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Equipment specification (C) Issued By Production Engineering Assembly, SMG

Date 12-May-23
Distri Budget Document
- Classification
Cop
butio Prep By Check By Check By Approval
ies
n
Place

Anudeep Pravin
Issue No. Ramesh Motohiro
On Yedage
Kumar Ono
30/04/23 on
on

Equipment name: Qty Installation Area

Supporting structure for Steering Gearbox
equipment in A plant. 1 Set Assembly A line

Total CONTENTS

1. KEY POINT :
In SMG Assembly A line, we have planned to install Steering Gearbox tightening machine. So, we
need a supporting structure for the equipment. To do so we have to do the following activities:
a) Install a supporting structure close to exitsting structure
b) Shift all the items from existing structure to this new structure. (SMG SCOPE)
c) Dismantle existing strcture.
d) Install new supporting structure for Steering gearbox equipment.

2．WORK PIECE DETAILS:

A. Supporting structure for equipment.
B. Supporting structure for shifting all necessary items.
3. EQUIPMENT STRUCTURE
A. Supporting structure for equipment.
 This supporting structure should hang 2 “I” beams parallel to the convyeor below
separated by a distance of 1000mm . Also,these two I beams must be hanging at a
height of 3500mm from the floor level, with provision to adjust by ±50mm.
S.No Item description Length QTY
(Metres)
1 C channel (150x75xt5) 6m 2
2 I beam (150x75xt5) 4.5m 2
2 Suspender (L55x55xt5)+ 4.5m 6
Brace Rod (L55x55xt5)
3 C channel (100x50xt5) 1.5m 2
B. Supporting structure for shifting necessary items.
 This structure consists of 4 suspenders hanging from existing C channel available and 4
C-channels connecting the ends of 4 suspenders to form a rectangular supporting
structue. (3150mm X1000 mm)
S.No Item description Length (M) QTY
1 C channel (75x40xt5) 3.5m 2
2 C channel (75x40xt5) 1.2m 2
3 Suspender (L55x55xt5) 4.2m 4

<<Note>> 1. Electricity specification should be based on "electric-apparatus specification [SES-M1202].

 Equipment specification (C) Page 2／9

CONTENTS

4.OPERATION : N/A.

5．SPECIFICATION
5.1 Basic specification:
1） Meeting a necessary function, and being design in consideration of
“Small, Few, Light, Short, beautifully”
2） Observe electric installation specification SES-M1202 of the SUZUKI issuance.
3） Observe safe specification SES-M3201- 3209 of the SUZUKI issuance and take safety measures.
4） The sensor for the operation checks of the actuator assumes actual parts detection basics in LS.
5） Sensors to use for facility can perform interchange easily.
6） In case of improvement, please suggest points regarding safety, quality, productivity, cost reduction.
7） The parts, which directly come in the contact of water or having any possibility of getting wet, must
be waterproof.
8） Carry out rustproofing measures for all parts including fasteners.
9） In case of moving elements, please provide safety cover to stop the operator from getting hand or
any part entangled in the moving element.
10） The electric control lets make PNP correspondence, and the N phase ground.
11） Provide safety signage on the rotating, moving and other parts of the machine.
12） Parts should not get dents, scratch and damage due to equipment movement. Use resin material for
the point contacting a work.
13） SMG side will provide the 3D data of the work.
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CONTENTS

A
Equipment must be made as easy as possible for the maintenance

Individual Specifications

A. Supporting structure for steering gearbox equipment:

 Height from floor of this structure is FL+3500mm.
 Make use of brace rods on both lateral faces to prevent the swing of the structure.
 Welding with building support is strictly prohibited.
 Refer below drawing for all other dimensions.
 Note: The brace rods in the drawing are just schematic. Use your own
understanding to place them as efficiently as possible.
B. Supporting structure for shifting necessary items:
 Bottom height of this structure is FL +2700mm
 Hang suspenders from existing C-Channels avialable.
 The rectangular structure so formed after assembling C channel should have dimensions
of 3150x1000mm.
 Also refer to the drawing below for all other dimensions.

Supporting structure for shifting necessary items.

Supporting structure for Steering Gearbox equipment.

(Schematic Layout)

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 Equipment specification (C) Page 4／9

CONTENTS

A. SUPPORTING STRUCTURE FOR STEERING GEEARBOX.

B. SUPPORTING STRUCTURE FOR SHIFTING NECESSARY ITEMS.

【Raw Material】
Raw Material used will be as per drawing or as per MSIL requirements.
All material used will be ISI approved and the make of material is as under:-
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 Equipment specification (C) Page 5／9

CONTENTS

A
• ISMC/ISMB : SAIL , TATA Steel, Jindal, VIZAG
• Plate : SAIL , TATA Steel, Jindal, VIZAG
• Sq. Tubes : SAIL , TATA Steel, Jindal, VIZAG
• Angles : SAIL , TATA Steel, Jindal, VIZAG
• Chequered plate : SAIL , TISCO
• Wire Mesh : SAIL, TATA Steel, Jindal,
• Flat : SAIL, TATA Steel, Jindal,
•Hardware : (8.8 grade) LPS, Unbrako, PFL,
• Welding Rod : ESAB, MODI , Dwekam
• Channels : SAIL, Tata Steel, Jindal, VIZAG
• Clamps : SAIL, TATA Steel, JINDAL, VIZAG
• High Tensile Bolts : (10.9 grade) Unbrako, RELFA, LPS
【Welding Equipment and Machine to be used for fabrication】
• Pug Cutting : For cutting of plates
• Profile Cutting : CNC profile cutting
• Bend Saw : ISMC/ISMB
• Power Press : For Angles/ rods
• Mig Machine CO2 : For Shop fabrication
• Magnetic Drill Machine: For site drilling
• Radial Drill Machine : Shop Drilling
【Primer and Paint (Make)】
• Paint : Asian Paint, Maruti White - Munshell Code – 2.33 Y 8.74/ 0.98
• RAL Code – RAL 9010
• Paint will be applied through brush only at site (Just touch- up)
• On shop fabrication through spray
• One layer of primer and two layers of paint must be applied over all structures
【Steel Quality】
• The steel used for the process should be essentially ST-55 grade structural steel
With the below mentioned standard properties
1.
Parameters Designated Measurement
Value Standard
Tensile Strength 550MPa IS:1608
Yield Strength 350Mpa IS:1608
%Elongation on gauge 28.0 IS:1608
length of 5.65VArea
Carbon(%Mass) 20% IS:228(P-1)
Sulphur(%Mass) 5.5% IS:228(P-IX)
Phosphorus(%Mass) 5.5% IS:228(P-III)
Mass(Kg/m) As per IS:808
Westermann
table.

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CONTENTS

• All the above-mentioned values are to be tested and certified through NABL.
Accredited 3rd party and report for the same are to submit to SMG before start of erection.
•Torque wrenches/ Ratchet wrenches of proper torque values will only be allowed for
Torqueing of bolts. Any torqueing, using open ended spanners will not be allowed. Torque value
must be kept within the tolerance value provided in the drawing.
•For all the bolted design; each of the bolts must be followed by one plain washer, one spring
washer and two nuts for tightening. After full tightening, at-least 3 rotation of threads should be
kept free after the nut.
• All the torqueing values of the structures are to be rechecked and retightened after 1 month
and 6 month of the SOP.
A report for the same has to be provided to SMG mentioning joint details and actual checked
bolts.

6．Interlocks:
N/A

7．Maker scope of work:

1. Complete design of the system, manufacturing, procurement of all bought out items, fabrication
and assembly of the machine in maker scope.
2. Tightening up all parts 1 month and 6 months after operation commencement and marking with
paint marker.
3. Submission of drawing for approval before start of manufacturing within 2 weeks of issue of
purchase order.
4. Installation of the system at plant, trials and commissioning of the equipment.
5. Packing & transport of trial parts from SMG to maker and subsequent return to SMG after trial.
6. Unloading, unpacking and shifting of equipment to site & scrap disposal.
7. All safety equipment required for installation of equipment.
8. Maintenance of hygienic and safe working conditions during installation.
9. The items which cannot be disposed off inside SMG, Supplier should take them back for disposal
as per SMG information.
10. Submit following documents in English Along with equipment.
a. Bill of Materials for all mechanical parts with functional details.
11. This work is to be done only on Sundays or other holidays if any. Please condisder this before you
give the quote.

8．SMG scope of work

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CONTENTS

A
1. Provision of primary power at one location & primary air (5.1 kgf/cm^2 +/- 1.0 kgf/cm^2)
connection.
2. Site for installation (Civil work if any after submission of drawing by maker)

9．Schedule
PO Release : End June 2023
Installation completion at SMG : End September 2023

10. Other:
[Quotation Requirements]
1. Plant requirements
To be determined.it will submit after the determination of details.
2. The scope of quotation
The quotation has to be contained Design, Manufacturing, Trial, Transportation, Installation,
Adjustment, Installation/Adjustment Supervisor, Stand-by supervisor and so on.
The below is summary.
1. Design: Mechanical design, Electrical design, Trial parts manufacturing, Stress tests
2. Manufacturing: Material, Machining/processing, Parts purchasing
3. Trial: Mechanical assembling, Electrical assembling, Adjustment, etc.
4. Transportation: Disassembling, Packing, Transportation
5. Installation, Adjustment: Mechanical and electrical installation, Adjustment
6. Supervisor: Installation, Adjustment, Stand-by, Operation education, Maintenance explanation,
7. Tightening check after 1 week later
8. Other: Safety fence, Documentations
9. Spare parts: Submit a necessary spare parts list.
a. Parts to consume within 1 year, Parts to need long manufacturing term, Special parts.
b. Include recommended spare parts in the offer.
c. Refer to check sheet for Design/Manufacturing/Installation about quantities of spare
parts.
10. Warranty: The maker responsible problem has to be solved (temporary solution, problem
analysis, permanent solution) the free of charge immediately. And if serious problem is happen,
has to continue stand-by until countermeasures are completed.
11. Warranty term: 1 year after Installation (Aug, 2021)
12. Other:
a. The quotation shall contain the connection of equipment hanging point about the
primary power (NFB) and primary air (valve +short pipe union+ short pipe). Connection
work is prepared by SMG/SUZUKI.
b. The foundation work is out of quotation but need to the requirement drawing of the
foundation.
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 Equipment specification (C) Page 8／9

CONTENTS

A
c. Stand by supervision is required if problems are remained.
d. Covering of floor, other equipment, production parts is needed without a fouling and
damage. If covering is not enough then fouling and damage are happen, repair or penalty
cost of damaged parts will be recovered from maker.

3. Assignment requirements:
1. Fulfill the SUZUKI requirements and SUZUKI standards.
2. Problem is nothing after start of production or the aim of countermeasure is in sight.
3. There is not a pointing out or countermeasure is completed.
4. Complete the operation/maintenance explanations and educations.
5. Submit the requirement drawings of manuals, mechanical, electrical, pneumatic,
hydraulics etc.
6. Spare parts are delivered.

4. SUZUKI standard
1) Follow the below standards
SES-M-4243: Small/Few/Light/Short/Beautiful Standard for Equipment (ASSY shop)
SES-M-1203: Standard for Equipment Colors
Recommended parts list for Pneumatic parts (ASSY shop)
Check sheet for Design/Manufacturing/Installation

5. Submit the schedule

Submit the schedule within 2 weeks from the ordering.
1) Schedule plan: 1 pc -- Design, Manufacturing, Installation

6. Submit the Documentation

All documentation must be in English.
Necessary documentation is according to “table1”.
a. Confirmation drawing: 3 pcs
1) The drawing shall contain equipment configuration and details. Correcting and changing are
Required if details cannot be checked and details are not contained.
And need to submit device selection reason, strength test calculation also.
b. Final Documentation: 4 pcs
1) Submit the documentation within 1 month from start of product or modifications.
2) At first, 1 pc has to be submitted and got a confirmation from SMG and Suzuki.
After that, make 4pcs.
3) Above to be submitted in a binding folder (make Kokuyo / SONA or equivalent,
hard type-A4 / A3) with flag separators for sub sections. Moreover, on a cover and
a back cover, maker should indicate an equipment name & number.
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CONTENTS

A
4) Mechanical drawing and Electrical drawing should be separated.
5) In case of modification, submit all drawing which modification points are wrote.
But PLC software/drawing has to be updated all.
C. In control panel: 1 pc
1) Software with comments, Parameters shall be provided by USB pen-drive in control panel.
In case of modification, software and parameters shall update the latest version.

Table1
In
Confir
mation
Final control Necessary documentation Detail Note
panel
○ ○ ○ Control panel drawing device layout, switch layout…
○ ○ ○ Operation panel drawing
△ ○ ○ Terminal box drawing temporary is OK at confirmation
○ ○ ○ Layout drawing panel location, control area…
○ ○ ○ Control circuit drawing(Hardware) wiring drawing, configuration…
documentation

／ ○ ○ Control circuit drawing(Software)

Electrical

○ ○ ○ In/Output circuit table

○ ○ ○ External interlocking table wiring nos, name
○ ○ ○ Layout drawing for Safety device emergency stop, area sensor…
○ ○ ○ PLC configuration drawing
／ ○ ／ PLC parameter table
△ ○ ○ GP display configuration drawing summary is OK at confirmation
／ ○ ○ Coupler connection drawing
○ ○ ○ Cable routing drawing wiring method, distination
○ ○ ○ Usage parts list bought out item
○ ○ ／ Layout drawing
○ ○ ／ Full-assembling drawing working space/position…
○ ○ ／ assembling drawing mechanical structure…
documentation
Mechanical

○ ○ ○ Cycle time chart

○ ○ ／ Foundation/Pit drawing installation location…
○ ○ ○ Hydraulic pneumatic circuit drawing
○ ○ ○ LS location drawing installation location…
○ ○ ○ Cable piping routing drawing main routing
○ ○ ／ Usage parts list bought out item
／ ○ ／ Comsumption psrts list final shape drawing…
／ ○ ○ Program list
USB-pen drive
／ ○ ○ Backup data PLC program, parameters…
CR-ROM
／ ○ ○ Inverter setting table put on inside control panel
／ ○ ／ Operation manual operation/maintenance manual…
／ ／ ○ Device operation manual electric/pneumatic device manual…
Other

／ ○ ○ Trouble shooting
／ ○ ／ Maintenance sheet
○ ○ ／ Designing calculation result strength calculation…
／ ○ ／ Measurement/Inspection result
／ ○ ／ Setting requirement
／ ○ ／ Catalogue Copy
Check sheet
○ ／ ／ for Design/Manufacturing/Installation

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