Conveyor Standards ME-Conveyor Group

Conveyor Mechanical Specifications

Section 25.0 – Carrier Build and Validation

Index
Intent ............................................................................................................................. 4
Definitions ...................................................................................................................... 4
Safety ............................................................................................................................. 4
Repair Spur..................................................................................................................... 4
Carrier Design ................................................................................................................. 4
25.5.1 Design Considerations ....................................................................................... 4
25.5.2 Product Data & Changes .................................................................................... 5
Design Format ................................................................................................................ 5
Design Details ................................................................................................................. 5
25.7.1 Carrier detail mounting ..................................................................................... 5
25.7.2 Shims.................................................................................................................. 5
25.7.3 Clearances – details to product ......................................................................... 6
25.7.3.1 Clearance at Locators ........................................................................................ 6
25.7.3.2 Clearance at Pins................................................................................................ 6
25.7.4 Build Tolerance .................................................................................................. 6
25.7.5 Adjustability ....................................................................................................... 6
25.7.6 Product surface protection ................................................................................ 6
25.7.7 Stabilization ....................................................................................................... 6
25.7.8 Personnel protection ......................................................................................... 6
25.7.9 Product contact points ...................................................................................... 6
25.7.10 Paint Shop Carriers ............................................................................................ 6
25.7.11 Phosphate E-Coat Carriers ................................................................................. 7
25.7.12 Fusion Welding .................................................................................................. 7
Design Review ................................................................................................................ 7
FEA (finite element analysis) ........................................................................................... 7
FMEA (failure mode effects analysis) .......................................................................... 7
Multiple models per carrier ........................................................................................ 7
Interaction with Tooling Line Integrators .................................................................... 7
25.12.1 3D models of carriers......................................................................................... 8
25.12.2 Interferences with Tooling equipment .............................................................. 8
Deliverables – Carrier Design ...................................................................................... 8

Page 1 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

Prototype Carrier Build ............................................................................................... 8

25.14.1 Use of Jigs .......................................................................................................... 8
25.14.2 Weld Validation ................................................................................................. 8
25.14.3 Level ................................................................................................................... 8
25.14.4 CMM .................................................................................................................. 9
Prototype Carrier Validation ....................................................................................... 9
25.15.1 Track mounted................................................................................................... 9
25.15.2 Product for Tryout ............................................................................................. 9
25.15.3 Product Review .................................................................................................. 9
25.15.4 Tilt Test .............................................................................................................. 9
25.15.5 Comments/Changes .......................................................................................... 9
25.15.6 Master Carrier.................................................................................................... 9
25.15.7 Prototype at Tooling Line Integrator ................................................................. 9
25.15.7.1 Set-up............................................................................................................... 9
25.15.7.2 Feedback ........................................................................................................ 10
25.15.7.3 Review............................................................................................................ 10
25.15.8 Validation Approval ......................................................................................... 10
25.15.9 Deliverables – Prototype Carrier ..................................................................... 10
Gauge Engineering ................................................................................................... 10
25.16.1 Gauge Quantities ............................................................................................. 11
25.16.2 Design Considerations ..................................................................................... 11
25.16.3 Design Format.................................................................................................. 11
25.16.4 Design Details .................................................................................................. 11
25.16.4.1 Shims & Adjustability ..................................................................................... 11
25.16.4.2 Gauge Points .................................................................................................. 11
25.16.4.3 Measurement Tools ....................................................................................... 11
25.16.4.4 Counterbalanced Details ............................................................................... 12
25.16.4.5 Gauge measuring accuracy ............................................................................ 12
25.16.4.6 Gauge Construction ....................................................................................... 12
25.16.4.7 Carrier Camber............................................................................................... 12
25.16.4.8 Carrier Bearing Surface Wear ........................................................................ 12
25.16.4.9 Manually Loaded Carriers .............................................................................. 13

Page 2 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

25.16.5 Design Review.................................................................................................. 13

25.16.6 Gauge SOP ....................................................................................................... 13
25.16.7 Deliverables – Gauge Design ........................................................................... 13
Gauge Build .............................................................................................................. 13
25.17.1 CMM ................................................................................................................ 13
Master Carrier Use ................................................................................................... 13
25.18.1 For new conveyance systems .......................................................................... 13
25.18.2 For existing conveyance systems .................................................................... 14
25.18.3 CMM Data ........................................................................................................ 14
Gauge Installation and Set Up................................................................................... 14
25.19.1 Location ........................................................................................................... 14
25.19.2 Conveyance Requirements .............................................................................. 14
25.19.3 Set Up .............................................................................................................. 14
25.19.3.1 New conveyance systems .............................................................................. 14
25.19.3.2 Existing conveyance systems ......................................................................... 14
Carrier Build ............................................................................................................. 14
25.20.1 Weld Testing .................................................................................................... 15
25.20.2 Painting ............................................................................................................ 15
Carrier Management Plan ......................................................................................... 15
Carrier Installation ................................................................................................... 16
25.22.1 Pre-installation Gauging .................................................................................. 16
25.22.2 Lifting / Handling Carriers ................................................................................ 16
25.22.3 Carrier / Running Gear Assembly .................................................................... 16
25.22.4 Carrier Gauging ................................................................................................ 16
25.22.5 Validation ......................................................................................................... 17
25.22.5.1 During Carrier Installation ............................................................................. 17
25.22.5.2 Functionally.................................................................................................... 17
Carrier Lift Assist ...................................................................................................... 17
Mechanical Interface/Electrical Interlocks ................................................................ 17
25.24.1 Mechanical Interface ....................................................................................... 17
25.24.2 Deliverables - Mechanical Interface ................................................................ 18
25.24.3 Electrical Interlocks .......................................................................................... 18
25.24.4 Deliverables - Electrical Interlocks ................................................................... 19

Page 3 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

Intent
This carrier specification shall apply to all mainline and subassembly carriers. FCA can make
exceptions for simple carriers such as tire hooks. Our goal is to provide a specification that
clearly states the process that will produce high quality, reliable conveyor carriers

Definitions
For all purposes of this Guideline, except as it is otherwise expressly provided herein, or unless
the context otherwise requires, the terms defined shall have the meanings assigned to them in
as noted below.
 “Designer” refers to entity hired to design/build/install carriers
 “Owner” refers to FCA ME Group
 “User” refers to the assembly plant
 “Tooling Line Integrator” refers to FCA Tooling Line Integrator

Safety
New and/or modified carrier designs shall be subject to FCA Corporate Safety approval.

Repair Spur
All carriers shall have a pull off repair spur or a designated area for carrier repairs. The spur will
be designed to handle a minimum of three carriers. Sufficient space shall be provided for the
carrier gauge and a storage location with installation gates to facilitate removal of a carrier.
Refer to FCA Conveyor Mechanical Specification section 1.22 for service rail requirements and
section 22 for repair spur requirements.

Carrier Design
The design shall follow the requirements set forth in this document and is the full responsibility
of the Designer to provide a successful design. Carrier Design shall be considered to incorporate
all aspects of design work – i.e. meeting minutes, 3D design, 2D detail, presentations, CMM,
buy-off, mark-ups, and test validation.

25.5.1 Design Considerations

The Designer shall take the following items into consideration when designing the carrier:
 Require part orientation at both load and unload
 Style of conveyor
 User feedback
 Clearances between parts and/or other carriers

Page 4 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

 How the part will be transfer to/from the carrier

 End-effector design of transfer equipment
 Special needs of Tooling Line Integrator (position tolerance, orientation, etc.)
 Part/product weight
 How the carrier will be positioned
 Stack-up tolerances on conveyor
 Closures in partially opened positions due to paint props

25.5.2 Product Data & Changes

The product design will change and update during the assembly system and process
development. It is the Line Integrator’s obligation until Final Buyoff and/or Job 1 + 60 days, to
download latest product data and investigate all process and product changes and proposals at
no additional cost to FCA. Product download and evaluation for changes is estimated but not
limited to a minimum of 6 times.
 Program kick-off
 Basic & Detailed Design Verification (EEM Step 2)
 Prototype Carrier buy-off
 Manufacturing & Installation (EEM Step 3)
 Pilot & Launch (EEM Step 4)
 Final Buy-off / Job 1

Design Format
The Designer shall develop the carrier in a 3D solids system in a format compatible with NX.
When providing a non-native NX file, the part must be an assembly with individual components
(not monolithic). Model shall be in body position.

Design Details

25.7.1 Carrier detail mounting

Carrier details making contact with an in-process vehicle and vehicle sheet metal shall be
provided on mounting plates bolted to the carrier perch. Mounting plates shall consist of
elongated or oversized bolt holes to permit adjustment of detail. Mounting plate size and shape
shall take into account detail adjustment range to ensure proper fit and tolerances. Mounting
plates and details shall be square to the body.

25.7.2 Shims
Carriers shall be provided with shims between the detail mounting plate and the carrier perch.
The contractor will utilize shims as necessary during the carrier gauging process. Once the
carriers are correctly gauged and details are bolted to the carrier, the mounting plate and shims
shall be tack welded to the carrier. Shim packs shall be 0.25” [6.4mm].

Page 5 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

25.7.3 Clearances – details to product

25.7.3.1 Clearance at Locators

Unless otherwise specified, cross-car and fore/aft clearance between mainline carrier
locators and body sheet metal shall be 0.188” [4.8mm] measured from Catia data.
Subassembly carriers shall also incorporate 0.188” [4.8mm] clearance between carrier
locators and subassembly surfaces.

25.7.3.2 Clearance at Pins

Unless otherwise specified clearance around locating pins and mainline body PLP
holes shall be 0.188” [4.8mm] measured from Catia data.

25.7.4 Build Tolerance

Build tolerance for all carriers shall be no greater than +/- .125 [3.2mm]

25.7.5 Adjustability
All mainline carrier fore/aft locators shall be adjustable by a minimum of 0.25”[6.4mm] from
center in both the fore and aft directions. All cross-car locators shall be adjustable by a
minimum of 0.25” [6.4mm] from center in both the left and right directions. All carrier locating
pins shall be adjustable by a minimum of 0.25” [6.4mm] fore/aft and left/right of center.
Subassembly carrier perches/nests and locators shall be adjustable by a minimum of 0.25”
[6.4mm] in all (3) axis (x, y & z). After final alignment, all locators and pins shall be welded.

25.7.6 Product surface protection

If class A surfaces are used in for product nesting, FCA approved protection from
scratching/marring must be provided.

25.7.7 Stabilization
All carriers that interface with automatic or manual process stations (i.e. load or unload) shall
include carrier stabilization features as approved by FCA. The Designer shall ensure that
included stabilization holds the carrier within the clearance tolerances. Remember that
tolerances stack-up.

25.7.8 Personnel protection

All carriers with details that are in areas of production personnel access must ensure that no
sharp edges are permitted. Bolts and fasteners that may loosen due to process operations must
be matched-marked for ease of identifying if the bolt or fastener becomes loose.

25.7.9 Product contact points

Load bearing capability of product contact points shall be approved by AME Product Engineers.
Failure to do this could create ISD or deformation of the product.

25.7.10 Paint Shop Carriers

Paint shop carriers that convey units through Powder/Prime or Topcoat shall have cone shaped
set screws located on all horizontal product touch points. The purpose of these points are to
break through paint build up on the touch points created from overspray, in order to provide a

Page 6 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

grounding connection between the body and the carrier. This grounding is required for
electrostatically applied paint for increased transfer efficiency. The cone pointed set screw shall
be 0.250” [6.4mm] diameter x 0.50” [12.7mm] long. The horizontal touch point on the carrier
shall be drilled and tapped. The cone shaped set screw shall be secured in place using a tack
weld to the bottom of the screw after setup has been approved by FCA.

25.7.11 Phosphate E-Coat Carriers

 Four locks per body on systems 50 JPH and over.
 Front to back carrier support points need to be spaced a minimum of 50% of the body
length apart with a minimum of four (4) support points.
 Carrier support details shall have lead-ins on all sides
 Touch points on carrier shall be minimized to allow for maximum E-Coat coverage.

25.7.12 Fusion Welding

All carriers exposed to fusion welding processes that incorporate carrier grounding shoes, shall
electrically isolate their free trolleys.

Design Review
The Designer shall have a carrier design review meeting to present the 3D model for review and
acquire preliminary design approval by the Owner. It is the Owner’s responsibility to ensure the
Designer validates all aspects of his design during this review; however, this does not preclude
the Designer’s design responsibility. Meeting minutes of this review shall be taken by the
Designer.

FEA (finite element analysis)

After the Design Review and before any fabrication, the Designer shall perform a FEA on each
carrier type that conveys loads over 100lbs. The carrier must meet or exceed the required
Factor of Safety of >4.0 on yield strength. The FEA shall include a measurement of the number
of cycles to failure (fatigue life). The FEA shall be reviewed and stamped by a Professional
Engineer licensed in the state where the plant is located.

FMEA (failure mode effects analysis)

The Designer shall perform a FMEA on each carrier design.

Multiple models per carrier

When a carrier conveys more than one style or one part the Designer shall ensure that a 3D
model is provided for each style or part in body position.

Interaction with Tooling Line Integrators

Throughout the carrier design process the Designer is responsible to maintain communications

Page 7 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

with the Tooling Line Integrators in regards to carrier design.

25.12.1 3D models of carriers

The Designer shall make 3D models of the carrier design available to the Tooling Line Integrator
for the Tooling Line Integrator to provide feedback on feasibility with his design.

25.12.2 Interferences with Tooling equipment

The Designer shall request from Tooling Line Integrator(s) designs of the end-effector or transfer
equipment for review and design coordination.

Deliverables – Carrier Design

Deliverables include:
 Approved Carrier design(s) in 3D and 2D
 Review meeting minutes
 PowerPoint Presentation(s)
 3D model(s) placed in Team Center
 FEA(s)
 FMEA

Prototype Carrier Build

The Designer shall provide a prototype of each carrier type for use in validation. Quantities of
prototype carriers shall be detailed in the bid specification for the program. Prototypes may be
required by Tooling Line Integrators during tool build and debug.

25.14.1 Use of Jigs

The Designer should incorporate the use of jigs in all levels of carrier build. Final assembly of the
prototype carrier shall require the use an assembly jig.

25.14.2 Weld Validation

The Designer shall magnaflux test 100% of the weld joints on each type of prototype carrier.
This test shall be performed by a qualified 3rd-party testing company engaged in this type of
work. The Designer shall provide the Owner with a report prepared by the testing company
which details the test results. If the tests show statistically poor quality of welds, the Designer
shall be required to test 100% of the welds on all new carriers being provided at no additional
cost to Owner.

25.14.3 Level
Use a laser level or four to eight foot (appropriately sized) spirit level to check all the details
pre/post CMM check while carrier is secured in checking fixture or similar plane. Check side-to-
side and front-to-back details and use shims if needed to set a zero horizontal plane.

Page 8 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

25.14.4 CMM
The Designer shall CMM the carrier to ensure proper placement of all carrier details.

Prototype Carrier Validation

25.15.1 Track mounted

The Designer shall track mount the prototype carrier for review with product. The track shall
match the final track style and be mounted in such a way that a tilt test can be performed.

25.15.2 Product for Tryout

The Designer shall provide the Owner with a written request stating all product types required,
with timing, to support carrier validation. This request shall be made at least 8 weeks before
required need.

25.15.3 Product Review

The Designer shall load the required product onto the carrier for review. The Designer shall
demonstrate that all design criteria related to product/carrier integration has been achieved.

25.15.4 Tilt Test

All carriers must be tilt tested for product stability at the maximum incline/ decline angles
encountered on the conveyor path. PTEC/D carriers to be drop tested with a deck crane using
±5° of the steepest curve. The tilt/drop test shall include complete body with all closure/prop
tooling.

25.15.5 Comments/Changes
Any comments/changes shall be recorded on carrier design drawings.

25.15.6 Master Carrier

After reworking the prototype carrier based on the validation comments and recertifying the
perch locations based on CMM, the prototype carrier can now be painted and labeled as the
Master carrier.

25.15.7 Prototype at Tooling Line Integrator

25.15.7.1 Set-up
Set-up at the Tooling Line Integrator requirements shall include:
 The Designer may be required to provide a track section to the Tooling Line
Integrator per bid package requirements. Any section shall have carrier
stabilization included.
 The station is setup dimensional by the Tooling Line Integrator using the approved
Mechanical Interface drawings. The Designer may also provide the Tooling Line
Integrator with drawings showing a typical load/unload station for further
dimensional information not in the Mechanical Interface drawings. Refer to
Section 25.23 for additional information on the Mechanical Interface and
Electrical Interlock drawings.

Page 9 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

 It is not required to have auto functionality of the conveyor section and/or

components. If a stop and positioner are provided they can be engaged manually.
Refer to Section 25.23 for additional information on the Mechanical Interface and
Electrical Interlock drawings.
 If a conveyor stop and/or positioner are not provided the Tooling Line Integrator
is required to ensure the carrier is secured in the proper location.

25.15.7.2 Feedback
The Designer shall maintain communications with the Tooling Line Integrator to ensure
that any feedback on carrier’s design/capability is captured. The Designer is responsible
for any carrier changes required to ensure successful tooling integration during this
stage.

25.15.7.3 Review
The Designer and Owner shall meet with the Tooling Line Integrator for a formal review
of the Tooling Line Integrator’s setup and operation. Load/Unload capabilities shall be
observed to ensure proper operation, clearances and timing are achieved. Minutes shall
be taken and a sign-off of carrier capability shall be signed by all parties.

25.15.8 Validation Approval

Carrier design drawing shall be used for formal approval of design at conclusion of this
validation. For this approval Designer shall provide a carrier design drawing with signature box.
Approval signatures shall include Designer, Owner, and any other Team Members that the
Owner deems required. Scanned copies of the signed drawing shall be transmitted to all
attendees.

25.15.9 Deliverables – Prototype Carrier

 CMM data
 Carrier validation sign-off
 Final carrier detail (shop fabrication) drawings in both PDF and native format.
 Final carrier 3D model in NX compatible format.
 All aspects of carrier design (see 25.13) shall be placed in Team Center
 Master Carrier
 Prototype carriers for Tooling Line Integrator use (if required by program)

Gauge Engineering
The Designer shall design all carrier gauges per the requirements in this document and per the
FCA Conveyor Mechanical Specifications. Carrier Gauge Design shall be considered to
incorporate all aspects of design work – i.e. meeting minutes, 3D design, 2D detail, buy-off, and
mark-ups.

Page 10 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

25.16.1 Gauge Quantities

A gauge will be supplied for every set of carriers supplied under this contract. The gauge must
be approved by FCA.

25.16.2 Design Considerations

The Designer shall take the following items into consideration when designing the carrier gauge:
 Location size
 Stability of location
 “In System” – meaning carrier presented to gauge by conveyance
 Clearances and integration to conveyance in repair spur
 Carrier Complexity
 Existing designs
 User feedback retroalimentacion
 Type of conveyor system
 Design for 0.5” [12.7mm] gap between gauge block and all carrier gauged surfaces
 Set net blocks to 0.5” [12.7mm], clearly mark gauge as NET (color code yellow)
 Set go/no go gauge to 0.438” [11.1mm] and 0.563” 14.3mm], clearly mark gauge as
GO (color code green) / NO GO (color code red)

25.16.3 Design Format

The Designer shall develop the gauge in a 3D solids system in a format compatible with NX.
When providing a non-native NX file, the part must be an assembly with individual components
(not monolithic). Model shall be in body position.

25.16.4 Design Details

25.16.4.1 Shims & Adjustability

Details will be attached to main members with bolted construction and 0.5" [12.7mm]
shim plates or telescoping bolted tubing to allow for future changes in carrier design.
Immediately after gauge certification (CMM’d), all shim plates and slotted construction
shall be tack welded.

25.16.4.2 Gauge Points

The gauge will measure each point that touches the product and will reference (or be
referenced to) the conveyor track.

25.16.4.3 Measurement Tools

A go/no-go gauge will be used for each detail-to-metal carrier point. Both go/no go and
net block tools shall be provided for each gauge point.

Page 11 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

Gauge Examples

25.16.4.4 Counterbalanced Details

All swing-in details shall have an adjustable counterbalance to minimize the force
required to lift/lower the details.

25.16.4.5 Gauge measuring accuracy

The gauge will measure the relationship between all details, free rail, hold-back bar, and
carrier positioner on trolley in all (3) dimensions with + 0.063" [1.6mm] accuracy.

25.16.4.6 Gauge Construction

The main construction of the gauge shall be minimum 5" channel and 3" sq. tubing and
utilize either swing-in details or be roll-on type with V-groove wheels. The carrier shall
be positioned and held in the gauge station and gauged using hinged 1" [25.4mm] gauge
block, rest blocks, side guides and sliding details. Details will have handles and use 0.5"
[12.7mm] dia. hinged pins. For OH carriers with camber, the frame shall be hinged on
one side with adjustment to match the camber.

25.16.4.7 Carrier Camber

 For carriers built with camber (e.g. C-shaped carriers), the gauge shall have a
camber check to ensure that the camber is within acceptable tolerances.
 The checking fixture for carriers built with camber should incorporate a pivot
point on the fixed side of the carrier and screw adjustable supports on the open
side (where the camber is) so that the angle of the checking fixture can be
adjusted to match the camber of the empty master carrier.

25.16.4.8 Carrier Bearing Surface Wear

Carrier fixtures for overhead carriers that interact with tooling and/or automatic
load/unload devices shall incorporate a sliding measurement gauge that interfaces with
a fixed point on the carrier. This point will be measured and recorded for each carrier at
mastering for use as a baseline for that particular carrier. The point will then be used to
check for and measure bearing surface wear (e.g. king pin wear, pivot bolt wear, etc.)
that will cause the carrier to rest lower over time, changing the height of the perch
points at transfers.

Page 12 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

25.16.4.9 Manually Loaded Carriers

Carriers that are manually loaded and unloaded may have hand gauges made of
aluminum tubing with bolted steel details, that are adjustable and tack welded after
certification. The use of hand gauges requires FCA approval.

25.16.5 Design Review

The Designer shall have a carrier design review meeting to present the 3D model for review and
acquire preliminary design approval by the Owner. It is the Owner’s responsibility to ensure the
Designer validates all aspects of his design during this review; however, this does not preclude
the Designer’s design responsibility. Meeting minutes of this review shall be taken by the
Designer.

25.16.6 Gauge SOP

The Designer shall generate a gauging SOP showing the proper procedure for gauging all points
on the carrier. This procedure will have color photographs of each gauging step. Procedure
shall be printed in large format (minimum 24”x36”) and laminated. Procedure shall be properly
hung at the repair spur adjacent to the gauging fixture. Designer to supply unistrut stand to
properly hang and display SOP.

25.16.7 Deliverables – Gauge Design

Deliverables include:
 Approved gauge design(s) in 3D and 2D
 Gauge detail (shop fabrication) drawings in PDF and native format.
 Review meeting minutes
 PowerPoint Presentation(s)
 3D model(s) placed in Team Center
 SOP for gauge in laminated hard copy, color PDF and native format.

Gauge Build
The Designer shall build the gauge(s) per FCA Conveyor Mechanical Specifications and as defined
in Section 25.16.4 of this specification.

25.17.1 CMM
After installation and set-up, the Designer shall CMM the gauge. CMM data is a deliverable to
the Owner.

Master Carrier Use

The Master Carrier number shall always be 1. Proper use and care of the Master Carrier is a
critical part of a successful conveyor system.

25.18.1 For new conveyance systems

The Designer shall CMM the Master Carrier at User’s plant to ensure structural integrity and

Page 13 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

then install into the conveyor system. The Designer shall use the Master Carrier to set all details
on the carrier gauge. Once the gauge is set up the Master Carrier is removed from the system
and placed in a safe storage location (repair spur storage is preferred). The Master Carrier is
only used to check and/or re-set the gauge.

25.18.2 For existing conveyance systems

The Designer shall CMM the Master Carrier at User’s plant to ensure structural integrity and
then installed it into the conveyor system. The Designer shall coordinate with the Tooling Line
Integrator and use the Master Carrier to validate load and unload points within the conveyor
system. Changes may be required to the Master Carrier to be successful within these existing
integration points. The Designer shall be responsible for all changes. Once integration
validation is complete the Designer shall document all changes and CMM the Master Carrier
again. The Designer shall then use the Master Carrier to set all details on the carrier gauge.
Once the gauge is set up the Master Carrier is removed from the system and placed in a safe
storage location (repair spur storage is preferred). The Master Carrier is only used to check
and/or re-set the gauge.

25.18.3 CMM Data

The Designer shall provide, as a deliverable to Owner, CMM data for each Master Carrier.

Gauge Installation and Set Up

25.19.1 Location
The location of the carrier repair spur requires the approval of the Owner. The gauge location
shall be “in system” within the carrier repair spur. The gauge shall be leveled and securely
mounted.

25.19.2 Conveyance Requirements

Each type of carrier shall have a carrier gauge in the carrier repair spur. This will consist of a
stop, a positioner and a stabilizer section. The method of positioning and stabilization shall be
the same (or closely replicate) the set-up at the load/unload points.

25.19.3 Set Up

25.19.3.1 New conveyance systems

The gauge details shall be set by the Designer using the CMM’d Master Carrier. Refer to
Section 25.18.1 of this Guideline.

25.19.3.2 Existing conveyance systems

The gauge details shall be set by the Designer using a system validated Master Carrier.
Refer to Section 25.18.2 of this Guideline.

Carrier Build
All carriers shall be built using the jigs and assembly techniques developed for the Prototype
carrier. The quantity of carriers to be made for each metal phase (i.e. TTO, VPA, VPB, etc.) and

Page 14 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

at which phase the details will be final located and tack welded shall be determined by FCA
during the bid process.

25.20.1 Weld Testing

The Designer shall ensure that magnaflux testing of all welds occurs on a 10% sample of each
carrier style build. Data from this testing shall be a deliverable to the Owner. Designer is 100%
responsible for the quality of the carrier welds.

25.20.2 Painting
Carrier painting shall adhere to FCA Conveyor Mechanical Specification Section 1.36 and ME BIW
Specification (660.03) Painting

Carrier Management Plan

A Carrier Management Plan detailing the contractor’s plans for removal of existing carriers from
the system (if applicable) and insertion of new carriers into the system shall be created in
PowerPoint within 30 days of award of contract. This plan shall be presented to FCA personnel
for review and comments. The Carrier Management Plan must be approved by FCA prior to
commencement of field operations. The Carrier Management Plan at a minimum shall include:
 The lessons learned from previous installs. It is the responsibility of the Conveyor
Contractor to combine the lessons learned from their own past experiences with the
input of ME and plant personnel to provide a comprehensive plan.
 Carrier Removal Plans
o The plan for removal of carriers from the system at system strip out.
o Carrier layout maps highlighting the carrier removal point.
o Layout showing laydown/storage area for removed carriers
o Expected manpower loadings and equipment needed
o Timing of the removal operations by number of shifts needed.
o The Conveyor Contractor’s plan to remove the discarded carriers from FCA
property.
o The Conveyor Contractor’s plans for running gear refurbishment (if purchased)
including timing for return of components.
 Carrier Running Gear Validation
o For reworked systems where new running gear is being installed, the contractor
at no additional cost to FCA shall replace the running gear on no less than
twenty (20) carriers with new for testing at least thirty (30) days before
shutdown. The modified carriers shall be uniquely marked and tracked during
this period to ensure the running gear functions properly. On new installations,
the contractor shall install a minimum of twenty (20) carriers into the system at
power-on and run these carriers on the system for a minimum of thirty (30)
days prior to running production to ensure proper functionality of the running

Page 15 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

gear. All issues that arise with the new running gear shall be logged and the
contractor shall perform and submit for FCA approval, a root cause analysis
(RCA) with corrective action plan for all failures.
 Carrier Insertion Plans
o The insertion of new carriers shall be in coordination with the pilot build plan to
eliminate any potential blocking of the system.
o Layout showing Contractor laydown/staging area.
o Carrier repair/gauging spur shown on a conveyor layout map.
o Carrier insertion point shown on a conveyor layout map.
o Schedule for delivery of new carrier equipment including any storage of carriers.
o Expected manpower loadings.
o Timing of the insertion operations by number of shifts needed.
o Conveyor Contractor’s gauging/validation plan (see requirements in section
25.22)

Carrier Installation
A proper carrier installation is required for a successful conveyor system. All carriers installed
into a conveyance system are required to be mastered/gauged.

25.22.1 Pre-installation Gauging

To help facilitate installation timing the Designer may choose to gauge each carrier before
installation. This does not preclude the requirement to gauge all carriers after system
installation but provides for less re-work of carriers at such time. This gauging usually occurs at
the time of carrier build.

25.22.2 Lifting / Handling Carriers

During installation all care shall be taken by the Designer to ensure no structural damage occur
to carriers. Proper support and/or slings shall be use to ensure that load is properly distributed
during the installation process.

25.22.3 Carrier / Running Gear Assembly

The installer shall assemble the carrier with the proper running gear and tow bar as per the
carrier design.

25.22.4 Carrier Gauging

All carriers shall be gauged when they are installed into the system. The checking fixture shall
be set up with net blocks at all gauged surfaces when initial mastering/gauging of the carriers
occurs. The carrier surfaces must be set to the net blocks and flush to the checking fixture to
eliminate carrier variation at initial mastering when every carrier is set to the master. After all
carriers are set, then the net blocks will be removed and the go/no go feeler/tools will be
utilized for periodic checking only of carriers in production. Go/no-go feeler/tools shall not be

Page 16 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

used to set or master the carrier.

25.22.5 Validation

25.22.5.1 During Carrier Installation

The Designer shall provide to the installer an iso-view drawing for each carrier that
displays and labels all carrier details. The installer shall use the iso-view to ensure
proper validation for each carrier. The Designer shall provide a carrier checklist for
validation. The checklist will contain all required check points for each carrier of that
type. Checkpoints include, but are not limited to, carrier detail location, carrier
stabilization, proper installation of nuts and bolts, lubrication, safety chains, running
gear, tow bar, etc… A checklist is required for each carrier type. Validation is provided
by installer adhering to checklist requirements with sign-off. Designer provides these
checklists to Owner as a deliverable.

25.22.5.2 Functionally
The Designer shall work with the Tooling Vendor to ensure the functionally of each
carrier at each load/unload station. The test will require full auto operation of both
conveyor and tooling. One test round shall consist of all carriers functioning through
each load/unload station once for each style the carrier conveys. This test shall be
performed a minimum of 5 rounds per carrier. The Designer shall track and maintain a
log of each test with observed results. Any work required to modify carrier shall be
logged. A successful carrier validation will be considered as no observed issues on the
last two rounds for each carrier.

Carrier Lift Assist

For each carrier type supplied, the Designer shall design and supply a lift assist device for
inserting/removing carriers from the system. This lift assist device is essentially an engineered
lift jig designed to properly engage the carrier and provide a safe and stable lift point for carrier
removal. At the top of the lift assist there shall be a properly sized lift-rated eye for attachment
to the hoist in the repair spur. The safety factor of this lift assist shall be >5.0 on yield strength.

Mechanical Interface/Electrical Interlocks

It is the Designer’s responsibility to manage the development of mechanical interfaces and
electrical interlocks at all conveyor load/unload locations. Proper design and implementation of
these requirements are a must for a successful system. Design and function shall take into
account all aspects of safety and pinch points.

25.24.1 Mechanical Interface

The Designer shall adhere to all the requirements of Section 1.38 of the FCA Conveyor
Mechanical Specifications. The following requirements also help ensure a successful system.
 The Designer shall coordinate interface meetings with the Tooling Line Integrator.
 The Designer shall take minutes to ensure items and commitments are retained.

Page 17 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

 The Designer shall produce an interface drawing from the specified interface documents
that details all aspects of the mechanical interfaces. This includes dimensional references
for both conveyor and tooling components and their relationships to each other.
 Conveyor components include track, stops, positioner, stabilization, screen guard, carrier
in position, part on carrier and any other component required for a complete system.
 Tooling components include transfer device, tooling station, fencing, and any other
component required for a complete system.
 Buy-off of the interface drawings signifies validation by signees. Buy-off is a sign-off of
mechanical interface drawing provided by Designer. Signee’s include Designer, Tooling
Line Integrator, FCA Conveyor Group and any other team member deemed necessary by
FCA Conveyor Group. These drawings are a deliverable by the Designer to the FCA
Conveyor Group.
 Validation of interface drawing, either at set-up in Tooling Line Integrator’s shop or by
using 2D and 3D modeling, must occur prior to station’s installation and use.
 Note that electrical components are shown on the electrical interlock drawing.

25.24.2 Deliverables - Mechanical Interface

Deliverables include:
 Signed Mechanical Interface Drawings

25.24.3 Electrical Interlocks

The Designer shall adhere to all requirements of Section 9 of the FCA Conveyor Electrical
Specifications in addition to the below requirements.
 The Designer shall coordinate interlock meetings with the Tooling Line Integrator.
 The Designer shall take minutes to ensure items and commitments are retained.
 The Designer shall produce an interlock drawing from the specified interlock documents
that details all aspects of the electrical interlocks. This shall include a layout drawing for
both conveyor and tooling components and their relationships to each other, complete
with a Controls and Mechanical Responsibility Matrix. It shall also include a detailed
drawing of individual electrical interlocks complete with wire & I/O numbers, and timing
chart.
 The interlock drawing shall include conveyor components including track, stops,
positioner, stabilization, carrier & conveyor component actuated switches, part detect
switches, safety devices, and any other component required for a complete system.
 Tooling components shown shall include transfer device, tooling station, fencing, safety
devices, and any other component required for a complete system.
 Buy-off of the interlock drawings signifies validation by signees. Buy-off is a sign-off of
interlock drawings provided by Designer. Signee’s include Designer, Tooling Line
Integrator, FCA Conveyor Group and any other team member deemed necessary by FCA
Conveyor Group. These drawings are a deliverable by the Designer to the FCA Conveyor

Page 18 of 19
Revision Date: July 2018 Revision 1.0
Conveyor Standards ME-Conveyor Group
Conveyor Mechanical Specifications
Section 25.0 – Carrier Build and Validation

Group.
 Validation of interlock drawing shall occur during installation/commissioning at the plant
and must occur prior to station’s automatic operation.

25.24.4 Deliverables - Electrical Interlocks

Deliverables include:
 Signed Electrical Interlock Drawings

Page 19 of 19
Revision Date: July 2018 Revision 1.0