PLC Programming MPS 152

Autoliv Inc.
Manufacturing Process Specification

MPS 152 PLC Programming
AUTOLIV INC.
MANUFACTURING PROCESS SPECIFICATION
PLM No: E2702680
Process: All
Product Area: All
Owner: Marius Marica Approved by: Staffan Olsson

Version: 2.4 Release date: 21-Jul-2023 Pages: 25
MPS 152 version 2.4 / 21-July-2023 Page 1 of 25

Autoliv Inc. Manufacturing Process Specification
Table of Contents
MPS 152
1 SCOPE........................................................................................................................................................ 3
2 PRODUCT SPECIFICATION ..................................................................................................................... 3
3 PROCESS DESCRIPTION ......................................................................................................................... 3

3.1 DEFINITIONS AND ACRONYMS ................................................................................................................ 3
3.2 PROCESS FLOW .................................................................................................................................... 5
PLC Program structure (example) ................................................................................................. 6
3.3 VERIFICATION OF PLC PROGRAM FOR NEW MACHINES (BEFORE TG3 / SOP) ......................................... 7
For all machines, the following verification shall be part of the Machine Acceptance,
Qualification Plan and/or Go, See and Fix workshop prior to start production: .......................................... 7
3.4 CHANGE MANAGEMENT (AFTER TG3 / SOP) .......................................................................................... 8
3.5 ACCESS RIGHTS MANAGEMENT / PASSWORDS MANAGEMENT ................................................................. 8
Access to machine parameters managed by PLC: ....................................................................... 8
Access to the PLC Program........................................................................................................... 8
3.6 STANDARD BLOC OR LIBRARY (AOI)....................................................................................................... 9
3.7 PROACTIVE REVIEWS – PEER REVIEWS .................................................................................................. 9
3.8 STANDARD MODES ............................................................................................................................... 9
3.9 PROGRAMMING LESSONS LEARNED, WIP MANAGEMENT, RULES ........................................................... 11
3.9.1 Cycle start: ....................................................................................................................................... 11
4 REFERENCES AND APPENDICES ........................................................................................................ 22
4.1 MANDATORY REFERENCES .................................................................................................................. 22
4.2 APPENDICES ...................................................................................................................................... 22
5 MODIFICATION INDEX ............................................................................................................................ 22

1 Scope
This MPS shall be applied according to AS405.
This MPS shall be applied for all PLC programming of processes and machines at
Autoliv Plants (PLC under ALV responsibility).
By default, machines controlled by a computer instead of a PLC shall comply to this
MPS 152, deviation on this requirement shall be documented in the PFMEA.
Each Plant shall train all its PLC Programmers on this document.
The MPS audits must start after the plant is compliant with ALV007.01 (PLC program
Change) and PLC program are stored in a system with revision control and plant is
documenting the change us describe in AS 007-ALV007.01.
2 Product Specification
All Product failures modes shall be defined in the DFMEA.
All Process failure modes shall be defined in the PFMEA.
The PLC Program of a machine shall be designed to detect all defined failure
modes according to DFMEA and PFMEA.
3 Process Description
3.1 Definitions and Acronyms
PLC: Programmable Logic Controller

PLC Programmer: An Autoliv employee trained with one of the software used by PLC
WIP: Work In Process – from a PLC programming standpoint, the WIP is the part status,
EBOM and measurements for a part at any time of the process execution.
AOI / Standard Bloc: Add On Instruction – a piece of standard code for a given
device/process/function (ex.: Barcode reader), valid for Allen Bradley – equivalent to
bloc for Siemens. An AOI can’t be modified on-line.
Point of no return: It is the timing in the sequence of a given process after which the
part has to be scrapped if the cycle is interrupted or paused. For each process, the
GPD/LPD or GPEA/LPEA shall define the point of no return.
MVP: Master Verification Part
MCP: Master calibration Part
Traceability system: Software and database that sends Bill of Material, Settings and
Control target and limits for a given Part Number to the Machine. The system records
Component Lot information, Part status, Measurement data for each part or lot
processed according to AS004.
Station to Station Tracking: It is the system that verifies the part has been processed
successfully through all the stations. Before processing a part, the Traceability system
and/or the PLC program of a machine has to verify the part has been properly
processed at the previous machine (up-stream) in the manufacture of serialized parts
(Level 1 – AS4). In the manufacture of non-serialized parts (Level 2 – AS4), the station
to station tracking is accomplished with the WIP in the PLC.
HMI/OIT: Human Machine Interface / Operator Interface Terminal
GPD / LPD: Global Process Development / Local Process Development

GPEA/LPEA: Global Process Equipment Authority / Local Process Equipment
Authority
PE/QE: Process Engineer / Quality Engineer
Referencing: When a machine door is opened and closed after, the actuators have to
go back to their initial position (before the door has been opened), before the machine
can restart production.
TEMP: Temporary variable (recorded temporarily in a PLC memory zone)
Machine Acceptance: It is also called “Buy-off” (it is the machine compliance
evaluation and audit versus the scope of work and Autoliv standards at the machine
supplier facility prior to shipping the machine to the ALV plant)
Ladder logic: PLC Programming language (Figure 13 page 20 shows an example of
a ladder logic program with several “rungs”).
Rung: A rung is a “line” of code in a ladder logic program.
LVDT: Linear Variable Differential Transformer is a type of electrical transformer used
for measuring linear displacement (position).
DB: it is a Database
PPAP: Production Part Approval Process
L2L: Leading To Lean is a production software for dispatch management
Monitoring a sensor signal: it is the action to verify the signal of a sensor for a given
period of time and at a defined frequency
Checking a sensor signal: it is the action to verify the signal of a sensor once at a
defined time of the process sequence.
Location Specified Status (specific for PLI plants): In some process, the status of
a part is apparent by its location on the machine. A part could not be at that location
unless it had passed all previous process requirements. To meet the requirement of
this definition, the location must be strictly controlled to limit access by either a lock,
machine designed restricted access, or parts shall be scrapped if the access door is
opened (example: initiator oven).
Auto-adjust function: It is a function in the PLC Program which is using measurement
data to recalculate a target setting of a machine within defined limits (examples: slurry
dispensing adjusted based on weight, gas filling pressure based on weight and
temperature).
PID: Proportional, Integral, Derivative controller loop feedback, uses system feedback
to continuously control a dynamic process

Product model parameter: are machine parameters that are linked to the Part
Number produced.
Common machine parameters: are machine parameters that are common to all Part
Numbers produced on the given machine.
Adjustable Parameters: are machines parameters that can be adjusted to
accommodate variations.
LAT: Lot acceptance test
3.2 Process flow
The PLC can store instructions to implement control functions such as

sequencing, timing, counting, arithmetic, data manipulation and
communication. The Input / Output interfaces provide the connection between
the PLC and the information providers (Inputs are for example pushbuttons
and sensors) and the controllable devices (Outputs are for example valves,
relays and lamps). These controllable devices will be connected with
actuators (for example motors, cylinders, heaters and lamps).
Command signals Status signals
Push Buttons, Selector Limit Switch, Proximity, LVDT, Machine
Switches, etc. Pressure sensors, etc.
PLC
Inputs
Outputs
Controllable devices
Valves, relays, lamps,
etc.
HMI
Actuators
Motors, cylinders,
heaters, robots, etc.
Figure 1: PLC general concept
Figure 2: Basic PLC description

PLC Program structure (example)
The chart below shows the structure of a PLC Program with links to the
traceability system.
Traceability system
Data Records (measurements and

component batches, ...)
Data Product / Process (BOM, controls

and settings, targets and limits,
batch #, Serial #, ...)
Central server Line PC
Data Records (measurements and

component batches)
HMI
PLC
Data Process :
-Initial Limits control (target)
-Configuration Values (Vision,
sensor, pressure )
- Components reference
Downloaded from the local DB, never
modified by the PLC
Main program
« Live » Master Data Process:
Limits calculated (coordinator /
Data that are used by the program sequencer)
and that can be modified by the
program
Station 1 Station 2 Station N
Working Data: Function 1 Function 2 Function N

Part Status
Sub Function 1 Sub Function 1 Sub Function 1
Robot Orientation
Mass Calculated Sub Function 2 Sub Function 2 Sub Function 2
Data that are recorded in the
Sub Function N Sub Function N Sub Function N
traceability system
Calculations
Non process data
Operator aids
Standard Siemens data
Figure 3: PLC program structure example

3.3 Verification of PLC Program for New machines (before TG3 / SOP)
For a copy of an existing machine (repeated machine), the PLC Program of the existing
machine shall be provided to the supplier and used for the new machine. At the
Machine acceptance step, the PLC Programmer responsible for the new machine shall
compare the new machine program to an existing machine one and verify both are the
same. Any difference shall be addressed. Addressing a difference means:
Remove it if there no reason to have this difference or understand, create new back-
up if it is needed and document it. In this case, the difference may need to be Yokoten.
For a new machine with differences to existing ones, a PLC Program of an existing
“similar” machine shall be provided to the supplier (sample code).
At the Machine acceptance step, 1 PLC Programmers shall verify the program and its
compliance to this standard. The best practice is to review with 2 PLC Programmers.
For all machines, the responsible PLC Programmer shall verify that all Yokoten and
revisions to Standard Blocs or AOI’s have been updated in the machine program
before machine acceptance testing.
For all machines, the PLC program shall be saved to the plant’s PLC back-up or
version control system immediately after machine acceptance testing has been
completed in line with AS007- ALV007.01 requirement.
Verification of PLC Program for all machines
The following verification shall be part of the Machine Acceptance,

Qualification Plan and/or Go, See and Fix workshop prior to start production:
o Create bad parts of all failure modes listed in the PFMEA, verify the failure is
detected, ensure the operator is alarmed (precise message on the HMI), and
the part is scrapped, and the machine sends the failure record to the Machine
acceptance system.
o When processing multiple parts in the same cycle, create a bad part on one
position and verify the bad part is scrapped. This test has to be repeated for
each position.
o Verify the traceability for all data listed in AS4 are consistent and complete: PLC,
HMI and Traceability System
o Create cycle interruptions of different types (e-stop, power loss, change of
mode) at different steps of the sequence and verify the machine recovers as
defined, and correctly dispositions the in-process parts according to the rules
defined in this standard.
o Install the wrong tool on the machine and verify the program stops and alarms
the operator.
o Disconnect or disable each sensor and launch cycles to verify the machine
stops and alarms the operator with the proper message.
o Create air pressure losses and verify the machine is safe and that cylinders,
grippers and vacuum hold their parts. If not, the dropped parts have to be
managed (operator message, scrap)
o Verify Station to Station tracking is working properly by introducing a part that

has not passed the previous station and re-processing a part, these parts need
to be properly identified as non-conforming.
o On machines that generate a serial number, verify the date/time function is
working correctly.
o Verify machine detects and alarms (HMI notification) when introducing incorrect
components and start a cycle and before the point of no return.
o Introduce all machine’s MVPs and verify they are rejected, and the proper
message is displayed on the HMI
The station must be audited using MPS 152 Appendix A (for lines in Launch phase)
Compliance Audit Checklist.
3.4 Change Management (after TG3 / SOP)
All PLC Program changes shall follow the change process described in AS007-
ALV007.01 for PLC Program Changes.
All PLC program must be audited using MPS 152 Appendix B (serial) Compliance Audit
Checklist.
3.5 Access Rights Management / Passwords management
Access to machine parameters managed by PLC:
Adjustable parameters should be defined during the Product / Process Development

phases (Example: PLI SEM 000 – E1403751) with nominal, minimum and maximum
limits in which these parameters can be adjusted.
All adjustable parameters managed by the PLC/HMI and accessible to operators or

maintenance personnel, shall be defined with minimum and maximum limits by the
Process Engineer and the Quality Engineer.
All other parameters and limits shall not be accessible for modification.
Guideline:
− It is recommended that Operators and Maintenance people have a read access
capability on all parameters for trouble shooting purpose.
Access to the PLC Program

Guidelines:
− Maintenance should have a read access to the code for trouble shooting
purpose.
− Critical portion of the code should be password protected for modification or
embedded inside a standard bloc or AOI.
− It is recommended to password protect the entire code for modification.

3.6 Standard bloc or library (AOI)

Guideline:
− It is recommended to create reusable standard blocs or AOIs for standard
devices, standard processes or standard functions.
3.7 Proactive reviews – peer reviews

Guideline:
− It is recommended that each plant develops a plan to have periodic proactive
peer reviews of the machine PLC code.
3.8 Standard Modes
Below are listed the different machine standard modes:
• Auto mode: normal production cycle through the standard sequence with all
standard controls and records to the traceability.
Guideline: When switching from any other mode to Auto mode, it is
recommended to download the production configuration from the
traceability system
• Without Traceability: same as auto mode but no communication with the

traceability system, all parts produced with this mode shall be scrapped. This
mode shall have access limited to PLC programmers and PE of the process.
• Off Mode: allows doors to be opened, all outputs shall be cut. Referencing is
required when closing the door and re-starting.
Guideline: All parts should be scrapped when a door is opened.
Alternatively, part presence and position should be monitored to ensure no
part mixing, or the machine should be designed to protect parts and
components from being moved or removed. Operators must be trained on
Safety, Quality Risks and Best Practices when opening a door.
• Manual mode / Maintenance mode: the operator or maintenance technician

can move each device in a different sequence than the standard one. All parts
produced with this mode shall be scrapped. It is recommended to
secure/interlock motions to avoid crashes or human safety issues.
• Step by Step / Single step mode: sequence executed one step after the other
with a hit button to move from one to the other. All parts executed in Step by
Step / Single Step mode shall be scrapped. If not, each situation shall be
approved by the PE and QE.
• Start-up and Stop mode: in some cases, a specific mode is needed to start a
machine or to stop it (warm-up, cool down, priming for slurry dispensing, or to
go in initial position/condition).
Guideline: Any part present before entering Start-up mode or ending Stop
mode should be scrapped.
• Purge mode: a purge mode may be needed on some machines to purge the
machine of in-process parts and components before starting a new Part Number

production or stopping the machine. In purge mode, the machine shall not start
processing any new part.
• MVP Mode:
o As MVPs are to prove out the software as well as the hardware, the
MVPs shall be processed in Auto Mode.
o In some cases, a specific mode is developed to run MVPs. In this
situation, MVPs shall be run under the same logic as Auto mode,
especially for the control/sensor being tested.
o The program used to test MVPs shall use the same identical code as the
serial production code.
Guideline:
− The best practice to accomplish this identical code is to program the core
software in modules or elements that are callable by both an MVP specific
program wrapper or by the serial production program.
− The best practice is to avoid by-passing part presence detection for MVP checks
done in specific mode
o The read value of MVPs or calibration parts shall be verified and checked
that it is in an acceptable range.
Guideline:
− The best practice is to record MVPs values and Calibration part value in the DIS
or Traceability system.
− The PLC Program should automatically call for MVPs based on quantities of
parts produced (cycle count) and/or timing and changeover. Another option is
to use L2L Dispatch to call for MVPs.
• MCP mode/ calibration mode: is a mode to verify the measurement system

is calibrated within acceptable limits and to calibrate the system if needed. It
shall be defined PE and QE.
• Special / Test mode: for special part builds that needs a different program,
parameters or flow than normal production parts, the best practice is to create
a Test Reference or Test Part Number in the traceability system, then run a
changeover when starting the test, changeover back at the end of the test and
finally to disable the Test Reference / Part Number from the traceability system.
If a modified PLC program is needed, then the following rules must be followed:
o All parts produced during a special mode of operation shall be cycled in
Without Traceability mode (no traceability record) or in situations where a
record is required, all parts produced shall be marked as a test part with a
non-production status. (examples: hydro part, LAT part)
o After running a machine in a Special/Test mode, the PLC shall verify that all
parts and special components are purged from the machine prior to
returning the machine to normal production (Auto mode).
o A machine shall not enter a special mode from an operator push button. A
special mode of operation shall only be activated by a qualified PLC
programmer.
o The production AMG, process engineer, and quality engineer responsible
for the machine shall be notified before a machine is entered a special mode

of operation. Going to Special or test mode must be considered as a change

and lead to a L2L dispatch.
o The production AMG, process engineer, and quality engineer responsible
for the machine shall also be notified once the special mode of operation
has been completed.
o All special modes of operation shall be programmed to automatically disable
the special mode. Examples: disable on part count, switching from
Auto/Special or Test to Manual mode, or based on a timer.
o The original version of the PLC program shall be uploaded at the end of the
Special/Test mode run.
3.9 Programming Lessons Learned, WIP management, rules

1) Cycle start:
o When a machine cycle starts, there shall be a method to consider the
part is NOK. The status of the part can be change to OK when all good
status conditions are met.
o Before processing a part, the machine shall verify its station to station
tracking status.
2) Part status
o All parts executed in Auto mode shall be passed if:
▪ Station to Station tracking is ok (in case tracking is required)
▪ Process executed and completed (no cycle interruption after point
of no return or only after critical sequence is completed)
▪ All controls passed and within the specification/limits
o All parts executed in Auto mode shall be failed if any of the above
conditions are not met
3) Cycle interruption:
o Power loss: when the power is restored, all in-process parts shall be
scrapped that don’t have a Location Specified Status.
o Emergency stop: in-process parts that don’t have a Location Specified
Status shall be scrapped
o For any other cycle interruption, the part shall be scrapped if it happens
after the Point of No Return.
Guideline:
− Do not interrupt/pause the cycle after the Point of no Return till the end of the
cycle, the door should be locked.
−
− On manual machines with serialized traceability, the best practice is to scan the
barcode of the part after the start button is pressed by the operator. If the
barcode is scanned before the start button is pressed, any light curtain breakage
or part presence loss between the first scan and the start button press shall lead
to clear the serial number in the PLC memory, a new scan of the barcode and
a new verification of the traceability

4) Scrap
o All parts failed by the PLC shall be scrapped at the station or at a defined
location (like line central red box area). The PLC shall verify the part has
been disposed or placed at the expected location.
o When a part is failed by the PLC, the machine shall lock the part. Locking
the part can be done using 1 of the following options:
▪ The machine automatically moves the part to the red box and the
PLC verifies the part arrived in the red box.
▪ The machine cycle is frozen, the operator is notified on the HMI,
the operator acknowledges the failure on the HMI, removes the
part from the machine, moves it to the red box and the PLC
verifies the part arrived in the red box.
▪ For serialized product, the PLC sends the corresponding scrap
code to the traceability system. One of the 2 systems, PLC or
Traceability, must ensure that scrap part is disposed into the
station red box or into the central red box area.
Guideline:
− identify scrap with a label and the reason for scrap (description or code)
− use of buffer parameter in ATRAQ is a solution that ensure that scrap part arrive
in the red box or central red box area
o For combined parts chutes (see example figure 4), the minimum
requirements are:
• The default Selection Flap position shall be “Scrap position”
• A Sensor shall confirm the flap is ”Scrap position”. It shall directly
detect the flap position (not the flap actuator motion). The position of
this sensor shall not be adjustable.
• The Selection Flap shall be moved at the beginning of each cycle
to verify flap position sensor works properly (change of state)
• 2 chute sensors shall confirm the part went through the right
chute.
Guideline: It is recommended to add a second sensor on the flap “Good
position”.

COMBINED
CHUTE
SCRAP POSITION
SENSOR
GOOD POSITION
SENSOR
(recommended)
SELECTION
FLAP
SCRAPPED PARTS GOOD PARTS
CHUTE SENSORS
Figure 4: Example of a combined part chute (flap shown in “scrap

position”)
5) Change of state Sensors:

o All sensors critical for quality checks (refer to PFMEA SC/CC) shall have
a Change of state check,
o According to AS 409 and based on PFMEA (AS104) with associated
Control plan (AS105), master validation parts must ensure prevention
and detection of any critical sensor incorrect behaviour after start of
production
Guideline:
− It is recommended that a sensor change of state happens for good part, so that
if a sensor malfunction appears all parts would be scrapped.
− Sensors should be monitored constantly, switching shall occur at the right step
of the sequence of a process (Reference to PLS – Standard Programming for
Check Sensors – see Figures 7, 8 and 9) :
Examples:
signal
Process cycle
A1 B A2
A: sensor not switched
1 B: signal required
A1 + B+ A2 = monitoring
time slot in process cycle
0
1 2 3 4 5 6 7 8 9 10 11 12 step
Figure 7: Process cycle has 12 steps. Requested sensor function: sensor signal
is on (1) for step 4 and off (0) in other steps. Sensor function OK.

signal
Process cycle
A1 B A2
1
0
1 2 3 4 5 6 7 8 9 10 11 12 step
Figure 8: Check-sensor is permanently on (1). Behaviour does not comply with

requested function (see above) and therefore to be recognized as NOK.
signal
Process cycle
A1 B A2
1
0
1 2 3 4 5 6 7 8 9 10 11 12 step
Figure 9: Check-sensor is fluctuating between off (0) and on (1). Behaviour does
not comply with requested function (see above) and therefore to be recognized
as NOK.
o Sensors that can’t be monitored or no switching occurs (e.g. an end

position which is never exceeded in normal process), must be verified
with an MVP (or other method) at a defined frequency
o When operator interaction (hand, body parts, clothes…) can influence
result of sensor detection, 2 hands start or light
barriers shall be ensured that detection area is free of any
operator interference during full detection cycle and until
detection result is acknowledged by machine.
In case that 2 hands start is released during the cycle, or light
barrier interrupted, detection cycle will be interrupted and
needed to be restarted.
PLC program validation must ensure that all possibilities to
defeat these protections are covered.
6) Analog sensors/measurement:
o Analog sensor (variable data) and associated signal conversion
hardware shall be chosen to reach the requested accuracy according to
the targeted tolerance.
o Stability for a defined period shall be verified prior to recording the
measurement and passing/failing the control.

o Records from the previous part shall be cleared from the PLC memory
before processing the next part.
Guidelines:
− Monitoring the signal constantly can be a solution to detect abnormal conditions
during the process (slide monitoring for crushed igniter tube, laser power,
temperature for laser welding, leak check, etc.)
− In order to detect damaged sensor, it is recommended to compare the actual
value to the previous ones (quantity to be defined) to verify variation in
measurement results.
− The home value and stability should be verified between every part
(recommended) or during the calibration check at a defined frequency. This
value must be within limits, an offset can be recorded by the PLC or a zero-
function triggered on the sensor to take the drift into account. If the value isn’t
within the limits, machine shall alarm the operator to call the maintenance and
part must be scrapped.
7) Auto-adjust function:
o All auto-adjust function shall have limits on how far an adjustment can go
and how fast the adjustment can happen (step(s) by step(s) adjustment
– ex: slurry dispensing).
o Number of values to consider and the calculation formula (algorithm) in the auto-
adjust shall be defined by the GPEA or GPD. Auto-adjust functions shall not be
change without a GPD or GPEA pre-approval. If a change is decided on an
auto-adjust function, it shall be peer reviewed.
8) Dial tables:
o Each position of the dial table shall be identified and verified by the PLC
to ensure a dial only indexes once to avoid missing operation.
o If the dial index fails, all parts shall be scrapped.
o The dial index sensor state shall be monitored between triggered
rotations. If the sensor’s state cycles (ON-OFF-ON) more than once
without the processes cycling all parts shall be scrapped. Required to
protect against two consecutive rotations resulting in skipped operations.
9) Tools/Nests/Fixtures:
o On machines where part tracking is accomplished using WIP, the
machine shall verify the part and WIP serial numbers match at offload.
The part shall be scrapped if serial numbers do not match.
o On conveyor lines, the end of line machine shall verify the part and pallet
serial numbers match at offload. The part shall be scrapped if serial
numbers do not match.
o The PLC program shall verify the tool model for the Part Number to
produce.
Guideline:
− Pallet Identification (conveyor line) or Nest Identification (dial table) should be
recorded in the traceability system for trouble shooting purpose.

10) Communication PLC / Equipment & Robots:

o When the PLC sends a command to an equipment or a robot, the
equipment or robot shall acknowledge the received command and its
execution by sending a response to the PLC (handshake or indirect
feedback). If no response is received, a time-out shall alarm.
o Just before processing a part using an equipment, the PLC program shall
verify the equipment status is “ready to process”. As an example, for a
burst disc laser weld, the PLC must check the laser and the motor are
“ready” just before starting the weld sequence.
Guideline:
− for cycle time performance reason, Unicast / multicast options should always be
set to unicast unless otherwise necessary
Actuators / Actuators /
Equipments Equipments
PLC PLC
Figure 10: Unicast (preferred) Multicast
11) Part presence and position:

o Before loading a part or a component on a tool/nest/machine, the PLC
shall verify that there is no part/component in the tool/nest/machine.
12) Automatic loading/unloading:

o Component or part presence shall be verified at the pick position and at
the place position.
o When automatically adding a component to an assembly, the component
presence and position shall be verified after installed in the part and once
the component can’t be moved or removed.
o For all processes, the part presence and position shall be verified just
before and just after processing the part.
▪ Guideline: monitor the part presence during the entire cycle.
o When adding automatically a component to an assembly with a vacuum

tool and controlled with a vacuum sensor, 2 vacuum limits shall be set
(1st limit to verify vacuum system is not blocked with dirt or debris, 2nd
limit to check component presence) and verified by the PLC as
described below:
▪ 1st limit to verify the vacuum circuit is not blocked with dirt or
debris. This limit has to be verified at each cycle prior to pick the
component with the vacuum tool, 1st limit will be set below 2nd
limit. If the vacuum level of 1st limit is true, i.e. detection for
blocked circuit, the machine shall fault and request for a cleaning
of the vacuum circuit, or, if the vacuum level of 2nd limit is true,
detection for part, the machine shall fault and request for a
cleaning of the vacuum circuit. (Like this we control both limits to
have the right limits set and avoid human error if limits are

adjusted, example: by mistake 2nd limit is equal with 1st or lower

than 1st)
▪ 2nd limit to confirm the component has been picked with the
vacuum tool. The component presence shall be monitored on the
loading tool during the entire loading cycle if presence or position
is not monitored at the pick point and after installation. If a
component falls during the loading sequence, the component and
the part shall be rejected (per Product Line Quality procedure)
with alarm on the HMI to the operator.
▪ After component has been placed, If presence or position was not
monitored at the pick point and after installation, the vacuum
circuit check for system plugged will be performed again. If the
vacuum level of 1st limit is true, detection for plugged circuit, the
machine shall fault and request for a cleaning of the vacuum
circuit, or, if the vacuum level of 2nd limit is true, detection for
part, the machine shall fault, component and the part shall be
rejected (per Product Line Quality procedure) with alarm on the
HMI to the operator.
13) Time sensitive process between 2 operations:

o If there is a time sensitive process or inspection, then a time out shall be
defined, and parts scrapped after this time out is reached. (examples:
slurry loading – Helium injection; hot air / cold stake)
14) Printers / laser etching:

o The buffer (printer memory) of printers/lasers shall be cleared between
2 prints to avoid duplicated prints
o The system (PLC or the Traceability) must verify the print serial number
is not duplicated.
o For serialized products, the system (PLC or Traceability) that
create the serial number must also check the number with
information receive from barcode reader.
o Further details can be found in MPS 135
15) HMI messages / Machine fault:

o For each potential fault of the machine, the PLC shall alarm the operator
with an understandable error message in the country language.
o All HMI displays shall be in the country language.
Guideline:
− In some cases, English version of the messages could be a useful option.
16) Process variable data:

Data can be loaded in the PLC memory as Global Variables/ Static Memory or
as Local Variables/Temporary Memory. Temporary memory can be used
several times in a program. Considering it can be overwritten at different
moments and different conditions in the sequence, the following shall be
applied:
o A temporary variable shall be used in one and only one rung.
o A temporary variable shall be defined or calculated at the beginning of a
rung and read by this rung before the end of its execution.

o Conditions to read a temporary variable shall be the same as the

conditions to write to it
Rung 1 :
"Start_
OK
Measurement" "Part_OK"
"Measurement"
Measurement_
Measurement "Part_NOK"
OK
Measurement_
read
NOK
"Part_NOK"
write
"Part_OK"
Figure 11: in the example above, the use of a temporary variable (TEMP) is ok.
NOK
Rung 7 : Measurement calculation
"Step1"
"Step2"
#TEMP_ #TEMP_ #TEMP_
MEASURE MEASURE MEASURE
Writ
e
Rung 8 :
"Step1" "Part_OK"
"Measurement"
"Step2"
#TEMP_ Measurement_
Measurement "Part_NOK"
MEASURE OK
"Step3"
Measurement_
Rea NOK
"Part_NOK"
d "Part_OK"
Figure 12: in the example above, the conditions to read the TEMP are different from
the conditions to write it. Also, the same TEMP is used in 2 different rungs

Rung 3 :
NOK
Read "Part_OK"
"Part_NOK"
Rung 4 :
Read "Part_NOK"
"Part_NOK"
Rung 5 :
"Start_
Measurement"
"Measurement"
Measurement_
Measurement
OK
Write
Measurement_
NOK
Figure 13: in the example above, the TEMP is read first and written after: the TEMP
value is unknown when read. Also, the same TEMP is used in 2 different rungs.
Guideline:
− at the beginning of each bloc, the Temporary Memory shall be cleared or
initialized.
Guideline:
− at Machine Acceptance phase, the memory status should be verified to make
sure it’s not overloaded (Maximum limit 75% used)
The table on Figure 14 describes if a data can be recorded in a temporary memory or

not depending on its type. The PLC program shall follow this table.

Data Static Memory Temporary memory Comments

Fixed Process Data (received from Temporary memory not allowed
Traceability): Bill Of Material, controls
targets, controls limits, settings targets
Yes No
and limits.
Adjustable Process Data: auto-adjust Temporary memory not allowed
functions, calculated limits.
Yes No
Part Process Data: batch numbers, serial Temporary memory not allowed
number, measurements, status.
Yes No
Calculations: signal conversion (from Temporary memory can be used for calculation
sensors). Yes Yes only, results shall use Static Memory on the
same rung.
Calculations: measurement vs limits. Temporary memory can be used for calculation
Yes Yes only, results shall use Static Memory on the
same rung.
Calculation: non critical data / operator Temporary memory can be used
information (ex. Cycle Time).
Yes Yes
Standard functions from suppliers. These are functions developped by Siemens
Yes Yes and/or equipment suppliers that may us
Temporary memory
Figure 14: rules of memory type usage depending on data type for Siemens PLCs
17) WIP records management:

o All WIP move data (part status, process data, serial number, etc) for a
part shall be grouped together in the PLC scan. That is to ensure that
there is no potential for the WIP status of a part to be updated while the
WIP is being moved from station to station.
o WIP shall be moved in a manner so that there is no potential to have WIP
representation of a part in more than one WIP Location.
o The WIP status of a part in the program shall follow the part physical
location in the machine.
o If pick and place or robot grippers are opened in any mode, the WIP for
those grippers will be cleared.
o WIP move shall follow the physical movement of a part without exception
or other condition. (example: WIP moved after a dial indexed
successfully)
o All parts affected shall be scrapped if a moving device, such as a dial or
robot fails to move successfully except if the part status is guaranteed
and documented by risk analysis.

18) Re-test:
o Retest on inspection machines shall be reviewed for acceptance by the
GPD/GPEA and the Quality Engineer per the corresponding MPS and
AS064.
19) Automated part feeding system (for example: vibration bowl and rail,….)
o The automate feeding system shall be stopped by a sensor to detect
when system is full
o The machine should stop automatically and alarm if the sensor is not
activated after an optimized time (not more than 5 minutes).
20) Changeover for batch production

Change over procedure should be program in line with local standard/procedure
requirement.
Guideline:
o Changeover is the most critical situation where components or lots can
be mixed or assembled with the wrong Part Number. Therefore, the first
part(s) produced after a changeover shall be sampled for COP/LAT/First
Piece Check. Testing and serial number of that part must be tagged as
such in the traceability system.
21) Barcode scanning

If information from a barcode need to arrive in PLC memory (directly or via
traceability systems) the requirement is that all digits will be consider in the PLC
logic (not allowed that traceability will cut digits).
PLC must receive full barcode information (including part no. serial number /
colour code / date) and PLC program should remove unnecessary information
and use it in the logic of PLC program.
Example: PLC receive from scanner / traceability system 622533354CDO / PLC
logic use 622533354
22) Manual step(s) in a machine sequence

When in machine sequence we have some manual action from operator and
automatic action from machine, PLC program shall verify the manual step(s) is
(are) done by using some features or inputs such as timers, doors opened, light
curtain triggered, etc.
In case there are manual operation that can be monitor by the PLC, it is
recommended to use some features or inputs (such timer, doors or curtain
trigger).
Example: if the operator is asked to clean the tool inside the machine, he
acknowledges the message on the HMI but the PLC should monitor if the
operator open the door to perform requested activities

4 References and Appendices
4.1 Mandatory references

o AS004
o AS007
o AS064
o AS403
o AS405
o PLS – Standard Programming for Check Sensors
o ALV007.01 - PLC Program Changes
4.2 Appendices
o Appendix A: MPS 152 Appendix A Compliance Audit Checklist New
Equipment
o Appendix B: MPS 152 Appendix B Compliance Audit Checklist Serial
Equipment
5 Modification Index
Version # Date / Team Modification
1.0 23-Jun-2017/ PLI - First version
Philippe Emig
Lawrence Hiss
Gary Iser
Vincent Marie
Kevin Wright
Masaya Kawasaki
Bo Zhu
Guangwei Yu
Zhijie Fang
Jeff England
Catalin Radu
Stig Engebratt
Stuart Probasco
Yann Le Gall
1.1 3-July-2017/ Minor updates references in figure and text
Yann Le Gall references
1.2 22-Aug-2017/ Added “Special/test mode” in section 3.9
Yann Le Gall Added section 3.10 item 19 “Process
Control data” for Pyro Loading and Gas
Filling machines
1.3 22-March-2019 / Updated section 3.9, 3.10-4
Yann Legall Added sections 3.10-20, 3.10-21, 3.10-22,
3.10-23
1.4 11-July-2019 / Updated sections 3.10-1 and 3.10-10
Soren Svensson
Yann Le Gall

2.0 25-Nov-2019/ Entire document reworked for all ALV

Marius Marica Product Lines and Plants
Craig Perry
Hinnerk Witt
Lori Smith
Daren Sagers
Sylvain Perrault
Juan Gamez
Danny Jackson
Yasufumi Suganuma
Yann Le Gall
2.1 29-Sept-2020 / Correction in the checklist and change
Marius Marica wording for clarification
2.2 7-May-2021 / Updated section 3.9-4 and 3.9-12
Yann Legall
2.3 5-Dec-2022 / Yann Updated sections 3.5.1, 3.8 (Auto-mode and
Legall Special/Test mode) and 3.9-6. Removed
question #2 Appendix B
2.4 21-July-2023 / Updated sections 1, 3.9-4 and 3.9-10.
Yann Le Gall

Appendix A Compliance Audit Checklist New Equipment

MPS: MPS 152 PLC Programming (ver.2.4) - new Equipment Audit date:
E-Number: E2702680 r010 Audited by:
Site
Line:
Equipment
ID:
Audit Result:
Compliance verified: Yes No Signature:
Please observe - Auditing the process the MPS Checklist shall be accompanied by the General MPS 0-2 Checklist added as a 2nd page
MPS 152 PLC Programming Compliance Audit Checklist
Standard
Item
Requirement Reference Result Comment/Observation
1 For a copy of an existing machine, is the program communicated to the machine supplier ? 3.3 Yes No
For a new machine (non copy), is the program verified by at least 1 Autoliv PLC programmer that comply
2 3.3. Yes No
with this MPS?
For all machines, have all Yokoten's and revisions to Standard Bloc / AOI's (based on regional stanadards)
3 3.3 Yes No
been updated to the machine program before SOP ?
4 For all machines, are all verifications listed in section 3.3.1 performed and documented prior to SOP ? 3.3.1 Yes No
Are all adjustable parameters where operatior or maintenance have access to change, contorl by the
5 3.5.1 Yes No
PLC/HMI with defined minimum and maximum limits ?
Are all other parameters where other operatior or maintenance have access to change managed by the
6 3.5.1 Yes No
PLC/HMI password protected or hardware key ?
Is part status per standard mode defined according to the rules described in section 3.8 (in auto mode can
7 3.8 Yes No
get flag OK, in all other modes should be register NOK in the traceability system)?
If a special/test mode is programmed on a machine, does it follow all requirements listed in section 3.8
8 3.8 Yes No
"Special / Test Mode" ?
When a cycle starts, is there a method to consider the part as bad unless all good status conditions are
9 3.9 - 1 Yes No
met ?
10 Before processing a part, does the machine verify its station to station tracking status (skip station)? 3.9 - 2 Yes No
Are all conditions met in Auto mode to pass a part ?(Station to station tracking, Process executed and
11 3.9 - 2 Yes No
completed, all controls passed and within limits)
12 Are parts scrapped in case the cycle is interrupted by a power loss or an e-stop ? 3.9 - 3 Yes No
Are parts scrapped in case the cycle is interrupted after the point of no return for other cases than a power
13 3.9 - 3 Yes No
loss or an e-stop ?
Are all product failed by the PLC rejected at the station and does the machine detect that failed product is
14 3.9 - 4 Yes No
physically rejected (or according specific red-bin local procedure for rejects) ?
15 Are combined part chutes compliant with requirement from sction 3.9-4 ? 3.9 - 4 Yes No
Are MVPs processed in Auto Mode ? If not, for MVP specific code, does it use the same logic as Auto
16 3.8 Yes No
Mode for the control/sensor being tested ?
Are all SC/CC sensors critical for quality checks having a change of state check and being monitored
17 3.9 - 5 Yes No
constantly (except those that cannot be monitored or no switching occurs)?
Are all SC/CC sensors critical for quality checks that cannot be monitored or no switching occurs verified
18 with an MVP (or other method) at a defined frequency and according AS409 to ensure the detection of any 3.9 - 5 Yes No
incorrect behaviour after start of production?
When operator risk of interaction in detection sensor zone, is it 2 hands starts or light barriers used to
19 ensure a free detection area during full detection cycle.? In case of cycle interruption see 3.9-3. 3.9 - 5 Yes No
Are all analog sensors and associated signal conversion hardware selected to achieve the requested
20 3.9 - 6 Yes No
accuracy according to targeted tolerances ?
For analog sensors, is the stability verified before recording the measurement and passing/failing the control
21 3.9 - 6 Yes No
?
Are all auto-adjust functions limited (minimum and maximum) ? Is the auto-adjust calculation formula
22 3.9 - 7 Yes No
defined by GPD or GPEA ?
23 Is there a sensor to verify dial tables index only one step ? Are all parts scrapped if a dial table index fails ? 3.9 - 8 Yes No
On machines where part tracking is accomplished using WIP, the machine must verify that part and WIP
24 serial numbers match at offload. Scrap the part if serial numbers do not match. (ex. Switch part on the palet 3.9 - 9 Yes No
or nest during the process -the part shuld be detected NOK)
When the PLC sends a command to an equipment, is the command execution verified by receiving a
25 3.9 - 10 Yes No
response and use a time-out to alarm ? (hand shake)
Before loading a part or a component on a tool/nest/machine, does the machine verify that there is no
26 3.9 - 11 Yes No
part/component in the tool/nest/machine ?
In case of automatic loading, Is component or part presence verified at the pick position and at the place
27 3.9 - 12 Yes No
position ?
28 Are vacuum loading/unloading tools controled with 2 vacuum limits as described in section 3.9-12 ? 3.9 - 12 Yes No
For time sensitive processes or inspections, is a time out defined and are parts scrapped after this time out
29 3.9 - 13 Yes No
is reached ?
Is the buffer (printer memory) of printers/lasers cleared between consecutive prints to avoid duplicated prints
30 or 3.9 - 14 Yes No
The machine or Treaceability system verify the print content ?
For each potential fault of the machine, does the machine alarm the operator with understandable error
31 3.9 - 15 Yes No
message in the country language or English ?
Are Temporary Variables only used following the programming rules described in section 3.9 item 16 ? (as
32 3.9 - 16 Yes No
of checklist version 1.2 - only applicable for Siemens)
33 Is the WIP programmed following the rules described in section 3.9 item 17 ? 3.9 - 17 Yes No
34 On inspection machines, is retest only programmed when approved by the GPD / GPEA ? 3.9 - 18 Yes No
35 Is the programing of automatic part feeding system following the rules described in section 3.9 item 19 ? 3.9 - 19 Yes No
When information from a barcode need to arrive in PLC memory (directly or via traceability systems) , all
36 digits will be consider in the PLC logic (not allowed that traceability will cut digits). 3.9 - 21 Yes No
In case there is a manual operation that can be monitor by the PLC, there are features or inputs (such
timer, doors or curtain trigger) used to monitor manual activity? Example : if the operator is ask ed to clean
37 the tool inside the machine, he ack nowledge the message on the HMI but the PLC should monitor if the 3.9 - 22 Yes No
operator open the door to perform requested activities.

Appendix B Compliance Audit Checklist Serial Equipment
MPS: MPS 152 PLC Programming (ver. 2.4) Serial Equipment Audit date:
E-Number: E2702680 r010 Audited by:
Site
Line:
Equipment
ID:
Audit Result:
Compliance verified: Yes No Signature:
Please observe - Auditing the process the MPS Checklist shall be accompanied by the General MPS 0-2 Checklist added as a 2nd page
MPS 152 Compliance Audit Checklist
Standard
Item
Requirement Reference Result Comment/Observation

Are all adjustable parameters (where operatior or maintenance have access to change) control by the
1 PLC/HMI with defined minimum and maximum limits ? 3.5.1 Yes No
Is part status per standard mode defined according to the rules described in section 3.8 (in auto mode can
2 get flag OK, in all other modes should be register NOK in the traceability system) ? 3.8 Yes No
If a special/test mode is programmed on a machine, does it follow all requirements listed in section 3.8
3 "Special / Test Mode" ? 3.8 Yes No
4 Before processing a part, does the machine verify its station to station tracking status (skip station) ? 3.9 - 2 Yes No
5 Are parts scrapped in case the cycle is interrupted by a power loss or an e-stop ? 3.9 - 3 Yes No
Are parts scrapped in case the cycle is interrupted after the point of no return for other cases than a power
6 loss or an e-stop ? 3.9 - 3 Yes No
On conveyor lines, the end of line machine must verify the part and pallet serial numbers match at offload.
7 Scrap the part if serial numbers do not match. (ex. Switch part on the palet or nest during the process -the 3.9 - 10 Yes No
part shuld be detected NOK)
Before loading a part or a component on a tool/nest/machine, does the machine verify that there is no
8 part/component in the tool/nest/machine ? (process should not start with an empty nest or if the parts stay 3.9 - 12 Yes No
in the nest - 2nd cycle)
When automatically adding a component to an assembly, are the component presence and position verified
9 after being installed in the part and once the component can’t be moved or removed ? 3.9 - 12 Yes No
When automatically adding a component to an assembly with a vacuum tool, is the component
presence/absence monitored on the loading tool during the entire loading cycle if presence/position is not
10 monitored at the pick point and after installation ? If a component falls during the loading sequence, are the 3.9 - 12 Yes No
component and the part scrapped with an alarm on the HMI to the operator ?

PLC Programming MPS 152

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PLC Programming MPS 152

Uploaded by

Copyright:

Available Formats

Autoliv Inc.

Manufacturing Process Specification

MPS 152 PLC Programming

PLM No: E2702680

Product Area: All

Owner: Marius Marica Approved by: Staffan Olsson

MPS 152 version 2.4 / 21-July-2023 Page 1 of 25

2 PRODUCT SPECIFICATION ..................................................................................................................... 3

3 PROCESS DESCRIPTION ......................................................................................................................... 3

MPS 152 version 2.4 / 21-July-2023 Page 2 of 25

3.1 Definitions and Acronyms

PLC: Programmable Logic Controller

GPD / LPD: Global Process Development / Local Process Development

MPS 152 version 2.4 / 21-July-2023 Page 4 of 25

3.2 Process flow

The PLC can store instructions to implement control functions such as

Figure 1: PLC general concept

Figure 2: Basic PLC description

MPS 152 version 2.4 / 21-July-2023 Page 5 of 25

PLC Program structure (example)

Data Records (measurements and

Data Product / Process (BOM, controls

Central server Line PC

Data Records (measurements and

Working Data: Function 1 Function 2 Function N

Figure 3: PLC program structure example

MPS 152 version 2.4 / 21-July-2023 Page 6 of 25

Verification of PLC Program for all machines

The following verification shall be part of the Machine Acceptance,

o Verify Station to Station tracking is working properly by introducing a part that

3.4 Change Management (after TG3 / SOP)

3.5 Access Rights Management / Passwords management

Access to machine parameters managed by PLC:

Adjustable parameters should be defined during the Product / Process Development

All adjustable parameters managed by the PLC/HMI and accessible to operators or

Access to the PLC Program

MPS 152 version 2.4 / 21-July-2023 Page 8 of 25

3.6 Standard bloc or library (AOI)

3.7 Proactive reviews – peer reviews

3.8 Standard Modes

Below are listed the different machine standard modes:

• Without Traceability: same as auto mode but no communication with the

• Manual mode / Maintenance mode: the operator or maintenance technician

MPS 152 version 2.4 / 21-July-2023 Page 9 of 25

• MCP mode/ calibration mode: is a mode to verify the measurement system

MPS 152 version 2.4 / 21-July-2023 Page 10 of 25

of operation. Going to Special or test mode must be considered as a change

3.9 Programming Lessons Learned, WIP management, rules

MPS 152 version 2.4 / 21-July-2023 Page 11 of 25

MPS 152 version 2.4 / 21-July-2023 Page 12 of 25

SCRAPPED PARTS GOOD PARTS

Figure 4: Example of a combined part chute (flap shown in “scrap

5) Change of state Sensors:

MPS 152 version 2.4 / 21-July-2023 Page 13 of 25

Figure 8: Check-sensor is permanently on (1). Behaviour does not comply with

o Sensors that can’t be monitored or no switching occurs (e.g. an end

MPS 152 version 2.4 / 21-July-2023 Page 14 of 25

MPS 152 version 2.4 / 21-July-2023 Page 15 of 25

10) Communication PLC / Equipment & Robots:

Figure 10: Unicast (preferred) Multicast

11) Part presence and position:

12) Automatic loading/unloading:

o When adding automatically a component to an assembly with a vacuum

MPS 152 version 2.4 / 21-July-2023 Page 16 of 25