PEDCO - Technical dossier - Assembly and testing requirements and

questions - Ops & BOM data 1

1- The production capacity of each type of battery charger on which the plant will be designed.
 

  1.  CP 70 R   from 300 A to 600 A

  2.  FR 40 R   from 50 A to 250 A

Volumes per year SEC sold by Pedco: (PEDCO)

2019

 FP40R => FP50R: 30 Units

 CP70R => FP70R: 18 Units
2020

 FP40R => FP50R: 9 Units

 CP70R => FP70R: 24 Units
2021

 FP40R => FP50R: 90 Units

 CP70R => FP70R: 30 Units
2022

 FP40R => FP50R: 43 Units + 60 Units (Expected)

 CP70R => FP70R: 2 Units + 20 Units (Expected)
2023

 FP40R => FP50R: 100 Units

 CP70R => FP70R: 45 Units
2024

 FP40R => FP50R: 125 Units

 CP70R => FP70R: 50 Units

The yearly sales of chargers in entire Saudi market at an average of USD 15 Million (Source: Saudi customs).

Please define charger ratings, with both dc voltage and current (48Vdc 50, 100, 160, 250A and 110Vdc 100, 160, 320, 400, 600A for
example).

The most common ratings and dc voltage are as below:

 125VDC – 100A, 200A, 450A, 550A

 48VDC – 100A, 200A
 50VDC – 50A, 100A

Other volumes per year sold by Chloride to ABB and other OEMs for Saudi Customers => Chloride

 FP40R => FP50R:

 CP70R => FP70R:
2- Factory outlines per product.

Assembly line layout. Basic information => Chloride

 FP40R (and later FP50R) at first

3. Production phases with description of manufacturing processes for each product with technical
specifications for equipment.

Key steps of assembly and testing => Chloride see below table
Sequence Description of assembly step
1 Baseframe assembly
2 Mechanical structure frame & Transformer mounting
3 Bridge subassembly manufacturing & mounting
4 Capacitors & coupling diodes
5 Distribution components mounting & cabling
6 Display mounting &cabling
7 Power cabling
8 PCBA cabling and additional wiring
9 Anti contact Protection elements
10 Cabinet covering / panel
11 Stickers & labels
12 Mechanical Protection elements
13 Lifting rings
14 Ground continuity test
15 Routing tests
16 Packing

Pre-requisites:

Define who does what (Chloride and Pedco) based on standard routings => Chloride

See below table (point 4)

4- Raw materials, types and sources of access.

Assembly/ Supply Chain strategy:

 Target: 30% to 35% local content including material and labor

 FP40R (and later FP50R): 90% is material and 10% manufacturing/testing hours
o Use of the following 5 ratings compliant to TMSS:
 125VDC – 100A, 200A, 450A
 48VDC – 100A, 200A
o In BOM/Charger system value: % of cost per commodity
We consider that PEDCO share could be between 25 to 33% of MMC (according to ratings and systems configuration)
This may not be achieved as a first step (to be discussed)
This needs to be refined according to local labor rates and local material prices
Panels, part of protections and part of MSC (miscellaneous) would be supplied by PEDCO
To be added, local engineering, manufacturing and test need to be also added

Star item Rating STRUCTURE PANELS TRANSFORMER BRIDGE/CAP ELECTRONIC PROTECTIONS MISC TOTAL
211 311 399 649 728 154 460 2912
FP40R1I-1640931 FP40R 48Vdc 100/110A
7% 11% 14% 22% 25% 5% 16% 100%
266 369 554 509 414 234 483 2830
FP40R1IB-10191008 FP40R 48Vdc 200A
9% 13% 20% 18% 15% 8% 17% 100%
277 369 675 550 581 199 427 3077
FP40R1IB-14307894 FP40R 125Vdc 100A
9% 12% 22% 18% 19% 6% 14% 100%
441 402 918 1188 485 210 420 4063
FP40R1IB-14306217 FP40R 125Vdc 200A
11% 10% 23% 29% 12% 5% 10% 100%
635 927 1769 1063 558 686 1062 6700
CP70R1I-1552019 CP70R 125Vdc 450A
9% 14% 26% 16% 8% 10% 16% 100%

Hours rate 50 30 35

Star item Rating Project Manufacturing Test TOTAL

8 20 8 36
FP40R1I-1640931 FP40R 48Vdc 100/110A
31% 47% 22% 100%
8 22 8 38
FP40R1IB-10191008 FP40R 48Vdc 200A
30% 49% 21% 100%
8 25 8 41
FP40R1IB-14307894 FP40R 125Vdc 100A
28% 56% 21% 105%
8 27 8 43
FP40R1IB-14306217 FP40R 125Vdc 200A
27% 54% 19% 100%
8 30 10 48
CP70R1I-1552019 CP70R 125Vdc 450A
24% 55% 21% 100%

Rating Material Project Manufacturing Test TOTAL MMC

2912 400 600 280 4192
FP40R 48Vdc 100/110A
69% 10% 14% 7% 100%
2830 400 660 280 4170
FP40R 48Vdc 200A
68% 10% 16% 7% 100%
3077 400 750 280 4507
FP40R 125Vdc 100A
68% 9% 17% 6% 100%
4063 400 810 280 5553
FP40R 125Vdc 200A
73% 7% 15% 5% 100%
6700 400 900 350 8350
CP70R 125Vdc 450A
80% 5% 11% 4% 100%

Define what requires Chloride factory qualification => Chloride

 CP70R (later FP70R): 80% is material and 20% manufacturing/testing hours

Will be a 2nd stage.
5- Technical product specifications.

 PEDCO has it. PEDCO to send product specifications to Chloride for double check. => PEDCO
o TMSS specification FP40R product compliance.
o Shall we send standard catalog datasheet for FP40R and CP70R.

6. Cost of raw materials required to cover production for each separate product.

 See Question 4. => Chloride

7- Environmental impact of the plant

Weighted risk rating

Category Activity Risk identified and addressed Potential impact Means of control / mitigation
(likelihood x impact)

PPE, fire extinguishers, evacuation protocols, training

Electrical test Equipment testing product test incident: outbreak of fire - fire - explosion Air pollution 3 - High
of personnel, incidents simulations
 Basic safety
Building/ General
services
Room lighting Unnecessary / excessive usage
Excessive energy
consumption
Utilities provider consumption KPI, Internal policies and
training on good practices and behaviours
3 - High devices we shall
Building/ General
Occupation of a
building: Air
use of air conditioning, heat pump, electric heaters,
Excessive energy
Utilities provider consumption KPI, thermal insulation
diognosis and improvements (warehouse area +
3 - High
implement in
services conditioning / heating
of buildings
consumption framework) maintenance, renewal of equipments (< 5
years) shopfloor
IT office
Use of computer
equipments, copy Servers energy consumption
Excessive energy
consumption
Electricity consumption KPI 2 - Medium o PPEs
machines
Use of computer
Waste from Electrical and Electronic Equipment
o Testing
IT office equipments, copy Waste KPI: waste production Waste sorting instructions 2 - Medium
(WEEE)
machines
Business trip / Air travel (business KPI CO2 emissions, deployment of remote Factory
Emissions of CO, CO2, NOx, SOx, VOC, ... Air pollution 2 - Medium
Commuting travel) Acceptance Test, deployment of video Training
Incoming inspection, storage rules (duration,
Storage of packaging Air and/or soil conditions)
Warehousing Burning in case of fire from external cause 2 - Medium
materials pollution Extinguishing equipments, internal rules for PPE,
training of personnel
Incoming inspection, storage rules (duration,
Air and/or soil conditions)
Warehousing Cardboard storage Burning in case of fire from external cause 2 - Medium
pollution Extinguishing equipments, internal rules for PPE,
training of personnel
Incoming inspection, storage rules (duration,
conditions)
Warehousing Battery storage Burning in case of fire from external cause Air pollution 2 - Medium
Extinguishing equipments, internal rules for PPE,
training of personnel
Maintenance, Renewal of equipments, installation at
Building/ General
Air conditioning Use of an air conditioning system Noise pollution the property boundary noise measurement every 5 2 - Medium
services
years
Sizing of fleet, implementation of electric powered
Building/ General Use of handling and
Traffic Noise pollution device, shopfloor implementation limiting need for 1 - Low
services lifting equipment
goods mouvements

Business trip / Car trips (Business

Emissions of CO, CO2, NOx, SOx, VOC, ... Air pollution parking 1 - Low
Commuting trips, home-work trips)

Business trip / Car trips (Business Excessive energy

Fuel usage parking 1 - Low
Commuting trips - fleet vehicles) consumption

Business trip / Car journeys (home- Gasoline consumption tracking, possibility to worl from
Emissions of CO, CO2, NOx, SOx, VOC, ... Air pollution 1 - Low
Commuting work journeys) home for eligible positions
Improper waste storage (hazardous products not
Manufacturing Waste generation placed on retention bins, hazardous products on Air pollution Training / awareness 1 - Low
pallets)
Usage of potentially
Definition and deployment of list of approved
hazardous substances Air and/or soil
Manufacturing Exposure of personnel and risk of splillage substances (including register of MSDS for each) and 1 - Low
(solvant, painting, pollution
associated rules of usage and training of personnel
glue)
Manufacturing Wiring Product manufacturing: Scraps Waste KPI: waste production 1 - Low

Logistics & Logistics: Loading and Product supply or transport: Oil or fuel leak from the
Soil pollution Spillage control equipments and protocols in place 1 - Low
transportation unloading of material truck - Fire - Explosion
Maintenance: Supply
Logistics &
of spare parts and end of life of electrical and electronic products Waste KPI: waste production 1 - Low
transportation
spare parts
Using an air
Manufacturing Noise Noise pollution periodic checks 1 - Low
compressor
Logistics & Transport of
Transport of equipment Air pollution CO2 emission 1 - Low
transportation equipment
Electricity
Test Presence of transformers Soil pollution periodic checks of retention tank 1 - Low
transformation
External body: periodic
Use of external service prevention plan + QHSE policy + HSE reception
checks, maintenance, consideration of environmental criteria All 1 - Low
providers included + signed HSE charter + communication
works
Building/ General Use of handling and
Spill of hazardous materials Soil pollution spillage kits in premises 1 - Low
services lifting equipment
Building/ General Use of an air
Refrigerant circuit leak Air pollution Maintenance, Renewal of installations 1 - Low
services conditioning system
Excessive
consumption of raw Tracking of consumption, campaigns of communication
IT office prints paper consumption 1 - Low
materials and to users
production of waste

IT office prints Production of waste paper Waste KPI: waste production 1 - Low

Excessive energy KPI: consumption of electricity with distinction: building

Manufacturing Equipment testing Equipment testing 1 - Low
consumption vs Testing activity

KPI: Waste production, Scrap, waste sorting procedure

Electrical test Equipment testing Damaging or breaking parts Waste 1 - Low
/ available bins
Manufacture of
electrical and KPI: Non conformities, scrap, waste production &
Manufacturing Damaging or breaking parts Waste 1 - Low
electronic equipment improvement action plans
(wiring, assembly)
Excessive
consumption of raw
Packaging Logistics Packaging of equipment KPI production of recycled packaging waste 1 - Low
materials and
production of waste

Test Testing Loads, test benches noise pollution noise measurement 1 - Low
Use of external service Use of external service monitoring + audit + signed HSE charter +
environmental performance of suppliers All 1 - Low
providers providers communication
Logistics & Control and receipt of
Supply: Unpacking of packages Waste KPI: waste production 1 - Low
transportation supplies
retention tray, Spillage control equipments and
Warehousing Used battery storage Spill of hazardous materials Soil pollution 1 - Low
protocols in place
IT office prints Production of waste cartridges/toners Waste Recycling 1 - Low
Using an air
Manufacturing Oil leaks Soil pollution Spillage control equipments and protocols in place 1 - Low
compressor
Excessive
Building/ General Connection to the consumption of raw
Drinking water consumption Consumption KPIs 1 - Low
services drinking water network materials and
production of waste

Warehousing New battery storage Spill of hazardous materials Soil pollution Spillage control equipments and protocols in place 1 - Low

standards
 o Manufacturing standards

 Basic environmental devices we shall implement in shopfloor

o Waste management
o Energy requirement (for testing mainly)
o Floor
o Ventilation
o Storage conditions
o Dangerous goods
o Etc…

Timeframe:

 Answer expected 30th May latest.