Ford Otosan

TECHNICAL SPECIFICATIONS
of
LINE H10
FOL SOUNDPROOF ISOLATION

October 09th, 2023

Craiova, Romania

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 Line H10 FOL Soundproof Isolation
Ford-Type:
Supplier-Type:

Country, City: Romania, Craiova Location: Craiova Press Shop

Delivery Date: 01/08/2024 Ready for Production: 15/08/2024

Project: FORD OTOSAN

Supplier:

Contact person: Name Mail Symbol Phone

Sales:

Project Coordinator:

Mechanical Responsibility:

Electrical Responsibility:

Ford:

Contact person: Name Mail Symbol Phone

Buyer: FORD OTOSAN - CRAIOVA +90-262-315-5000

Project Coordinator: Mustafa ÜNLÜ munlu@ford.com.tr +90-262-315-xxxx

Mech. Responsibility: xxxx@ford.com.tr +90-262-315-xxxx

Electr. Responsibility: xxxx@ford.com.tr +90-262-315-xxxx

Electrical approval: Mechanical approval:

Date: Date:

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 Table of Contents
1. PROJECT OVERVIEW 4

2. SUMMARY-SCOPE OF DELIVERY 6

3. PRESS SHOP PRODUCTION REQUIREMENT & ENVIRONMENT 7

4. TECHNICAL DETAILS 8

5. ELECTRICAL 10

6. ELECTRICAL RECOMMENDED COMPONENTS LIST 16

7. PAINTING 17

8. BUYOFF PROCEDURE 18

9. TRAINING 18

10. DOCUMENTATION 19

11. INSTALLATION AND LAUNCH ASSISTANCE 21

12. LAUNCH AND SERVICE 21

13. SPARE PARTS 22

14. WARRANTY 22

15. RELIABILITY & MAINTAINABILITY 23

16. SPECIFICATIONS FOR OCCUPATIONAL SAFETY AND HEALTH 23

17. ENVIRONMENT SPECIFICATIONS 24

18. ERGONOMY SPECIFICATIONS 24

19. STANDARDS 25

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1.0 PROJECT OVERVIEW
1.1 Purpose
The aim of this project is to make soundproof isolation revision including ATC for Robots #1 and #2 on the H10 Line in
Presshop of Ford Otosan plant, Craiova, Romania.

1.2Timing

RFQ September 15, 2023

Bids Due September 30, 2023
PO Placement January 15, 2024
Installation Start August 01, 2024
Commisioning & Launch August 15, 2024
1.3 Supplier responsibility
1.3.1 After receipt of order, Supplier is responsible for design, manufacturing, shipping ( DAP at Ford Otosan
Craiova Plant in Romania ) , installation, commissioning and final buyoff.
1.3.2 Supplier is responsible to send all the design data and spare part information (with manufacturer part
numbers and serial numbers) within 16 weeks from the receipt of Purchase order. The required spare
parts will be determined and ordered by FORD OTOSAN according to the design.
1.3.3 Supplier needs to meet all corporate and local government, safety and environment standards. Supplier
should make sure no patent disputes of the project.
1.3.4 The facility power, air and water requirements shall be confirmed and verified by the supplier, with
reference to this standard.
1.3.5 The Supplier's Project Timing Chart shall detail all required actions, resources, and milestones, as they
relate to the timely completion of the project. The Project Timing Chart submitted to Ford O t os a n
during the tendering period shall be updated and finalized within fifteen (15) days of receiving the
formal purchase notification. The project schedule shall then be updated and reviewed on a bi-weekly
basis.

The completion of the project in our plant is of importance for the correct start of a major FORD program.
Therefore it is mandatory to submit a timing schedule after order placing. The timing plan should show
at least the start and the end of the following actions :

- Design and Engineering

- Ordering of material
- Testing the components at vendor's plant.
- Dismantling and packaging
- Shipping
- Installation in FORD OTOSAN plant (with the details:
- installation of main components
- electrical and mechanical tests
- internal testing of supplier
- etc.
- Final tests
- Training and Launch Assistance

FORD OTOSAN will consider exceptional actions to ensure that timing is maintained. Actions
could include more frequent progress reporting of achieved status, additional checks by FORD
OTOSAN engineers, etc.

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 Therefore FORD OTOSAN prefers computer-aided timing/project-managing by the supplier.

1.3.6 Deviation from this standard shall require the advance approval of the requisitioning activity.
Deviations shall be proposed in writing by the supplier at the time of or before bid submission; without
a request for deviation on or before the bid due date, it will be assumed the supplier's proposal
complies with this standard. Any waivers granted shall apply only to the order in question and
shall not be considered as permanent amendments to this standard

1.4 Standarts and specifications

• The specification package is assembled in below parts:
o This document, main specification
o Ford Standards
o Ford Global Terms and Conditions
o Turn–key installation

1.5.1 This requisition attaches particular importance to:

• Health & Safety
• Life Cycle Cost
• Spare Parts Availability
• Designs Already Proven in Existing Installations
• Reliability and Maintainability

1.5.2 Conformity and Safety of Machines

• Safety shall never be compromised in any way. It is expected that the equipments/projects
delivered to different regions globally, have a common approach to the safety systems. Differences
shall only be driven by regional regulatory health & safety requirements.
• It is desired to utilize common components globally. The selection process should be based on a
single component that meets the most stringent standards that could then be applied globally. An
exception could be local availability, but must be approved by the requisitioner.
• Ford safety standards shall be adhered to.
• Risk analysis and documented buyoff process shall be completed by the supplier and conform to
Ford FAS08-35 and FAS08-36 standard guidelines.
• Occupational Health and Safety of Craiova, Romania Plant

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2.0 SUMMARY – SCOPE of DELIVERY

2.0.1 The disassembly of the current FOL fence and isolation system
2.0.2 The current doors will be kept and used in the new design and installation
2.0.3 The current equipments ( robots, conveyors, load carts, oiler&brusher ) will be kept and there will be no
position change.
2.0.4 The new FOL soundproof isolation design will be done by the supplier according to the requirement.
2.0.5 The installation of the new isolation body and covers
2.0.6 There will be new ATC stations for the robots
2.0.7 The required sensors or switches will be placed to the required places if needed.
2.0.8 The required PLC program changes will be done according to the changes.
2.0.9 The required Robot program changes will be done according to the changes.
2.0.10 The current control and operator panels for the doors will be replaced
2.0.1 The operation of the automatic tool change on 2 robots of H10 line will be automatic during die change. The
first two robots and the rest 5 robots will be on synchronous operation while ATC

2.1 Shipping & Support Services

2.1.1 Packaging & Shipping DAP cargo delivered to Ford Otosan, Kocaeli Stamping Plant.

Shipment and Shipping Insurance belongs to the Supplier. All items which are separate in the equipment
delivery note must be written down separately.

• Sea worthy packaging Supplier

• Transportation to sea harbor ( if required ) Supplier
• Sea transportation ( if required ) Supplier
• Harbor Costs ( if required ) Supplier
• Transportation to plant Supplier
• Transportation inside plant to build up place Supplier
• Set-up at plant Supplier

• Disposing of packing material at customer plant (Supplier to Supplier

transport to a local marshalling area on site, for disposal by Ford)
• Storage area at plant inside Ford

The supplier is also responsible to make the complete installation in Ford Otosan Craiova premises by its
crew. Handling & lifting equipments if possible ( if FO has the equipments ) will be supplied by Ford
Otosan.
2.1.2 Spare parts list , see DR-40 Ford SBU Standard, will be supplied ( According to "DR-40 SBU standard and
Ford Universal Spare Parts Template 0314 R1")
2.1.3 Maintenance manuals and M tasks, see DR-32 Ford SBU Standard, will be supplied.

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 3.0 PRESS SHOP PRODUCTION REQUIREMENTS & ENVIRONMENT

Working days per week 6

Shifts per week 18

Hours per shift 8

Usage efficiency of the production line ≥95%

Electric
Line voltage – Romania VAC/Hz 400/ 50Hz
24VDC
Control voltage – Romania DC

Permissible line voltage tolerances % +10 / -15

Compressed Air

• Building air supply

Bar 6

Operating Conditions
Ambient temperature °C 10 - 40
Relative atmospheric humidity 50% - 85%

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5.0 TECHNICAL DETAILS

1. Disassemble of current isolation and system

• The H10 Front of Line section measures 15.4x10.86 m. Contractor company has to measure the
dimensions after PO.

• Front of Line has two rolling doors for blank load carts, a rolling door for oiler&brush cleaner and two
operator gates.

• The FOL part of the line is completely covered with a wire fence system. The height of the wire fence
system was realized as 2 m.

• The safety fences around the FOL area will be dismantled by the contractor company.

• The Rolling doors for blank load carts (x2) and oiler&brush cleaner (x1) and their frames will be kept
at the same position and they will be used as they work.

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 • All the control and operating boxes for rolling doors, any gates or equipment will be disassembled by
the contractor company. They will be replaced to the new positions on the soundproof panels
according to the new design.

2. Design of The new Soundproof Isolation

• The FOL shall be designed with sound enclosures and sound absorbing heavy materials to
attenuate noise levels and be in compliance with Ford Standard w-SX-1.

• Soundproof panel mounting area will be designed by adhering to the safety fence dimensions. In
addition, the two rolling doors used for blank loading carts and one Rolling doors for the oiler&brush
cleaner machine and their frames will remain fixed during the design phase.

• Operator doors will be manufactured by using soundproof panels by keeping the positions on the old
layout.

• All windows on the new soundproof isolation will be manufactured by safety glass Window material
shall be Laminate Safety Glass or Diamond coat Plexi-glass.They have to be designed and assembled
as easy as the plant maintenance team can change the glass easily in future. Provisions shall be
made for easy window replacement and cleaning. The assembly and disassembly methodology of
Windows replacement will be approved by SBU team.

• There will be a safety door lock system at the operators’ doors. The supply and installation of the
safety lock system belongs to the contractor company.

• Tool change areas will be designed for IRB6660 and IRB7600 robots. Area dimensions will be
designed according to the largest tool size.

• Robot tool change doors will be designed to as robot1 will have fixed tool change posts and a tool
change room and robot2 will have rotating (180 degrees) door.

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 • The tool change doors will be designed as soundproof and will have two windows. All lifting gate,
access doors, tooling change gates ( except kept ones ) must be sound isolation design and
approved by SBU.

• The movement system of the tool change doors will be provided by the contractor company. Ground
connection will be designed accordingly.

• The rotating door of the second robot will have an area scanner at the outside of the enclosure to
detect an existancy of an human being there.

• The ATC room door of the first robot will have an interlock switch that enable the operator to go inside.

• Connection points will be designed on the revolving door for the robot tool adapter connection.

• Tool change areas will be designed with safety wire fences and their sides will be closed according to
the door rotation angle. The floor will be painted yellow / black for visuality.

• Soundproof bottom panel will be designed according to the dimensions of the blank loading carts’
doors whose height remains constant, and the upper panels will be designed according to the robot
tool change need.

• In the FOL crown area, the panels will be removable. Connection points will be designed for lifting the
panels with the help of a crane.

• The ceiling panel layout will be designed in such a way that the robot and the feeding conveyor can
be removed from the ceiling with the help of a crane. All sound enclosures are to be designed to
allow removal key components without the disassembly of the sound enclosures. The supplier
should allow for removable hatches / service doors for crane access or load points for hoisting /
disassembly of the equipment for service.

• The steel construction that will carry the FOL ceiling panels will be placed in such a way that it will not
obstruct the working area of the IRB6660 robot.
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 • FOL ceiling panels will be designed to be walked on.

• On the upper part of the FOL ceiling, railings will be manufactured and assembled according to the
standard, 1100 mm high skirted (100mm) railings covering perimeter dimensions. The railings will be
bolted. Railing paint will be RAL 1028.

• Instead of the control panels that have been relocated within the scope of the FOL revision work, the
supply, installation and commissioning of the control boxes shown in the picture below will be done
by the contractor company.

• Industrial ladder will be designed for the transition from the press crown area to the FOL ceiling area.
Stair steps will be in the form of a non-slip grid.

• Supply and installation of EAE (or Waldmann) brand LED Luminaires to the acoustic sound insulation
panel indoor units built within the scope of the FOL revision will be done by the contractor company.

i. 3x LED fixtures of 38Watt or more on the infeed conveyor

ii. 3x LED fixtures of 38Watt or more in blank loading stations
iii. 2x 38Watt LED luminaires for Robot Tool Change stations
iv. 6x LED luminaires of 38Watt or more on the centering conveyor

• All lighting will be individually controllable. Control switches will be placed on a control panel that
operators can easily reach.

• The illuminations on the centering unit will be selected considering the requirements of the optical
centering camera.
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 3. Soundproof Panel Technical Details

• At the end of the sound proof panel application, the panel thickness will be designed by the contractor
company so that the noise level will be below 80dB. The prescribed panel thickness is 80-100 mm.

• A1 class non-combustible acoustic material (rockwool) with a density of 150kg/m³ and fireproof
moisture barrier will be used in the internal structure according to the panel thickness. Material
certificates will be delivered to the project authority. Noise consuming elements designed according
fire-safety-standards.

• Sound absorbing material is to be protected by perforated metal panels. The surfaces of the panels
facing the inside of the line will be covered with galvanized coated perforated sheets. The hole
diameter will be 3 mm and the axis between the holes will be approximately 5 mm..

• Panel paint will be Ral1013 rough electrostatic powder paint.

• After panel installation, the openings on the sides or bottom of the panel will be closed with slats in
the panel color.

• At the end of panel manufacturing, there will be no manufacturing-related fluctuations on the outer
surface of the panel. This item will be taken into consideration in the preliminary acceptance.

.
4. Tooling Technical Details

• Maximum and minimum tool lengths that are used on Line10 (H10) can be seen below.

Min: 2070 x 722 x 110 (Length x Width x Height )

Max: 2970 x 1380 x 400 (Length x Width x Height )

• Robot 1 have fixe crossbar directly connected to the robots 6th axis.

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 • Robot 2 has a linear 7th axis and the crossbar connected to this 7th axis like shown below. Fixed
crossbar part numbers are 3HES47010010101 and 3HES47010020101.

General Layout of the 7th axis

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 • Tooling’s are connected to these fixed crossbars with saddle. Saddles’ receiver sides are mounted
on crossbars and they have guiding pins. Saddle part number is 3HES47055100606 and
3HES47055200606.

• Robot1 will have tool change room behind it between two loading carts’ doors. These area will be
protected while the operator prepare the next tool. Protection will be supplied by hardware and also
by robots safety software. Toolings will be placed in vertical direction.

• Robot2 will have tool change rotating door. The door will rotate around it by 180 degrees. Robot will
leave the current tool and door will rotate to the another side so robot will take the next tool. Toolings
will be placed in horizontal direction.

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 • There will be no change on toolings that are currently used in operations. The toolings will be changed
( leave & take operations ) by using ABB standard tool holder seen below.

• These tool holders will be placed on fixed posts and rotating doors.
• Robot programming will be renewed according to these new tool change sequence.
• There will be sensors on tool holders to detect the existence of the toolings. If there is a miising
signalization then the system will warn the operator.

5.0 ELECTRICAL
General electrical scope of delivery shall include:

1. Engineering

2. Project-management

3. Delivery of complete hardware and software

4. Electrical installation

5. Coordination and connection of interfaces

6. Start-up, commissioning, and buy-off

7. Documentation, software license

General design concepts shall include:

1. High safety standards for personnel and equipment in accordance with Ford and regional safety
standards. Press line safety control system should achieve or keep PL-e or category 4 level
requirement according to EN 954 and ISO13849.
2. The project shall be designed according to the Supplier’s standards, regulatory government and
industrial standards, Ford Motor Company Manufacturing Standards, and all Ford Motor Company
Safety Standards. Refer to applicable standards list.
3. High performance functionality
4. High reliability
5. Long service life
6. Ease of operation through Human Machine Interfaces with enhanced graphics
7. Quick fault diagnostic and fault elimination through alarm screens and messaging
8. Quick installation and start-up (Use of approved components and plug in modular designs)
9. Use of proven reliable components and systems
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 10. Limiting to a select base of standard component suppliers. Use of components and systems from
highly acclaimed manufacturers to assure long-term availability.
11. Simple structure of control system, with limited types of networks
12. Use of remote PLC I/O, where practical and possible
13. Extensive service and spare part capabilities
14. Detailed and comprehensive documentation done with CAD/E-Plan systems

Specification Electrical Equipment - Line

Programmable logic controller (PLC)

a) Line specific software with supplier standard software functions is required.

b) Programming in ladder logic is preferred. Other IEC1131 compliant programming methods, such as
Function Block Diagram requires special approval. Supplier to state intended PLC logic in proposal.
PLC should be equipped with Static memory backup. (No battery backup for memory)

c) PLC's of comp. Siemens, Type S7-1517F

d) Bus System : ProfiNET.

e) The guidelines of the material manufactures have to be observed.

f) If the control is switched off, flags, timers and counters may not be set or reset by any change of input
signal.

g) Software design must be carried out, that all flags are programmed reset- dominant.

h) For later internal networks the first plug-in place next to CPU in each PLC has to be kept free for the
installation of a communication processor. The parameter of the operand identifier should exist only
once in the whole software.

i) Software layout of program structure (block diagram) with function description of each block is part of
documentation. (In S7-text editor only)

j) The operand areas should be significantly follow the machine functions.

k) The documentation includes comments as function description of segments, assignment and

statement comments, a title block on each page, a cross reference list and a table listing of operands.

l) The comments have to be written according to machine functions. Abstract descriptions will not be
accepted. The comments should show the status of Inputs, Outputs and Flags when they have a
logical "1", also the programmed function of timers and counters. The comments in hardware
documentation and in assignment lists should be with inputs/outputs of the PLC in fully accordance.

m) The comments have to be written in language of the country where the equipment will be installed.

n) The function of FB's and DB's have to be explained in this documentation.

o) At the end of commissioning the program should be transmitted to Flash EPROM.

p) The complete software has to be stored on USB memory drive and handed over to Ford Otosan. This
drive contains the program of the controller and the matching documentation files (symbolic,
comments, etc.).

q) The copyright of the complete software belongs to Ford Otosan.

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 r) Retentive type components e.g. pulse valves must be controlled by outputs with retentive
characteristics.

s) For valves have to be used 2A output cards only.

t) Indicating lights have to be controlled separately. (additional output cards).

u) There has no more than one (1) operating contact connected to each input of PLC except for circuit
breaker.

v) Potential free input/output modules have to be used.

w) The program should be written so far as possible as ladder diagram (LAD).

x) Each block must have a block header where the function of this block is described.
y) The function of function blocks has to be described in block header.

z) In the segment- comment the operand symbol has to be shown.

aa) One segment rung must be of such a size that it can be completely displayed on the screen of the
programmer. The make of the operating instruction needs to contact Ford Otosan.

bb) The power supply for I/O- cards has to be generated by a separate 3- phases transformer with
protected earth (screen winding) and 24V, DC bridge rectifier. This voltage should be monitored to
voltage level and residual ripple.

cc) In case of failure the supply of outputs has to be cut off.

dd) Installation of data cabling must be in steel conduits or similar in case of avoiding noise.

ee) In the control panel have to be installed two sockets (waterproof) for the PG. One for power supply
and the other for data transfer. The power supply for the sockets of PG and power supply of CPU
must have the same phase sequence. The sockets are to be labelled definitely according to PG.

ff) Software design should be done on programming unit Siemens PG and with Tia Portal Version used
in Ford Otosan.

gg) In front of delivery of the machine the complete software incl. documentation (Data-books, instructions
manuals, etc.) has to be handed over for approval to the responsible electrical department of FORD
OTOSAN.
Motors and Motor Controllers

a) Motors that are currently used on equipments will be kept.

a) If required and there will be a change for motors, All motors shall be IEC frame, high efficiency,
automotive industrial rated and conform to IEC 60034-2-1, Motors and Generators

b) Selection of the motor controller ( Brand will be SIEMENS ) will be the responsibility of the supplier.
Sufficient measures shall be taken to ensure the rating of the motor controller is a minimum of 125%
greater than the full load rating of the motor.

c) Motor controllers shall have a programmable motor starting frequency limiter set to allow a safe
amount of starts per hour or alternately current verses time software to avoid motor winding
overheating.

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 Power Supply

• Main Voltage: 3x 380 V + 10%, 50 Hz

• Phase Voltage: 220 V, AC, 50 HZ
• Power supply for devices: 220 V, 50 Hz
• Control voltage: 24 V, DC
(6EP3437-8SB00-2AY0 Siemens Power Supply will be used )
(6EP4293-8HB00-0XY0 Siemens Buffer module will be used )
• Interlock voltage 24 V, DC
• I/O voltage of PLC: 24 V, DC
• Solenoid valves: 24 V, DC
• Cable cross section < 10mm2 :TN-S-Net
• Cable cross section > 10mm2 :TN-C-Net
• Peak short circuit current: Is = 100KA
• Net: TN-C-S Net without load on the neutral conductor.

Control Wire Color Code

Power circuits Control circuits

Load side of main Excepted circuits Load side of main Excepted circuits
disconnect disconnect
Ungrounded Grounded Ungrounded Grounded Ungrounded Grounded Ungrounded Grounded
/unearthed /earthed /unearthed /earthed /unearthed /earthed /unearthed /earthed
conductor conducto conductor conductor conductor conductor conductor conductor
r

AC Black White Orange White Red White Orange with White with
with black with red stripe orange
stripe orange stripe
stripe
DC Black White Orange White Blue White with Orange with White with
with black with blue stripe blue stripe blue stripe
stripe orange
stripe
Protective Green with yellow stripe
conductor

Electrical Installation

▪ Cabling must be oil resistant and flexible. Fixing material shall be included in the scope of supply. Socket
and plug connections must be in correspondence with FORD OTOSAN and must not be interchangeable.

▪ Cable, which are in working areas, should be installed in protected channels, tubes or protective hoses.
Cables in foot areas need specially mechanical protection. For operationally moved cables have to be used
only, high flexible cables in protective hoses.

▪ Cables constantly moved in operation must be connected by plugs and sockets at both ends.

▪ Reserve-wires have to be installed to terminals and documented.

▪ The complete electrical installation of the whole equipment and machine has to be carried out in channels
and conduits (open installation in accordance to minimum bending radius).

▪ Open installation fixed by cable strips is not permitted at all.

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 ▪ In operator panels and terminal boxes the auxiliary voltage with both potentials shall be returned to
terminals forming intermediate test points.

▪ In cross section and current of cables, attention is to be paid to voltage drop and short circuit protection,
and also to any possible influence (EMC) from adjacent circuits. For 24VDC installation a cross selection
calculation of each circuit is necessary.

▪ Limit switches for power drives should be complete connected and wired. Limit switches shall not be
actuated under pressure.

▪ Positioning cams have to be built sufficient to contact movement for maximum possible override.

▪ All cable entries, glands have to be metallic. Exceptions are plastic glands for plastic housings.

▪ The entry of cables into housings should be from the bottom.

▪ Diameters of wires in control cabinets:

• electronic > 0.75 qmm (connection to PLC-I/Q)
• control > 1.0 qmm
• 0.5qmm for encoders, subminiatur- plug and socket connectors.

▪ In case of noise emission, erection, installation, the complete electric’s have to follow the relevant
standard.

▪ The electrical control, excepted safety related circiutery, must be installed with decentralized remote
modules of Siemens, Profibus-Dp, ProfiNet. Cabinets, panels, terminal boxes are to be equipped with
input/output modules. The locations of modules have to be in easy maintainable places during operation
of press. EMC regulations have to be considered. Armed and twisted pair cables in accordance to Profinet
specification have to be used for bus cables.

Electrical Cabinets

▪ The maximum cabinet height is 2000-2200mm incl. base of cabinet. IP protection is at least 54 according
to the IEC 60529 ( VDE 0470-1)

▪ All cables and wires shall be labelled before the cable entries, in each cabinet cell.

▪ Cabinet doors have to be mounted by the way, that with opened doors the minimum escape space is
ensured. A remedial action can be a door angle of 180°.

▪ The cabinet base shall be designed, that after disconnection of all cabling each cell could be removed, this
means that the cabinet base can be get out from the cabling.

▪ Electrical devices in cabinets should be for front mounting in general. The wiring has to be in trunking. It
must be guaranteed, that the complete mounting, change and additional wiring of electrical devices can
be made from the front.

▪ The fixing of conventional control devices e.g. contactors, relays etc. has to be on the mounting rails using
snap- on fastenings (35mm, according to DIN EN 50022).

▪ Inside of cabinets, the cabinet doors, side panels, top- and bottom plates, mounting plates as well, should
be direct connected to the earth bar. The indirect connection is not permitted.

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 ▪ Colours of cabinets, operator panels and terminal boxes:
▪ Outside/Inside: Pebble gray RAL 7032
▪ Mounting plate: Zinc Plated

▪ For later modifications and extensions of the electrical cabinets there must be at minimum 15% reserved
space.

▪ Circuit diagram pockets must be of sheet metal with a lid and fixed on the door inner.

▪ Thermostat for temperature monitoring

▪ Door locking must be 7mm inner square

▪ FORD OTOSAN does not supply or rent at all any programming or electronically devices for PLC, EPLAN
etc. The supplier has to buy some from manufacturer of these devices.

Identification of electrical components

▪ The identification of components in the electrical documentation and at the machine should be made in
accordance with current diagrams.

▪ The electrical circuitry have to be split up into Ford standard function groups.
=0 power supply
=1 main motor
=2 slide adjustment
=3 adjustment
etc.

▪ Identification and labelling at the complete machinery must be in language of country where the
equipment will be installed.

▪ Each connected wire e.g. contactors, relays and motor circuit breakers, light indicators and control devices
as well, should be labelled like the identification tag on this connection point (e.g. 13, 14, A1, A2 etc.)

▪ PLC Input/outputs have to be identified by the absolute address which is common in the country where
the equipment will be installed.

▪ Identification labels for electrical components should be mounted visible, material: plastic (white) or
aluminum with black letters. Permanently fixed by screws or rivets.

▪ Labels and marks for motors, valves etc. should be easily to read where built in. Possibly an engraved label
has to be fixed beside that equipment.

▪ All cables and wires leading into terminal boxes have to be labelled in front of the cable entries, outside
of housing.

▪ All housings, which are equipped with electrical devices or terminals, have to be marked with a black
lightning flash on yellow background.

Failures

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 In case of a failure which will cause danger for the equipment or an operator, the equipment must be
stopped immediately.

There must not be a direct stoppage because of the failures that would not cause a danger to the
equipment or safety issue for the operators, Automation has to stop with “cycle stop”. After stoppage,
system has to restrict the start of operation until the failure removed.

Visualization screens, HMI

a) Required Features:
• Operation shall be via touch screens

• They shall assist in fault location and machine diagnostics

• Fault texts with information on fault causes, fault position and cross-reference to circuit
diagram and PLC program. A tree method of fault locating and showing has to be
prepared.

• Ease of navigation with prompting messages to be included.

b) Current Operator panel programs will be updated according to the added operations. Current user
interfaces will be kept and updated.

c) All menus are to be reviewed and approved by Ford Motor Company during the design phase

Diagnostics

a) The diagnostics screens provides system status messages.

b) The safety zone screen summarizes graphical displays of the status of all guard doors and the
emergency stop. The safety zone of the moving bolster driving area while the die change occurs and
moving bolsters are running has to be shown on these screens.

c) Diagnostic system must be compatible with the new Industry4.0 concept. All datas shown in
operator panel has to be more explanative. They have to point exact location of the equipments
and faults.

6.0 ELECTRICAL RECOMMENDED COMPONENTS LIST

The supplier is to submit deviations to the lists below in proposal. It is Ford Motor Company’s goal to minimize
spare parts investment and utilize standard, readily available components that are stocked by distributors in
close proximity to the production facility. Refer to 2630 except;

Air Conditioners Rittal or Pfannenburg

Main Motors Siemens
Aux Motors SEW, Siemens
Pump Motors IEC Frames, Siemens
Motion Control Beckhoff, Indramat, Siemens
PLC's Siemens
I/O and Remote I/O Siemens (IP67)
Safety PLC's Siemens
Safety Relays Siemens
Motion Controls Beckhoff Twincat, Siemens
Main Drives Siemens
Proximity Switches Turck, P+F, Balluff, Pilz
Level Switches Magnetrol, B&W – Gemco, Engler
Mechanical Cam Switches Balluff,
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Resolvers AMCI, T&R
Encoders T&R, SICK, HEIDENHAIN
Flow Meters IFM
Pressure Transmitters, Control 4-20 ma No-Shok
Pressure Transmitters, Read Out IFM-Effector
Pressure Switches, Industrial Schneider, Rockwell
Mechanical Limit Switches Schneider, Rockwell
Stack Lights Balluff Smart Light
Wire Markers Brady, LAPP, Thermal Plastic
Plugs and Receptacles Harting
Control Cabinets Rittal with ISO Handles,
Isolation/Safety Disconnects ISO Rated, Siemens, Rockwell, Telemechanigue (No Rotary)
Flexible Cable Olflex, TPC, LAPP
Wire Management Duct Panduit
Lockable Control Safety Switch Rees, Kraus Naimer, Siemens, Eaton
Mushroom and E-Stop Push Buttons Rees, Kraus Naimer, Siemens
Pull Switches Rees
Push Buttons, Pilot Lights Siemens, Telemechanique -22.5 mm, Metal Case
Terminal Strips Siemens, Rockwell, Telemechanique
Relays Siemens
Power Contactors Siemens
Motor Starters Siemens
Power Supplies Siemens, Sitop BUF series with buffer module 10s
VFD Drives Siemens, SEW
Power Track IGUS
Light Curtain Sick
Laser Scanner Sick
Photo Eye Sick, Siemens
HMI 19" Touch Screen – Siemens
Visual Software To Match HMI and Controls
PTC Thermistor Siemens
Thermocouple Transmitter 4-20 ma Acromag
RTD's Omron
Tank Heaters Chromalox
Fittings Thomas & Betts
Control Power Transformer Telemechanique
Terminals, Fittings, Grounding Thomas & Betts
Circuit Breakers Siemens, Telemechanique, Rockwell
Programming Computers Dell, Siemens PG
Software Licenses must be included for all software application
Cushion Control Bosch Rexroth NG series valves with MAC8 Control, Beckhoff

▪ It has to be ensured that all installed materials and electrical components are available in the Turkish
market.
▪ Silicon free materials have to be used only.
▪ Proximity switches have to be monitored by LED's and connected by plugs and sockets (type: Turck,
Pepperl-Fuchs, Balluff or equivalent).
▪ The connections of magnetic valves are carried out by plugs and sockets with varistor protection and LED
monitoring.
▪ For protecting circuits have to be used possibly automatic fuses with auxiliary contacts to indicate failures
▪ Cartridge fuses are installed only where automatic fuses from their own characteristics are not feasible.
The national regulations have to be observed.
▪ Separate lamp and separate push buttons could only be used by approval of FORD OTOSAN
▪ Motor circuit brakers, fuse brakers etc. must be monitored by auxiliary contacts.
▪ Contactors and relays are to be protected by varistors.
▪ Limit switches have to be connected by 5-pins Amphenol- Tuchel- plugs and sockets. Type: C 164-639F-5S
(20) with screw on the top or similar.

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 ▪ Installation of some thin wires into one terminal box e.g. proximity switches, there can be used multiple
cable entries "SKINTOP DIX" supplied by company Lapp or Pflitsch.
▪ NH-fuses (HRC fuse-links) can be used. Screw fuses shall not be used.

7.0 PAINTING
7.1 Use material
All materials entering Ford plant must be given Ford toxicology approval prior to use.
7.2 Paint

Prior to shipment, the machine or equipment and all accessories shall be prime painted with quick dry
primer, and finish painted as specified below (all paint numbers referenced are available from Sherwin-
Williams). Color code could be changed and given as RAL number, will align during design:

Outside Press Color ............................................. M-5J61A “Brilliant White” Oil Proof Enamel.
• Inside Press Uprights ........................................... M-5J81A “Ford Blue Sign”
Slide face sides .................................................... M-5J61A “Brilliant White” Oil Proof Enamel.
• Moving bolsters and tool change carts ................ M-314 “Alert Orange”
Guards and Rails ................................................. M-325 “Target Yellow”
• Hydraulic / Lube Lines, slides, bolsters ............... M-314 “Alert Orange”
Remote Oil Reservoirs......................................... M-5J61A “Brilliant White” Oil Proof Enamel.
Pneumatic lines and tanks ................................... M-5J61A “Brilliant White” Oil Proof Enamel.
• Welding / Cooling Water – Supply to heat exch. . M-332 “Brown”
• Welding / Cooling Water – Return ....................... M-316 “Green”
City Water ............................................................ M-316 “Green”
Oxygen................................................................. M-357 “Green”
Nitrogen................................................................ M-325 “Target Yellow”
• Free standing electrical panels ............................ M-5J61A “Brilliant White” Oil Proof Enamel
• Inside electrical panel doors ................................ M-5J61A “Brilliant White” Oil Proof Enamel
Primer................................................................... M-6J139A “Metal Primer Grey”
Transfer Feed Bars .............................................. M-314 “Alert Orange”
• Platform floors and stair steps ............................. M-5J11 “Flat Black Enamel”
• Blue stripe 300-600mm wide (proportional to Crown size) is to be painted around top of press M-
5J81A “Ford Sign Blue”.
Press Manufacturer Signs.................................... M-5J81A “Ford Sign Blue”
• Ford Manufacturer Signs ..................................... Ford Script M-5J81A “Ford Sign Blue”

Supplier must use paints that are free from heavy metals content as defined by the Environmental
Protection Agency. See special addendum published by the requisitioning activity. Paint must be “Lead
Free” and contain less than 600ppm (0.06%) by dry weight of lead. Supplier is responsible to verify
that the products used will meet or exceed this value. Testing should be provided as part of the closeout
documents. Any paint that is found to contain greater amount, the supplier will be responsible for any and
all cost to associated to correct at their cost.

Final touch up of paint on-site after installation.

8.0 BUYOFF PROCEDURE / ACCEPTANCE

a) Final buyoff is the responsibility of the supplier to perform the required tests to verify that the
system meets or exceeds the design specifications.
b) The final acceptance of the system shall be considered complete when all the equipment is
completely installed and operational at the Ford Otosan facility and the following items have been
completed;

• All devices are completely functional.

• Complete all the snag items defined in installation, commissioning and test period.

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 • One week of continuous operation without component failure.
• All documentation has been received.
• Energy usage measurements had been completed. Proved that 10% energy saving.
• Equipments have to be checked completely for oil leakage. No leakage observed.
• Training completion.

9.0 TRAINING

a) Training will be delivered by supplier company personel.

b) Training program needs to make sure that the personnel can properly operate and maintain the
complete equipment.

Supplier to propose a training program to cover required number of people stated below, 2 classes are to be
scheduled on each shift

• Maintenance operator – 12

c) Training manual will be provided for training for each group of classes stated above. Supplier to provide
original word, excel and/or PowerPoint files used in creating the files in an editable format in English or
Turkish language.

d) Training classes to be developed by the supplier or supplier’s agent. The supplier shall provide onsite
training to cover the following topics at minimum.

• Preventative and regular maintenance procedures

• Electrical system and functional review of all the new components
• Electrical operation and troubleshooting

e) The cost of all these trainings ( including travel and accommodation costs ) are belong to the supplier.
All trainings and training documents have to be in English or Turkish language and documentation will
be delivered to the people on training.

10.0 DOCUMENTATION
10.1 Supplier shall update the current operation and maintenance documentation according to the project
itself.
10.2 The delivery of the documentation will be in;
⚫ English & Local language
⚫ 1x in USB, 1x Hard copy
10.3 Structure of Documentation
▪ About manual
▪ Description of the equipment (Technical information about the line)
▪ Safety
▪ Structure and functions
▪ Operating and display elements
▪ Start-up
▪ Operation
▪ Maintenance
▪ Repair (fault analysis only), Diagnose System
▪ Putting out of operation, Storage
▪ Packing, Transportation

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 ▪ Disposal
▪ Spare and wear part lists and drawings
▪ Technical documents for electric system
▪ Technical documents for hydraulic and pneumatic systems
▪ Technical documents for mechanic system
▪ Documentation of purchased parts

10.4 Time of Delivery

The 1st version of all documentations listed below should be delivered before Installation, and last must
be delivered before final acceptance.

10.5 Technical Documentation: Transferred documents

The following documents are transferred to Ford and used for training:

▪ Spare part lists and overview drawings for identification of the spare parts
▪ General layout and plans
▪ Piping layouts and schematics
▪ Circuit diagrams
▪ Terminal layouts
▪ Operator’s manual
▪ Safety instructions for the operator and maintenance staff
▪ Maintenance instructions with indication of the control intervals
▪ Test record of the measurements required
▪ Test records by Supplier Standard

10.6 Supplier shall supply the edited format (For example: DWG) for all drawing file, when that do not relate
to company secret.
10.7 The supplier shall furnish a preliminary copy of these manuals for approval and scope at the time of
shipment. After approval the suppliers shall furnish one copy to the receiving plant (to use during startup
activities) and one set to the regional central engineering group. With each copy there shall be an
electronic version supplied on CDROM/USB that is software based and useable on Ford Motor
Company computer systems. Final (as-built) updated copies to be sent within thirty (30) days of final
buyoff at the receiving plant. The manuals shall contain, but not be limited to the following data:
▪ Ford purchase order number, equipment serial number(s) and identification.
▪ Equipment specifications showing all capacities and adjustments.
▪ Reduced copies of all prints and diagrams.
▪ A list of commercially available parts with original manufacturer’s catalogue. Drawings
displaying the location of these parts will be included.
▪ A list of parts manufactured by the suppliers and prints showing their location.
▪ Preventative maintenance recommendations and testing procedures.
▪ Prints for all wear strips, plates and inserts.
▪ Recommended spare parts list, including: Mfg. Part #, Price, Contact Name, and Phone Number.
▪ Lifting and rigging instruction for major components, along with associated diagrams.
▪ An illustrated description of the operation and instructions for a step by step procedure for
equipment operation - during automatic and manual operating modes.
▪ Hydraulic and electrical equipment layouts each separately superimposed on elevation plan
and detail drawings as required showing the location of all pertinent equipment.

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 ▪ A complete list of perishable items, including: all bearings, seals, packings, 0-rings, wear strips
and wear plates with sizes and locations.

10.8 Supplier Responsibilities - Copies of all final drawings and circuit diagrams of the equipment "as-built"
and USBs in the requested version of AutoCAD will be forwarded no later than four weeks after the
equipment has been accepted.
10.9 The final drawings and diagrams shall be identified with the Purchase Order number, serial number(s),
(Ford Project number) and a full description which will identify the particular equipment to which the
prints and diagrams pertain to. If any field changes are required, the changes shall be recorded and the
press/automation suppliers shall forward new copies of the changed drawings as replacements. A copy
of the latest marked-up version must always be on-site.
10.10 Sub-contractors
▪ All sub-contractors to be nominated at bid (Including filiale). Vendor cannot subcontract the
major components to sub-supplier without Ford approve.
▪ All sub-contractors to work to standards as laid out in this specification. Ford reserves the right
to visit any sub-contractor on request.
10.11 All CD-ROM/USB information needs to be run under "WinXP/Win7/Win8/Win10", NO DVD's allowed.

11.0 INSTALLATION AND LAUNCH ASSISTANCE

11.1 INSTALLATION

The automation supplier shall furnish technical field representatives as required to assist in the assembly of
supplied equipment.

The representatives will be on-site, before installation, when equipment starts to arrive to oversee that all
handling of said equipment is proper and safe. Press installation will occur working 2 – 10 hour shifts, 6 days
per week, this may vary determined on location and crew size, and support for the installation shall be covered
turn key. If the press supplier desires a separate office trailer, it will be at the press supplier’s expense, as well
as all utilities, etc.

Supplier need follow Ford Otosan Occupational Health and Safety Regulation and Contractor Safety
management.

General Responsibilities of the technical field representative are, but not limited to, the following:

a. Provide technical assistance to the Owner’s on-site field management, contractors, and/or trades
working on the assembly of the project.

b. Write daily reports of work progress, issues, etc. and submit to the requestor as well as to the Owner’s
on-site field management.

Project assembly
The actual Installation labor and materials requirements shall be addressed in a separate
specification.
a. Quote to include a separate price for installation manpower, material, tools, assembly, installation and
start-up of the equipment to commissioning. Included are all necessary connections between the
components as well as to the control cabinets.
b. The supplier is responsible for all necessary labor and material for assembly of wiring for connection
between the control cabinets and equipments.
c. The supplier is responsible for insurance, lodging, transport, translators and personal expenses of site
personnel.

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 d. The supplier site office and store is responsibility of supplier. Ford will provide power connection at
supplier cost.
e. The supplier's site supervisor(s) are to conduct daily shift to shift line up meetings and provide a weekly
report of work progress reflected on a master schedule.

12.0 LAUNCH AND SERVICE

• After final acceptance the project launch assistance by required number of electrical technician for (1)
one week is required and is a part of the order. Working in one shift ( working 45 hours/week ) including
the weekends and the public holidays is required.
• After final acceptance, sufficient personnel will be on site for coverage of failures on mechanincs and
electrics systems by one week. If there are failures comming up, which influencing the functions, this
coverage must be continued till one week of faultless run has passed.
• A withdrawal of personel is permitted only in coordination with the staff of the responsible department.

• In case of failures which don't allow a start of production, the manufacturer has to take actions (e.g.
provisions, manpower) for running production unhindered.

• For the time span from production start to production coverage and sorting out of all fault-items, the
staff of the manufacturer is fully responsible for the maintenance of the equipment. At this time all kind
of failures, stoppages, faults, defects will be repaired by the manufacturer and the equipment must be
observed and controlled in connection with the total production flow.

• Up to a perfect and reliable functioning of the equipment sufficient manpower on site for all that work
must be guaranteed.

• Irregularities, stoppages, failures and their reasons have to be written down in failure reports and in
daily discussions with the engineers. Measurements of repair found outs and required coordination
must be supplied. Resulting changes from that must be taken over to maintenance manuals, operating
manuals, drawings and circuit diagrams urgently.

13.0 SPARE PARTS

Along with the Equipment, the Supplier Company sends the recommended spare parts list,
consumables list and their supply term. In this recommended spare part list, names of sub-supplier
companies and how to contact these companies must be defined clearly. Spare parts shall be identified
on all drawings with the manufacturer's part number, not only the project supplier's I.D. number.

The supplier guarantees to provide spare parts upon FORD OTOSAN’s request for 10 years following
system delivery time.

All main spare and wear parts (except stand by parts) have to be available and procurable within 24
hours.

14.0 WARRANTY
Supplier shall provide as part of the base bid contract, warranty will start only final acceptance is signed:
o Full warranty on the total equipment during the tryout and subsequent 3-shift production for a period
of 24 months (Unless otherwise indicated in the sales agreement ) beginning with a date of final
acceptance by the FORD OTOSAN.
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 o Supplier to submit statement of compliance upon final acceptance showing date start of the
warrantee period as part of the closeout documents.
o The supplier cannot extend or reduce the warranty period on behalf of his suppliers for propriety
items but he has to be prepared to supply these items free of charge for the full warranty period.
This should not be applied in case of operating errors caused by FORD OTOSAN personnel.
Maintenance and repair during the warranty period;
o During the warranty period written in the agreement, the supplier company is obliged to transport its
required service personnel to FORD OTOSAN in 24 hours for direct breakdowns which may occur
on the Equipment; and in 48 hours for indirect breakdowns. All expenditures of service personnel
belong to the Supplier Company.
o If the replaced parts are replaced due to misuse, the cost of the parts will be paid by FORD
OTOSAN, and in other circumstances, these costs will be paid by the Supplier Company.
o In cases where a request - related to the issue of sending the replacement of defective parts without
a need for service personnel – comes from FORD-OTOSAN, the Supplier Company is obliged to
send the part in 24 hours if the spare part is in local agent's stock otherwise a minimum time from
supplier company has to be declared. All costs are paid by the supplier. After FORD-OTOSAN
replaces the defective parts with new ones, it will send the defective part to the Supplier Company
for inspections.
o Supplier shall provide the service plan/commitment for the after sales service in Kocaeli Plant during
the bidding. Supplier can prefer to deploy a local service team who trained by supplier. Supplier has
to keep its engineers’ visa ( work permit visa of Turkey ) ready to travel Kocaeli Plant in case of local
service and remote assistant cannot resolve the issue for the warranty period.

15.0 RELIABILITY & MAINTAINABILITY

High reliability and good maintainability has to be ensured. That means for example good accessibility,
modular design, high safety and use of synoptic-systems.

In additionally to this specification, Ford Otosan Reliability & Maintainability Specification has to be used.
Supplier will be responsible to cover all issues, which are identified in R&M Matrix and has to prepare own
plan according to this matrix.

Supplier will be responsible to reach MTBF/MTTR targets, which will be given by Ford Otosan within R&M
Matrix during phases.

Attachment 1: Ford Otosan Reliability & Maintainability Specification.

Attachment 2: R&M Matrix.
Attachment 3: R&M Program Plan Worksheet.
Attachment 4: R&M Environment Checklist.
Attachment 5: R&M LCC Analysis.
Attachment 6: FTPM New Equipment Criteria.

16.0 SPECIFICATIONS FOR OCCUPATIONAL SAFETY AND HEALTH

• For the project, CE certificates of the equipments must be delivered.

• The project must comply with Machine Directive 2006/42/EC, 2014/35/EU LVD, 2014/30/EU EMC
regulations.
• All warning signs on the machine must be Turkish.
• The protectors will protect the operator and the other personnel assigned to the equipment against
accidents, occupational accidents and occupational illnesses; it must have a quality and form which will
prevent piece splashes and dust situations. The protectors must also be in a form which will prevent the
contact of those – who are not directly related to the machine and who are around the equipment – with
the moving parts of the machine.
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 • The design of the equipment and its establishment on the machine must be in a way that does not hinder
the staff working on the equipment, that does not disrupt the production and that does not disturb the
quality.
• The protectors must be fit for purpose, fit and durable for use, and it must be in a way which allows
maintenance without removing them.
• According to the specifications of all equipment, operation points must be taken in the appropriate
protector.
• All platforms and ladders – which are in the scope of the equipment – must be proper and they must
prevent sliding.
• The points which require electrically locking/reset and hydraulic/pneumatic locking/reset will be marked
and labeled on the machine visually.
• The equipment must be designed in a way in which it does not start unless all of the protectors are
active.
• In order to prevent and control the dangers - which compressed air, oil, etc. can cause – there must be
a discharge valve on the equipment.
• If the electricity is cut off in the facility, the equipment units must be designed in a way which will not
allow their uncontrolled movement.
• In order to prevent the contact of operator to the rotating and moving parts in the equipment and to
prevent the entry to the machine during operation, all safety systems must be provided mechanically
and electrically.
• In areas which have more than 24 VDC/AC voltage value, there shouldn’t be any open contact point.
• Every electrical, pneumatic, hydraulic and lubrication component has to be identified by permanent
labels, which content at least the number out of the drawing. If main components respectively equipment
are covered, labels have to be installed on the covering. The language of the labels have to be both in
Turkish and English.
• All (sensitive) components in walkable areas have to be protected by coverings.

17.0 ENVIRONMENT SPECIFICATIONS

• Project will be fully compliance with ISO 14001 Environment Quality Management System.
• Hazardous wastes – which resulted from the usage of the equipment – must be defined (according to
the Directive on Control of Hazardous Wastes), and an approximate quantity must be provided if
possible. Reduction, recycling and elimination alternatives must be provided.
• If any coolant gas will be used while using the equipment, the specifications of the gas must be stated,
and the gas – which will be used – must be in compliance with the Directive on Reduction of Ozone-
Depleting Substances.
• The type of cooling gas must be R407c and its quantity must be notified after the order.
• The installed power and electric energy consumption of the machine must be notified after the order.
Necessary steps must be taken in order to reduce the electricity consumption.
• The chemicals – to be used – must be listed if they are determined; and their specifications must be
notified with a Material Safety Information Form. CAS numbers of the used chemicals and components
must be given.
• The manufacturer companies, their sub-suppliers, their alternatives of all chemicals such as oil, coolant
fluid, cutting fluid, cooling gas, all technical data related to these products and material safety information
forms must be delivered along with the machine.
• In order to prevent the leakage of cooling and cutting fluids and any oil – which will be used – to the
environment, necessary precautions must be taken, and they must be shared with FORD OTOSAN. The
impermeability tests must be conducted during installation and their reports must be provided during
admittances.

18.0 ERGONOMY SPECIFICATIONS

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 • All pushing, pulling, lifting and carrying procedures during the operation must be determined beforehand;
and by making their analyses, appropriate lifting and carrying elements must be used if necessary.
• There must not be any jagged and sharp points in the operation environment – to which the worker might
be exposed.
• The settlement must be designed in a way in which bending, twisting and rotating movements will be
decreased to minimum.
• The operator must not work at the head level for a long time. Controls must not be placed at these levels.
• The indicators of the controls must be defined in way in which they can be understood easily. Apart from
color separation, additional definitions must be provided in order that the color blind operator does not
have any difficulty or make errors.
• In order to facilitate the trouble-shooting and to accelerate the daily/weekly/monthly maintenances, the
indicators must be within easy reach.
• If the indicators or control points are left behind the protection covers, accessibility will be provided with
transparent or hinged covers.
• The maintenance must be enabled to be conducted in a way which does not allow inappropriate body
stances and movements.
• The noise level must not exceed 85 dBA at the distance of 1 meter away from the related equipment.
• A system – which enables the discharge of gas wastes such as vapor and smoke which occur after the
conducted procedure – must be available. The operation of this system must be described in the offer
clearly.

19.0 STANDARDS
Electrical equipment and installation shall conform to the most current version of the Ford and industrial
regulatory standards. The intent of the Ford Motor Company, and the suppliers bid, shall be to harmonize
both the Ford Manufacturing standards, and the regional/international regulatory standards to define a
single product that can be installed in multiple regions.

All equipment is to be supplied to conform with all relevant regulations, recommendations and standards
(safety in the use of power presses), and any other pertinent statutory or advisory bodies. Special attention
is required to comply with the relevant National Standards and Ford Standards.

The supplied machines, systems, units etc. must comply in each of their constituent components with the
provisions of the EC Directive for Machines / Directive of the Council dated 2006 (Machine Directive)
(2006/42/EG), and any current addenda or the national legislation into which these have been adopted.
The supplier must confirm compliance with the above/below mentioned requirement in his tender and is
responsible for its corresponding implementation in the event of being awarded the contract.

Also Ford General Electric Specification and Ford Energy Control and Power Lockout procedures are
valid and compulsory to comply with.

19.1 Ford SBU Electrical Hardware/Software, Pneumatic, Hydraulic and Lube design shall meet
Ford SBU Controls Standards:

• 2630 SBU Electrical Data Form

• DR 13 FNA General Electrical section 1-4 and 6
• DR 45 SBU Programming Standards
• DR 46 SBU Automation HMI Specification
• DR 48 SBU Controls Acceptance Checksheet 1.0

19.2 Ford SBU Maintenance and Spare Parts Requirements per Ford SBU MSO Standards:

1. DR 32 – Maintenance Elements_v1
2. DR 40 – Spare Parts Process_v1
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 3. Equipment Maintenance Requirements r3
4. M-Task Template
5. NA Universal Spare Parts Template 0314 R1

19.3 Ford Global Standards:

• Ford Standard w-EM1, AC Electric Motors
• Ford Standard w-EL10 Appendix 1 Design Build and Installation Assessment 07 May 14
• Ford Standard w-KA0, Manufacturing Equipment Guarding
• Ford Standard w-KA1, Weight Marking of Manufacturing Equipment
• Ford Standard w-KA2, Manufacturing Equipment Handling and Packaging
• Bulletin 1100, Construction Safety Guideline
• Ford Standard w-EJW, Global Jumper Wire Policy
• Reference Guide FMEA Handbook

19.4 Ford Safety Standards

• Ford Safety Bulletin FAS08-015, Health and Safety Rules, Work Permits, Licenses & Compliance
• Ford Safety Bulletin FAS08-035, New Process Design & Installation Review Procedure
• Ford Safety Bulletin FAS08-036, Risk Assessments
• Ford Safety Bulletin FAS08-100, Energy Control and Power Lock Out and Permitted Minor Tasks
• Ford Safety Bulletin FAS08-102 Energy Control and Power Lock Out Placards
• Ford Safety Bulletin FAS08-145, Secondary Restraints
• Ford Safety Bulletin FAS08-212, Occupational Noise Standard
• Ford Safety Bulletin FAS08-254, Global Confined Space Standard
• Ford ECPL Placarding Requirements, Placarding, Template for creating ECPL, ECSPMT and ECTLCD
(Energy Control Tasks using Lockable Control Device) Placards
• Ford "ProTag" Launch Requirements
• FAS08-037_FacilityJob_Risk_Assessment_and_Control
• ISO_Safety_Label_Reference
• Pre-Task Risk Form v1.0
• FAS08-075 Contractor Safety Management

19.5 ISO Standards

• EN 692 Mechanical Presses
• EN 982 Safety of Machinery, Safety Requirements for Fluid Power Sys & Their Components, Hydraulic
• EN 983 Safety of Machinery, Safety Requirements for Fluid Power Sys & Their Components, Pneumatic
• EN 1050 Safety of Machinery, Principles of Risk Assessment
• ISO 3864 Colors and Safety Signs
• EN ISO 4871:2009 Acoustics - Declaration and verification of noise emission values of machinery and
equipment
• ISO/EN 11161 Safety of Integrated Manufacturing Systems
• ISO/EN 12100 Safety of Machinery – Basic Concepts, General Principles for Design Parts 1 & 2
• EN ISO 12100:2010 Risk Assessment
• EN 13101 Steps for Underground Man Entry Chambers
• ISO/EN 13849 Safety Related Parts of Control Systems Parts 1 and 2 (Replaces EN 954-1)
• ISO/EN 13850 Safety of Machinery, Emergency Stops Devices, Principles for Design
• ISO 13854 Safety of Machinery, Minimum Distances to Avoid Crushing Injuries of Human Body (EN
349)
• ISO 13855 Safety of Machinery, Position of Protective Equip, Approach Speeds of Human Body (EN
999)
• ISO/EN 13857 Safety of Machinery, Safety Distances to Prevent Danger Zones Being Reached
• ISO 14118 Safety of Machinery, Prevention of Unexpected Start Up, Isolation, Energy Dissipation. (EN
1037)
• EN ISO 14118:2018 Prevention of unexpected operations (LOTO requirements)
• ISO 14119 Safety of Machinery, Interlocking Devices associated with Guards (EN 1088)

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 • ISO 14120 Safety of Machinery, General Requirements for Design and Construction of Guards (EN 953)
• ISO/EN 14121 Safety of Machinery, Principles of Risk Assessments
• EN 14122 – Safety of Machinery, Permanent Means of Access to Machinery, Parts 1, 2, 3, 4, Access
between levels, Platforms, Stairs and Guardrails, Fixed ladders
• EN ISO 14122-1:2016 Safety of machinery — Permanent means of access to machinery
• EN ISO 14122-2:2016 Safety of machinery — Permanent means of access to machinery; Working
platforms and walkways
• EN ISO 16092-1:2018 Machine tools safety. Presses. General safety requirements
• EN ISO 16092-1 : Machine Tools – Presses – General Safety Requirements
• EN ISO 16092-2 : Machine Tools – Presses – Safety Requirements for Mechanical Presses
• EN ISO 16092-3: 2018 Machine tools safety — Presses — Part 3: Safety requirements for hydraulic
presses
• EN 60204-1 : Electric Machines Equipment
• EN 61310 – Safety of Machinery – Indication, Marking and Actuation, Parts 1, 2, 3
• EN 61508-2 : Safety-Related Electrical/Electronics/Programmable Electronic Systems Requirements
• EN ISO 62061 : Functional Electrical, Electronic and Programmable Electronic Control Systems related to
Security
• 2006/42/EC Machinery Safety Directive
• 2014/35/EU Directive on the Electrical Equipment Designed for Use within Certain Voltage Limits
• 2014/30/EU Electromagnetic Compatibility Directive
• 2014/68/EU Directive on Pressurized Equipment
• 2000/14/EC Directive on the Noise Emission in the Environment by Equipment for Use Outdoors

19.6 OSHA Standards

• OSHA 1910 Machinery and Machinery Guarding, Subpart O OSHA 1910.211 Definitions
• OSHA 1910.212 General Requirements for All Machines
• OSHA 1910.217 Mechanical Power Presses, and App A, B, C and D OSHA 1910.219 Mechanical Power
• OSHA 1910.399 Electrical Definitions
• OSHA Publication 3067, Concepts and Techniques of Machine Guarding

19.7 UL Standards

• UL-508A Industrial Control Equipment

• UL-1998 Software in Programmable Components

<<<< END OF SPECIFICATION >>>>

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