2

MEG-PRG-CMF-001-100 Rev 01

Automatic inspection cell

CREATED / REVISED BY VALIDATED BY

Rodrigo Sánchez Yazmin Covarrubias
Process
Aug 2019 PML Aug 2019
Specialist
Function Date Signature Function Date Signature

APPROVED BY PLANT APPROVAL BY

Saul Brizuela / Bertha Silva Roman Malacara
Manufacturing
Aug 2019 PPTL Aug 2019
Manager
Function Date Signature Function Date Signature
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1. TABLE OF CONTENTS

1. Table Of Contents ........................................................................................................................ 2

2. Document Distribution ................................................................................................................ 3
3. Specification Revision Information ............................................................................................. 4
4. Project Overview ......................................................................................................................... 5
5. Part Variants ................................................................................................................................ 9
6. Tooling Specification ................................................................................................................. 12
7. Station specification. .................................................................................................................. 13
8. Sequence: ................................................................................................................................... 15
9. Equipment detail. ....................................................................................................................... 16
10. Summary of Quote ..................................................................................................................... 17
11. Appendices ................................................................................................................................ 18

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2. DOCUMENT DISTRIBUTION
2.1. Faurecia Personnel

Name Department / Location Signature

Rodrigo Sánchez Process / SLP
Saul Brizuela ME program manager /
SLP
Yazmin Covarrubias PML / Santa Fe
Roman Malacara PPTL /SLP
Bertha Silva ME plant manager

2.2. Vendor Personnel

Name Department / Location Signature

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3. SPECIFICATION REVISION INFORMATION

Current Section Modification Modified

Revision Modified By
01 All Creation R. Sánchez

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4. PROJECT OVERVIEW
4.1. This specification is for the integration of new Automatic inspection cell at the Faurecia plant in San Luis Potosí,
México that will be used to check specific quality inspection for all Cushion 6W/8W CMF references.
4.1.1. Machine will be built in a Generic cell concept where all the pneumatic and electric component that
are dedicated to the product, shall be part of the tooling (manifolds, master I/O link, slaves I/O etc), see
more detail in Tooling section.
4.2. Faurecia will provide drawing packages but the vendor shall remain design responsible, as the drawing package
shall be considered as reference only.
4.3. This specification shall be used in conjunction with the following specifications:
4.3.1. MEG-TECH-001-001 Rev 02 – Kick Off
4.3.2. MEG-TECH-001-002 Rev 01 – Concept Acceptance
4.3.3. MEG-TECH-001-003 Rev 01 – Design Acceptance
4.3.4. MEG-TECH-001-004 Rev 01 – Build Acceptance
4.3.5. MEG-TECH-001-005 Rev 01 – Ship Acceptance
4.3.6. MEG-TECH-001-006 Rev 01 – Run Off Acceptance
4.3.7. MEG-TECH-001-015 Rev 0.3 -- Mandatory Rules – Screwing
4.3.8. MEG-TECH-001 Rev 01 - Appendix D Ergonomic Memo.
4.3.9. FAU-F-DSG-6098 Machine Evaluation Form_version3
4.3.10. All safety devices must be according:
• FST-S-LSE-5829 HSE standard specifications - Issue 06.
• Specific requirements of Faurecia are:
• Are to be taken into account into the risk assessment:
• Small severities of injuries must be protected (S1 in ISO13849) – no injuries are admitted as
a residual risk, all significant risks identified by 3rd party must be solved before SOP (GATE 3)
• A double hand control is not considered as a mean of protection as a second employee may
be hurt. Double hand controls are prohibited except if used in setup mode or if necessary due to
any legal requirement
• Speed reduction is not a mean of protection if a risk of injury is still existing, if this is
technically not feasible Faurecia must be informed priory
• No self-starting machine are admitted (cf. ISO 12100) except if specified by FAURECIA
• Lighting: Led lights will be implemented by two, in phase opposition to avoid stroboscopic
effects. Lighting of Indoor work places must respect norm ISO 8995
• Faurecia ergonomic memorandum requirements must be respected FAU-S-LSG-5803 and
the Ergo golden rules FST-S-LSE-5811
• Automatic clamping must be realized by not creating any pinch risk (e.g.: with means of
graduated pressure increase, space reduction, “safe press tool principle”, etc.)

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• Any hydraulic press must be fitted with an automatic fail safe device preventing the stamp
from falling in the case of zero hydraulic pressure
• Any mechanical press must be fitted with an automatic fail safe device preventing the stamp
from falling in the case of zero hydraulic pressure
• ESPD’s (Electro Sensitive Protection Devices) must be checked with concerns to the position
according to ISO 13855, measurements and calculation shall be documented.
• Mechanical interlock must be able to be equipped with a padlock in case of intervention
inside the machine.
The metal equipment (tanks, capacity, piping) must meet regulations and standards,
particularly for explosive or flammable products. (tests for compliance of the capacity must be
done and certificate confirmed by supplier.
4.3.11. SRECS and SRP/CS design
SRECS = Safety Related Electrical Control System
SRP/CS = Safety Related Part of a Control System
• Design and validation of SRECS shall be in accordance with EN ISO 13849 T1/T2.
• The volume and the mode of operation of each safety function must be documented.
• All parameters which are relevant and described within the context of EN ISO 13849-1, such as
PL, MTTFd, PFH, Cat, CCF, DC, T10d, B10d as well as the block circuit diagrams must also
be delivered for the respective subassemblies or corresponding safety function used. It must be
possible to see clear references between the elements of the block circuit diagram and the real
components (e.g. through stating the equipment designation in the respective block circuit
diagram to a safety function).
• Furthermore, the project planning for the safety functions with the BGIA software "SISTEMA"
as well as the protocols generated by SISTEMA must be delivered. The SISTEMA project
status must be "green".
• Result will give PLr result. Every result below “d” means a single channel safety circuit and
this must be used only for low risk (absence of signal redundancy).
• The MTTFd must be designed for the following operating times of the machine:
• Cycle time specified in the requirement specification.
• Requirements for safety functions from setup frequency, interferences, etc.
• 24 hours runtime per day
• 6 days per week
• 50 weeks per year
Replacement of SRP/CS - required for the necessary Performance Levels (PL) before the end of
their service life of 20 years is prohibited. Deviations must be released formally by
FAURECIA.

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• . Cobots & Robots

Specifications:
• Faurecia nominates 3rd party to check compliance with the standards and legal requirements.
• HSE minimum criteria for Robot/Cobot
• Typical expectations on Robot/Cobot application safety:
• The Robot/Cobot application must be equipped with reliable protective measures to avoid
any injury to any person.
System integrator must present a risk assessment to demonstrate application is safe to operate
including tools (screw driver, iron…).
• Content of checks
• Robot/Cobot must obey the Standards (see list below) and all applicable local legal
requirements.
• 1) Local regulation (example for Europe: Machinery Directive 2006/42/EC) –this is up to the
3rd part expert to justify which regulation has been taken into account and why
• 2) ISO 10218-1 2011 : Robots and robotic devices -- Safety requirements for industrial robots --
Part 1: Robots
• 3) ISO 10218-2:2011 Robots and robotics devices – Safety requirements for industrial robots –
Part 2: robot systems and integration
• 4) IEC 62061 Safety of machinery: Functional safety of electrical, electronic and programmable
electronic control systems
• 5) ISO/TS15066:2016 Robots and robotics devices – Collaborative robots
• 6) EN ISO 12100 2012 Safety of machinery. General principles of machinery. General
designing principles – Risk assessment and risk decrease.
• 7) EN 349+A1 2010 Machinery. Safety. Minimal distances avoiding crush of human body parts
• 8) EN 1037+A1 2010 Safety of machinery – Prevention of unexpected start-up.
• 9) EN ISO 13857 2010 Safety of machinery – Safety distances avoiding touching to hazardous
zones with upper and bottom limbs.
• 10) EN ISO 13849-1 2016 Safety of machinery - Safety-related parts of control systems - Part
1: General principles for design
• 11) EN ISO 13850 2016 Safety of machinery - Emergency stop - Principles for design.
• 12) EN ISO 14120 2016 Safety of machinery - Guards - General requirements for the design
and construction of fixed and movable guards.
• 13) EN 60204-1 2010 Safety of machinery – Electrical equipment of machines – Part 1:
General requirements.
• 14) EN ISO 13855 2010 Safety of machinery -- Positioning of safeguards with respect to the
approach speeds of parts of the human body

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• Prior any usage (even trial) check system integrator has delivered:
• Protocol of design check
• Protocol of type testing
• Protocol of routine testing
• Commissioning protocol at Faurecia facilities
Procedure of periodical commissioning performed by the user (Faurecia).
• Schedule of regular checking with timeframe performed by authorized persons
• The system integrator must deliver manual in English and local language (including
maintenance and service)
Prior any usage (even trial) a training (including maintenance and service) needs to be
performed by system integrator or its representative

4.4. All assumptions and deviations to the specification are to be under the same heading in the quotation, or they will
be considered invalid
4.5. Delivery time requested to get the line ready to test good parts at Faurecia’s SLP facilities is Dec, 2019.
4.6. Ready for IJ CORE according to MEG-TECH-037 - IJ Core machine interface.pdf

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5.
5.1.
No.
Point

1820951X
8WP LHD
1820949X
8WP LHD M
PART VARIANTS

1874603X 8WP
LHD CCS MEMO
Machine shall test All CMF References.

1183312X
1875587X 8WP
LHD CCS no Memo
1875677X 6WM 1183311X
1820952X LH
8WP RHD
Characteristics

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1875691x 2004399X

P71A
1820950X 8WP LH
CMF-1

8WP RHD
L42P
1875701X 2000785X
1820953X 8WP LH memo
8WP RHD ODS

MEG-PRG-NISSAN-001-100 REV 001-AUTOMATIC INSPECTION MACHINE.DOCX6WP-8WP Cushion Conveyor

1735343X
1874604X
8WP RHD ODS CCS

1874602X
8WP RHD CCS memo

1875586X
8WP RHD CCS no MEMO
Supplier
Confirmation

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L21B

2167499X

2167494X

W33A
2444589X

2444599X

2444600X

P42QR
2548770X

2548771X

2548780X

2548728X

2548781X

2548733X

2548782X

2548729X

5.2. Drawings Overview (detailed information in the Appendix drawing folder package).

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5.3. Characteristics to be inspected.

5.3.1. 8W Example, 6 Lockbolts in different position for L42P (1875691X)

5.3.2. 6W Example, 4 Lockbolts in different position for L21B (1875691X)

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6. TOOLING SPECIFICATION
6.1. One tool for each reference.
6.1.1. Quick change over between families [CMF1, L42P, P71A, L21B, W33A, P42QR (if possible, no quick
change over between similar families).
6.2. Tooling concept shall be designed with the minimal technical solution.
6.2.1. Max two presence sensor to detect cushion.
6.2.2. Automatic clamping where its coincident between all references.
6.2.3. Clamping, or any point of the tooling must not damage the Cushion.
6.3. The tooling shall be designed using the Metric standard.
6.3.1. All purchased components shall use metric.
6.3.2. All drawings shall be in metric.
6.4. Where Faurecia does not provide their standard cell drawings, cells should not exceed 120% of the width of the
product.
6.5. The tooling drawings shall be provided to Faurecia in Solidworks.
6.5.1. The title blocks on all drawings shall clearly state that the drawings are Faurecia property.
6.5.2. All tooling drawings shall be numbered according to a defined BOM.
6.6. The lifetime of the tooling shall be assumed to be 10 years.
6.6.1. Working conditions are 7 days a week with 3, 8 hour shifts each day.
6.7. All material shall last a minimum of 5 years.
6.7.1. All material shall be approved by the FPS.
6.7.2. The vendor shall assume that the tool will have a minimum of 1,000,000 cycles per year.
6.8. Moving the line unit is to be done by forklift and handling to be done without any disassembly operation inside
the cell. This will allow for easy move and set up within the plant. Fork lift access must be 4-way and access
tubes dimensions to be 8” x 6”.
6.8.1. The vendor shall also provide 4 eyebolt locations for moving the equipment with a crane.
6.9. All shims and dowel pins shall conform to industry standard, custom made shims and dowel pins are not
permitted.
6.9.1. Faurecia uses NAAMS spacers.
6.9.2. The vendor shall work to limit the variety of spacers and dowels within the tooling.
6.10. All moveable tooling/sensors shall be positively located using spacers. No slotted movements are permitted.
6.11. Sensor mounting bracket will have a minimum material thickness of 6.35mm, and will not be subject to
deflection under operation loads

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6.12. All proximity sensors should be mounted within quick release collars.

6.13. All tooling elements shall have a minimum of two dowel pins to ensure proper location.
6.13.1. All dowel pins shall be minimum 6mm in diameter.
6.13.2. All dowel pins shall be “pull” dowels.
6.14. All tooling that needs to be changed over during production shall be designed to be removed with no special
tools.
6.14.1. Changeover time
• Heavy capacity equipment (presses, welders, etc.) shall be able to have tool changeover within 10
minutes.
• Final assembly equipment shall have changeover completed within one cycle. (changeover time <=
cycle time)
6.15. The VPM shall provide a detailed spare parts list indicating expected lifetime.
6.15.1. Purchased items and fabricated items shall be listed separately.
6.16. All fabricated components shall be engraved with their part number in accordance to the BOM.
6.16.1. The engraving shall be on a surface not exposed to wear.
6.17. Pneumatic valves and I/O modules shall be part of the tooling.
6.17.1. Quick connection for pneumatic and electric communication.

7. STATION SPECIFICATION.
7.1. HMI with acrylic protection.
7.2. Industrial PC as IJ CORE Back up, to store photos
7.3. Lighting and fan and work instructions holders
7.4. No dog cage allowed.
7.4.1. 3 Light barriers and a wall behind the machine is allowed.
7.5. The control cabinet must allow Lateral input / output of material
7.6. Handled scanner
7.7. Red bin for NOK parts
7.7.1. Red bin must be designed in order to avoid additional damage to the component.
7.7.2. Red bin will allow Maximun 1 part of the largest model

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7.8. The station must have printer by TCP/IP with printer Zebra Z410 (with termal transfer).
7.8.1. Label Lay out.

7.9. Finger print reader to allow specific action in machine [Machine will be allowed to store users by finger print
Min 5 users].
7.9.1. Reprint.
7.9.2. Remove parts from Red bin
7.9.3. Modify parameters

7.10. Robot / Cobot Solution.

7.10.1. Able to hold a Camera (Max 10 kg).
7.10.2. Able to enter inside the most hidden parts of the cushion (small size).

7.11. Camera or vision sensor that can:

7.11.1. Detect NOK condition for lockbolt process.
7.11.2. Measurement not necessary but recommended.

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8. SEQUENCE:
CT 20 sec as target with load and unload.
8.1. Operator Loads Cushion into jig.
8.2. Operator scan label cushion.
8.2.1. PLC will storage read labels to avoid have repeated labels (reprinted from assembly process).
8.3. Operator push start cycle (outside the danger zone).
8.4. Machine clamps part
8.5. Machine calls the routine and start the inspection.
8.6. All photos taken by the camera must be send to IJ CORE with the read label.
8.7. If ok, machine prints a Label
8.7.1. If NOK, machine ask to remove part and put in the Red bin (EKS required).
8.7.2. Machine will print NOK label and operator place it on cushion.
8.8. Operator place label on cushion.
8.9. Operator take parts and send to container box.

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9. EQUIPMENT DETAIL.
9.1. All pinch points must be cover, all edges rounded & manual clamping pinch points in red
9.2. Must achieve a R&R in key characteristics.
9.3. The vendor shall use Ethernet/IP for all communications (For Siemes PLC shall be used Profibus/Profinet).
9.4. HMI cabinet with Euchner reader.
9.5. The HMI must have little hooks or metal plate to place properly our PI Tag (MR3).

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10. SUMMARY OF QUOTE

10.1. The vendor must BREAKDOWN the quote on the following items:
10.1.1. Automatic inspection machine – Capital
10.1.2. Automatic inspection machine – Tooling
10.1.3. Shipping and installation at Faurecia-SLP, Mexico
10.1.4. Parts recollection in SLP to supplier facilities.
10.1.5. Training.
10.2. Vendor is responsible for:
10.2.1. Documentation (User Manual and drawings) in English and Spanish.
• Mechanic drawings deliver in 3D and 2D (pdf, DWG, solid works PTR, ASM files)
• Electric drawings in PDF and an editable format DWG file.
• Detailed BOM of the station drawings.
• Detail recommended spare parts high lighting the critic spare parts
• A detail shim log

10.3. Faurecia contacts:

10.3.1. Buying contact: Luis Barbosa
luis.barbosa@faurecia.com
+52 1 444 204 6997

10.3.2. Manufacture contact: Yazmin Covarrubias

yazmin.covarrubias@faurecia.com
+52 44 41 79 97 28

Rodrigo Sánchez
Rodrigo.sanchezrojas@faurecia.com
+5215562669260

10.3.3. Shipping Address: Faurecia Sistemas Automotrices de México S.A. de C.V.

Av. Central #200 Parque Logístico
Eje 140 #365
San Luis Potosí, SLP 78395 MEXICO.

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11. APPENDICES
A: Drawing package and product CAD.

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