U625 Aggressive Tooling - Final Gage

Title Page

Machine Components

1. Equipment List

PLC controller
PLC Controller picture
Switch Cell NAT
PICTURE
HMI
PICTURE
I/O in Cabinet
PICTURE
I/O on Machine
PICTURE
I/O on Tool
PICTURE
Printer Cell
PICTURE
Remote Controller
PICTURE
Switch Embedded
PICTURE
Guard locking and access control
PICTURE
Ethernet switches, connectors, and cables
Valves
Identification Rules Ethernet Device and cables
- Device ID family+ Number
- IP address
- Ethernet cable: example CLX1/HMI1.1
If not record what is there and take pictures
ID rules for Network Devices and Cables picture
Laser Etcher
Programming Port and Outlet

Machine Sign out Checklist

1. Is this a new technology or process that requires special evaluation?
2. Has the supplier provided the receiving Plant ME and Plant HSE Engineer with a document confirming that the equipment being shipped?
3. The design Review documentation available showing conformance to the FCM specs and EHSR &Ergonomics requirements?
4. Easy access to tooling, adjustments, or gages AND easy replacement of valves, cylinders, toiling, etc?
5. Fixtures labeled with Capacity Rating AND designed to avoid personnel falling off?
6. Colors<br>
7. Components list and spare parts
Documentation list
3rd party SISTEMA report
As-Built Electrical and MECHANICAL drawings
Complete Sequence of Operation
Printed and Electronic copies of all software programs
Operator AND Maintenance Manuals
Connection diagrams for all components
Completed Risk Assessment
Completed Failure Modes and Effects Analysis
FCM provided asset number
The safety related control systems FAIL SAFE. All the push buttons are outside the danger zone
LOTOTO

Cycle control have button located separate from electrical cabinets
Trap door are required space increasing distance between equipment
Total width of manufacturing equipment is equal or less than 120% of part width
When practical based on size, weight, and movement requirements is manufacturing equipment mounted on wheels?
Levels 1 and 2 maintanence can be performed by operators without moving the manufacturing equipment? (FCM TPM)
The equipment designed at different Takt times?
Auto eject present
The completed part is taken out of the machine at the same location at which it was put in?
Designed to stop if produces bad parts? (POKE Yoke validated)
The cycle start button can be reallocated on the machine under satisfactory safety conditions (light guard to pass MR #4
Single part every cycle
The machine can be started up instantly AND the 1st piece OK check can be done within one cycle time?

The machine can’t pass bad parts. Poka Yoke to address all S/R, KCC (critical characteristics of the produce), and KPC as defined in the previously completed Designed Failure Modes Effects Analysis (DFMEA) and Process Failure Modes Effects Analysis (PFMEA)
Poka Yoke confirmed?
A 20h dry run has been completed at the supplier?
A sample run has been performed at the supplier facility including a full tool change over in less than 10 min or deviation
Safety controller?

Extra