and designed as a complete system, including solenoid valves, level switches, pressure switches, air regulators, filters and gages?

1.11. Lubricant

  • Are the types of lubricants clearly specified?

  • Have the varieties of lubricant been reduced to a minimum?

  • The type of lubricant to be used was approved by Embraco?

  • Are the different types of required lubricants easy to be identified?

  • Was a method developed for removing dirty lubricant?

  • The oil consumption and the required quantity are clearly identified?

  • Does the system have heat exchange equipment that uses water? (Only if lubricant return to the tanks with temperatures above 45ºC).

2. DESIGN AND MAINTENANCE

  • Is there a service station for the maintenance of the lubricants and the lubrication equipment?

  • Are the lubrication points of the machine/equipment marked according to the DIN 51502 standard which also indicates the type of lubricant to be used?

  • Is there a procedure to identify lubrication endpoints that are not reachable by the lubricant (e.g. clogging or valve closed)?

  • Do all types of oil or grease feeders have non return valves installed on the line between the metering valve and the lubrication point?

  • All pumps, filters, tanks, lubrication points and so on, are in locations that are accessible for maintenance?

  • There are automatic lubrication systems in areas difficult to access? Do the guides and rails for the machine/equipment’s sliding displacement systems (rails, tables) have automatic lubrication points (centered) and protections (ex: telescopic, folding, scrapers, etc.)?

  • If the machine/equipment, where the lubrication system was installed, uses a PLC is this also being used to diagnose the lubrication components?

  • Are all lubrication devices installed rigidly and, in no case, supported by the hoses and pipes?

  • Are the sight glasses, points of removal and filling of oil, located in such a way to allow easy access for inspection and quick oil change in the shortest possible time?

  • Does the lubrication system have display devices for indicating the saturation of the filter, minimum oil level and lack of oil?

  • Is the supply of the lubricating oil also possible during the normal operation of the machine?

  • Do the components such as 90 ° bends, "T´s" and filters have snap on connectors to make the assembly faster?

  • Are the lubrication devices or pipe-work installed in a position that does not interfere with any adjustment or maintenance of the machinery/equipment?

  • Are there a pressure measuring system installed and interconnected to the equipment´s controlling system to indicate failures on lubrication system and, if there is risk, shut down the equipment?

Electro Electronical Audit

1. COMPONENTS

1.1. Motors

  • Are the AC motors, with squirrel cage rotor according to the following specifications?
    a) Execution and constructed according to ABNT NBR 7094/IEC 34;
    b) Performance category: High performance according to ABNT NBR 7094/IEC 34;
    c) Insulation class: minimum B, according to ABNT NBR 7094/IEC 34;
    d) Protection class: depending on the application IP 54 or IP 55 according ABNT NBR 6146/IEC 34, with the following options:
    - Sealed condensation water output drains;
    - Cable glands in the terminal box;
    - Connecting screw of the ground wire;
    - Terminal blocks;
    - When necessary must be protected against explosive gases or liquids;
    e) Monitoring PTC temperature (in special cases).
    f) Electromagnetic compatibility: according to IEC 60034-1
    g) Noise limits: according to IEC 60034-9
    h) Nameplates: according to IEC 60034 and ABNT NBR 17094 (for Brazil).
    Note: Specified on TST 000138 that these motors must only be applied in exceptional cases and by obtaining authorization from the maintenance area leadership involved. Check if this occurred.

  • Are the DC motors according to the following specifications?
    a) Execution in accordance with IEC 34, IEC 72, VDE 0530;
    b) Constructed according to ABNT NBR 5031/IEC 34;
    c) Insulation class: F, used according to class B (VDE 0530);
    d) Protection class: IP 54 or IP 55 according to ABNT NBR 6146/IEC 34, with the following options:
    - Sealed condensation water output drains;
    - Cable glands in the terminal box;
    - Connecting screw of the ground wire;
    - Terminal blocks;
    - When necessary must be protected against explosive gases or liquids;
    - Monitoring PTC temperature (in special cases).

  • Do motors up to 5.5 kW (7.5 HP) with the option of the following connection groups?
    - 220/380 V;
    - 220/480 V; (Exceptionally for Embraco Mexico)
    - 380/660 V;
    - 220/380/440/760 V

  • Are motors above 5.5 kW (7.5 HP) connected only on 380/660 V?
    NOTE: motors above 5.5 kW should not have direct start.

  • Are there temperature indicators on electric motors?

  • Are all motors commanded by contactors and/or electronic drives and still have individual protection against overload, short circuit and phase failure?

  • Is the Rotation direction marked on motors, gears and shafts?

  • Are the motor terminal boxes installed on the machine/equipment in such a way to allow free access to them?

  • Are all the motors equipped with terminal boxes provided with terminal block plates instead of loose conductors?

  • Are all motors with identification plates according to IEC 34?

  • Are the motor conjugates adequate for application? For starts in star-triangle/delta, the conjugates must be analyzed, case by case.

  • Is the voltage on an electric motor brake the same voltage as the motor? When the motor is controlled by a variable frequency drive, a separately controlled supply source shall control the brake.

  • Is there quick disconnect of electric motors?

1.2. Panel / Cabinet

  • Cables shall enter boxes/enclosures from side or bottom?

  • Are heavy components mounted toward the bottom of the cabinet, as expected?

  • Is the equipment / machine being supplied with preferable control voltage of 24V DC (direct current)?

  • Are the energy inputs placed so that connections are made at the top of the components?

  • Are there Light indicators for machine / equipment status?

  • Are the automation components in a separate place in the electrical panel?

  • Are the electronic control equipments (such as PLCs, CNCs, converters, etc.) located in the cabinet fixed in an appropriate height for easy access?

  • Are heat generating devices / transformers above 750VA be mounted externally, as expected?

  • Was Fold-out tray, for keyboard and mouse as well notebooks, provided in the electrical panels to support during programming activities?

  • Is there a polarized outlet/plug with protection up to 4A, exclusively for programming, installed internally to the panel?

  • Is there an outlet/plug of 10A installed externally to the panel?

  • Are the single-phase plugs used to connect the "programming cases" according to the NFT standard and properly identified? Note: The incorrect connection sequence Neutral-Phase-Ground can cause the burnout of the communication ports of the PLCs, CNCs and Programming Cases by return current.

  • Is there at least one duplex single-phase voltage receptacle and programming port for PLC hardware connection?

  • Minimum 15% panel free space has been provided? This shall not include reserved space for the transformer/disconnect. (Appropriately distributed among power and control voltage sections).

  • Is there a Cooling (forced ventilation with filters or industrial air conditioners) for protection against dust and humidity, at a maximum temperature of 35º C, if panel has electronic components?

  • Is there physical separation in between the electrical main lines and the electronic equipment/circuit?

  • Are there multi-plugs (male and female) for interconnection between cabinet and equipment?

  • Are there multiple male and female sockets for cases where there are interconnections between the panel and equipment, as necessary?
    Note: There must be blocks to prevent plug similarity.

  • Are the electrical panels bigger than 1200mm with internal lights?

1.3. Hardware

  • Do PLCs, CNCs and Robots have 20% of available memory as a technical reserve? (minimum 1 spare slot).

  • Are the points of I/O far from the panel containing the main CPU, using distributed I/O?

  • Do PLCs, CNCs and Robots have at least one available Ethernet communications port to enable remote maintenance and facilitate connectivity with MES (Manufacture Execution System)?

  • Do the control panel external I/O points where the PLC/CNC CPU is located use distributed I/O technology?

  • Is there Spare cable length for small panel moves?

  • Are 10% spare conductors and terminals provided? - (minimum of 4 for terminal boxes).

  • Are the panel wire raceway no more than 50% fill?

  • Are the external raceways no more than 50% fill?

  • Are the Cable connector assemblies with 10% spare wired pins? - (minimum of 4).

  • Are the proximity switches with well supported holders and quick change connectors?

  • Are the sensors connected with plugs and sockets?

1.4.Energy conservation

  • Are the motors sized at more than 80% of full load rating?

  • Are there soft starters on motors larger than 50 HP / 35KW?

  • Is the machine/equipment power factor, with power exceeding 15 kW, between 0.94 inductive and 0.94 capacitive, in accordance to Embraco standard?

1.5. Main Enclosures

  • Do Main panels with a PLC or PC have a folding shelf on the outside of the cabinet, an A3 drawing pocket, and a 110/120 Volt receptacle provided near the PLC?

  • Do Panel doors with electrical components mounted in them have an earth (grounding) bond using a flat-braided copper cable?

  • Do all panel doors are fitted with a 7mm square lockable handle?

  • Do the exterior of enclosures are painted RAL 7035 (Light Gray)? Do the interior of cabinets are painted White? Do the backplanes are painted White or galvanized?

  • Do all equipments are mounted between 0.4 meters and 1.8 meters from the working surface?

  • Are there door "stays" on all main electrical enclosure doors?

  • Are higher voltage components and terminals segregated from lower voltages components and terminals?

  • Is all cabling on the base of the cabinet neatly stored and adequately protected or cable tray / ducting?

  • Are the air conditioners setup, operated properly, and controlled by door switches and thermostats?

  • Are the electrical enclosures fitted with glass windows wherever possible for visual management?

  • Are all guards and covers transparent where internally visibility is required? Are there transparent covers for easy panel checking?

1.6. Junction Box, Operator Panels and Pushbuttons

  • Are the control circuit power conductors pulled with their respective grounded circuit conductors (neutrals) for trouble shooting?

  • Do the pushbuttons and pilot lights follow color code specification?

  • Are all junction boxes connected to ground / earth and connected back to main panel?

  • Are the terminal box covers fitted with a 7mm square locks?

1.7. Cable, Wire and Control Circuits

  • Are the wire colours according to TST 000138? Is wiring properly "triple" marked?
    Note: Identify the phase sequence in the supply conductor points, whose sequence is always clockwise.

  • If lineside wiring is specified, is it installed using proper wiring colors, separation, etc?

  • Are Jumpers for circuits greater than 50 Volts made from insulated stranded wire?

  • In busbars and terminal blocks not totally isolated where the tension is higher than 50 Vac, is there a clear polycarbonate protection? Are there holes in these protections so the tips of the multi-test can touch the busbar during the maintenance procedures?

  • Cables for analog electronic signals, thermocouples and the like must have electromagnetic shielding. Foresee individual channel or duct in the case of extension cables for thermocouples. In this machine/equipment, are these conditions being respected?

  • Are there extra wires run for future repairs or application requests?

  • Is there quick opening connection boxes?

  • Are there rapid clamps and connections that must be at the same time reliable?

  • Are wire terminal blocks with pressure spring (spring-cage, auto-spring and insulation displacement connectors) instead of screws?

  • Is the wiring composed of flexible cables with thermoplastic PVC insulation for 750V control and 0.6/1 kV power?

  • Is cabling appropriately routed and protected? Check that flex-cable is used in flexing applications.

  • Are none control devices installed in connection or junction boxes as expected?

1.8. Field Device

  • All metal parts belonging or not to the machine/equipment, not normally subjected to circuit current loads, must be connected to the ground through the grounding conductors. These will be connected to the grounding dissipation electrode, which are embedded in the soil, creating a safe ground, "protection". NBR 5410:2004 item 5.1.2.2.3, IEC 60364-5.
    The machine/equipment’s connection system must follow the TN configuration, a system which is consistent with EMBRACO’s system. NBR 5410 Item 4.2.2.2.1., IEC 60364-5. Are these conditions in accordance for this machine/equipment?

1.9. Programming, PLCs, HMIs and MES

  • Are the machine / equipment condition trends shown on the operator’s panel?

  • Does the programming logic follow the standards (structure, required blocks, motion backchecks and interlocks)?

  • Do the HMI screens follow the standards? All HMI required functionality is present?

  • Is the "Battery Low" signal displayed, either in HMI or an indicator light, for battery supported devices?

  • Is the cycle time display set up and the information correctly displayed?

  • If a UPS was specified, is the PC shutdown software loaded and correctly functioning even when power is unexpectedly removed?

  • Were the productivity requirements for the machine reviewed with the OEM? Check that machine specific configuration has been completed by the OEM and Embraco activity responsible .

  • Is the MES PLC function block loaded?

  • Is there a visual graphical layout of the machine shown at the operator panel so that the process and flow are easy to understand?

  • Are there machine / equipment sequence step screens?

  • Does it have starting conditions at screen?

1.10. Industrial Information Technology

  • Are there Hardware/Software for PCs and Data Collection protocols? If available on this machine/equipment, please refer to chapter 4 of the TST 000138 starting from item 4.4.3 and report the results in this checklist.

1.11. Automation / Robot

  • Is there a "Teach Mode" functionallity? – Selection And Operation (Auto Mode Not Allowed)

2. MAINTENANCE

  • Are the failure alarms and operation messages where it applies to diagnostic devices (ex.: synoptic, video monitor, terminal operation, etc.) in the language of the country where the machine/equipment will be installed?

  • Are Cables and wiring easy to identify and quick to substitute?

  • Can the machine / equipment indicate the root cause (the main cause, not all alarms/events generated) of a machine stop?

  • Are the alarms stored in memory with enough space for past data retrieval?

  • Does it have built – in breakdown diagnostic for detecting abnormalities, tracing causes, and restoring normal operation, or be easily diagnosed?

  • Is there any record of main functions important data in the machine / equipment that helps failures analysis tracking?

  • Does it have any self-diagnostic functions to issue messages describing the location and nature of any breakdown built in?

Functional Tests

1.1. HYDRAULIC

  • Hydraulic Pressure Loss: Check loss of pressure by creating a hydraulic system sensor fault (no damage shall be possible). Equipment shall react as agreed upon in writing between Embraco and OEM. Check Hydraulic restart ability after recovering from the system fault.

  • Level and Temperature Switches Fault: Check running temperature of hydraulic system and look for signs of overheating. Induce the following faults: 1.Low Level 2.Dirty Filter 3.High Temperature, and verify that they cause the machine stop at the end of the current cycle, all pressure is dissipated, display the correct message (HMI) or indication to the operator, and not start again until the fault is corrected.

  • Tank and Filters: Was the hydraulic storage tank tested properly before shipment? Was the tank drained and cleaned? Were the filters elements replaced with new? Was a certification form issued with the hydraulic tank?

1.2. LUBRICATION

  • Grease: Insure grease is getting to each bearing.

  • Lubrication Fault: Induce the following faults: 1.Low Level 2.Dirty Filter 3.Zone Switch 4.Lubrication solenoid 5.Air solenoid (if equipped) 6.Verify Auto Lube systems cycles at designed frequency, and verify that they cause the machine stop at the end of the current cycle, display the correct message (HMI) or indication to the operator, and not start again until the fault is corrected.

  • Are there are any points where oil can accumulate?

  • Lubrication system: Assure it can be started from any station as well as the operator console.

  • Does the machine/equipment need to stop operating to receive proper lubrication?

  • After the tests were all filters and lubricants used replaced?

  • The shortage of lubricant is signaled by warning lights and/or blocking of the circuit, turning off equipment at the end of the cycle?

  • In simple line systems the maximum pressure does not exceed 30 bar?

  • In progressive systems the maximum pressure does not exceed 100 bar?

  • For test purposes, a stainless steel 1/8 inch or compatible material with the system pressure outlet socket was installed with a needle valve in the pump outlet line between the pump and the oil filter? (When there is more than one pump, and the outlet socket and the valve will be installed on a common line pumps, before the filter. In systems where the installation of the outlet socket is impractical, install an outlet socket in the tank, at the average operating level.)

1.3. PNEUMATIC TESTS

  • Power down and E-stop: No trapped air in system when machine is E-Stopped or powered down.

  • Air Pressure Loss: Check loss of pressure by closing the main air shutoff valve. Equipment shall react as agreed upon in writing between Embraco and OEM. Check Pneumatic restart ability after recovering from the system fault.

  • Air consumption test: Overall air consumption for the equipment shall be shown and an actual metered test must be demonstrated prior to shipment.

  • Air Tanks: Were manufacturer's test certificates provided?

  • Clamping systems: Whenever a pneumatic device works as a means to hold parts, it shall be ensured that the part will not be released in case of air leakage or pressure variation at the feeding line or energy fall.

  • Main Air Pressure Fault: Induce this fault and verify that it causes the machine stop at the end of the current cycle, display the correct message (HMI) or indication to the operator, and not start again until the fault is corrected

1.4. ELECTRO ELECTRONICAL TESTS

E-STOP:

  • E-Stop: Verify all E-Stop PBs are working properly during various parts on the equipment cycle.

  • E-stop Circuits: Spot check functionality by breaking and restoring one channel to make sure system does not restart and the relay does not reset.

  • E-Stop: the machine at various parts of the cycle (transfer motions, advancing, returning, clamping, unclamping, etc.) and verify that the machine can be re-started.

  • E-Stop Recovery: Discuss the best method with the OEM to test recovery after an E-Stop at the "most complex" part in process while cycling (without cutting tools or no part(s) or both) and servo axis in "mid-travel". Check that parts will NOT be dropped.

  • E-Stop: a station that is in shutdown mode while a jog move is being made.

Emergency return:

  • Emergency return: the machine at various parts of the cycle (transfer motions, advancing, returning, clamping, unclamping, etc.) and verify that the machine can be re-started.

  • Emergency return: At a local station select semi-auto. Check that only that station will return.

  • Emergency return: At local station select automatic. Check that all units return to start position.

  • Emergency return: Select manual. Check emergency return is reset at local station

Manual and Automatic Cycle:

  • Manual Cycle: Verify Single Cycle works properly.

  • Manual Cycle: Verify all manual functions operates properly.

  • Automatic Cycle: Operate Stop at End of Cycle button(s) during various parts of the machine cycle (transfer motions, advancing, returning, clamping, unclamping, etc.).

  • Automatic Cycle: Check machine will restart auto cycle from the main console after any of the above.

  • Automatic Cycle: Check machine will restart only if all units are in the correct position.

  • Automatic Cycle: Select transfer screens on a station and ensure hydraulics will start.

  • Automatic Cycle: Ensure safety gates are operated after each of the above tests.

  • Automatic Cycle: Ensure gate access timers are set correctly.

  • Automatic Cycle: Check operation of virtual console at every station.

  • Automatic Cycle: Check all stations display the correct restart message (no fault).

Power off / Shutdown:

  • Energy Dissipation on Shutdown: Check that all energy is dissipated on shutdown or shall react as agreed upon in writing between Embraco and OEM.

  • Power Off at Main Disconnect: Verify Main Disconnect is functioning properly.

  • Power Off at Main Disconnect: Switch OFF main disconnect when the transfer bar is advancing.

  • Control Shutdown: Ensure all hydraulic pumps shutdown after a timed duration of 20 mins after machine has stopped at end of cycle and timed out.

  • Control Shutdown: Ensure air purge shutdown 30 mins after hydraulic pump has shutdown.

  • Control Shutdown: Ensure all spindles shutdown after a timed duration of 10 mins after machine has stopped at end of cycle and timed out.

Tool Change:

  • Tool Change: From the main console, operate return heads to tool change button all heads should move to their tool change position.

  • Tool Change: Check at each station that the tool change function is operational.

  • Tool Change: Check on index heads that the current head selected for part type is indexed to the tool change gate.

  • Tool Change: From the main console, cycle the machine in automatic all heads should cycle from their tool change position.

Teach Pendant (hand wheel):

  • Teach Pendant (hand wheel) Function: With the machine / gantry in Manual and teach pendant hooked up, check the jog speed of each axis. It should be 10% of normal running speed.

  • Teach Pendant (hand wheel) Function: Verify, if so equipped, that the points can be taught from the teach pendant.

  • Teach Pendant (hand wheel) Function: Verify liveman switch functionality (i.e., axis stops when liveman switch is released and when it is pushed to the end stop).

  • Teach Pendant (hand wheel) Function: Verify HMI is not able to move the gantry while the teach pendant is plugged in.

  • Teach Pendant: 1. Check to ensure HMI controls are disabled while teach pendant is active (there must be only one point of control at a time). 2. Check that liveman switch functionality removes motive power and machine immediately stops. 3. Check that the machine speed is reduced while manually moving machine axes. 4. Check E-stop functionality of teach pendant and that is hardwired and control reliable.

Others:

  • Initiate Manual Motions: Spot check that all manual motions are available and recovery from any position is possible. Use manual overrides on a valve(s) to place machine out of position/sequence and recovery from HMI and that no crash conditions can occur.

  • Machine Motions on Startup: Check the operation of visible (stack light) and audible (horn if equipped) conditions at startup. NOTE: Some machines have hardwired mode buttons so manual and AUTO modes may not drop but AUTOCYCLE MUST always drop.

  • Safety Devices: Check to see that all motive power (24volt power to outputs) is removed and that energy is dissipated when each safety device is actuated (E-stop, guard door, light screen, etc.). Attempt to place machine in a mode and start while E-stop is still pressed (nothing should happen). NOTE: For machines with multiple E-stops and or safety devices, after pulling out initial E-stops, reset and verify that the power is restored to the safety relay. Proceed to the next safety device and repeat and until all safety devices have been verified.

  • Machine Interlocks Strategy: Spot check that no crash-conditions are possible from HMI and review logic to see interlocks are in place. Check to see that sensors are guarded from the "environment" (chips, coolant, etc) to ensure the program receive correct information. Check logic and ask OEM to explain how "part clear signal" is achieved and that parts cannot be "double loaded". NOTE: OEM shall eliminate any potential machine crash with logic interlocks. Guiding principle: If the information to the PLC is correct programmed properly, the possibility of a machine crash is effectively eliminated.

  • System Interlock Strategy: Insure associated machine reacts as agreed upon in writing between Embrao and OEM when a safety device is actuated. Insure that the correct fault / diagnostic message appear on the HMI as well.

  • Homing Routines (If applicable): Spot check for recovery from "complex" machine positions.

  • HMI Diagnostic: unplug out a sensor / solenoid and check whether the I/O ID of the component is displayed correctly at HMI.

Training Audit

  • Does the supplier have a setup training plan?

  • Does the supplier have an operational training plan?

  • Does the supplier have a mechanical maintenance training plan?

  • Does the supplier have a electrical maintenance training plan?

  • Does the supplier have a software PLC training plan?

  • Does the supplier have a CNC programming training plan?

  • Does the supplier have an Information Technology (IT) training plan?

  • Does the supplier have a Measurement training plan?

  • Does the training plan consider the main topics to be taught to the involved team?

  • Does the training plan consider the suggested training schedule, duration and place?

  • Does the training plan consider the instructor?

  • Does the training plan consider the Machine/Equipment safety, operation and maintenance procedures?

  • Does the training plan consider the Machine/Equipment functional descriptions?

  • Does the training plan consider the Machine/Equipment failures and troubleshooting procedure?

  • Does the training plan consider the Machine/Equipment critical spare parts replacement procedure?

  • Does the training plan consider the Machine/Equipment devices calibration procedure?

  • Does the training plan consider the Machine/Equipment recommended maintenance activities procedure?

  • Does the Training Certificate was issued and delivered to all involved team members?

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