DaimlerChryslerConstruction Standards

Revised 05/03/06

SECTION 15199 – GENERAL WASHER SPECIFICATION

PART 1 - GENERAL

1.1SUMMARY

  1. This Section includes all new or re-tooled washers being procured by Purchasing for all Powertrain components.
  2. Related Sections include the following:
  3. Section 05500 "Metal Fabrications"
  4. Section 09910 "Painting”
  5. General Safety Specifications
  6. Section 15980 “Total Maintenance Spare Parts”
  7. Section 15140 “Domestic Water Piping”

1.2DEFINITIONS

  1. OEM: The Supplier of equipment quoted to be delivered to DaimlerChrysler, shall hereafter be referred as the OEM (Original Equipment Manufacturer). The term OEM in its context may refer to any designated employee(s), officer(s) or member(s) of said supplier organization.
  2. Purchaser: DaimlerChrysler Corporation, shall hereafter be referred to as the Purchaser. The term Purchaser shall include any designated employee(s) of said corporation. Usually this will refer to the project engineer assigned to the equipment procured.
  3. Deviation: This is a process that an OEM will have to request the appropriate deviation forms from Purchaser and submit them for approval. The deviation is deemed granted, if and only if the appropriate Purchaser’s approveand sign the request forms.
  4. Specifications: All corporate specifications, guidelines, do’s & don’ts, policies, procedures and any applicable government rules and regulations, shall be termed Specifications for the purpose of this document.

1.3OVERVIEW

  1. The following sections shall apply to all washers being procured by Purchaser for all Powertrain components. This specification supersedes all other washer specifications pertaining to washers. It shall be the responsibility of the OEM, where there is a discrepancy or contradiction within the body of this document, to acquire written clarification from Purchaser.
  2. It shall be the responsibility of the OEM to ensure that they are current with all updated specifications. Where there is uncertainty, it is the OEM’s responsibility to solicit assistance from the Purchaser to acquire said specifications.
  3. The OEM shall ensure specifications are followed at all times, and shall submit written requests for deviations when safety, equipment robustness, reliability, maintainability, and process capability are at risk. The OEM shall deviate if and only if they receive written approval to do so.

1.4REFERENCE SPECIFICATIONS

  1. DaimlerChrysler Corporation Tool & Design Do’s & Don’ts – Ergonomics Section
  2. DaimlerChrysler Tool Design Do’s & Don’ts – Safety Section
  1. DaimlerChrysler MachineToolSpecifications
  2. AMEPT Controls Specifications
  3. AMEPT CAD Specifications
  4. DaimlerChrysler Plant Engineering Specifications
  5. Global Project Procurement Specifications (AQP and Qualification Guidelines)
  6. DaimlerChrysler Powertrain Safety Specification
  7. Plant Specific Training Specifications
  8. DaimlerChrysler Sound Level Specification for Industrial Machinery and Equipment
  9. DaimlerChrysler Process Sign-off
  10. Applicable DaimlerChrysler SMI’s (Manufacturing Technical Instructions) & ETI’s (Environmental Technical Instructions) -
  11. American Society for Testing and Materials (ASTM) Standards
  12. American Society of Mechanical Engineers (ASME) Standards
  13. American National Standards Institute, Inc. (ANSI) Standards
  14. American Institute of Steel Construction (AISC) Standards
  1. QUOTATION

A.The OEM shall take note that this section does not replace any other section contained within the body of this corporate specification, regarding quotation requirements; however this section shall act as an addendum to other such sections.

B.The OEM will receive along with the RFQ document, a washer requirements summary sheet, filled out, with all relevant information pertaining to the particular product/part and equipment requirements. A blank form is attached to the ‘Reference Documents and Attachments’ section of this specification. The OEM shall ensure that all requirements are included in their proposal. Any requirements not included shall be expressly written in the proposal.

C.Any deviations to the parts of any specifications shall be clearly and expressly written in the quotation. Non-conformances that are not clearly documented in the appropriate sections of the quotation will result in the OEM absorbing the cost of adhering to the specifications.

D.The OEM shall quote a system that meets the prescribed specifications and ensure that the equipment is functional, reliable and process capable.

E.The OEM will be supplied an OEM conformance sheet and Program Controls Requirements, which shall be filled out by the OEM and submitted with the quotation when the quotation is delivered to the Purchaser. If there are any items that are not applicable, the OEM shall write Not Applicable and explain why in the description field. As much detail as possible provided in the description field will reduce the number of questions for clarification back to the OEM. A blank copy of this form is attached to Part 3 “Reference” section of this specification. The OEM shall submit both hard & electronic copies of the conformance sheet to the Purchaser, along with the quotation.

1.6QUALITY & RELIABILITY ASSURANCE

A.The OEM shall ensure that said equipment is designed such that product, pallets, and/or basket(s) carrying product are not damaged in any way, as they are processed through the equipment.

B.As an option the OEM shall quote a two (2) year equipment warranty in lieu of the standard one (1) year.

C.The OEM shall provide with the quotation package statistical downtime/uptime history as a percent, for the system being proposed. This data shall be from prior jobs, projects and customers that this system is currently being utilized.

D.The equipment shall be subject to all applicable DaimlerChrysler run-off procedures and policies to be determined by Purchaser and OEM. If OEM does not have the quality run-off procedures, it is their responsibility to contact the Purchaser and request such documents.

E.All coolants, oils or other materials shall be approved products in conformance with DaimlerChrysler ETI-103 and be supplied by the OEM during run-off at the OEM facility. DaimlerChrysler shall not supply any materials, chemicals, etc…. to perform the run-off. The only responsibility that DaimlerChrysler assumes is the responsibility to getting sufficient products, pallets and dunnage (not supplied by OEM), if required to be used for run-off.

1.7SUBMITTALS

A.Drawings & Manuals: The OEM shall submit one (1) hard copy and (1) electronic set of prints (including controls) for DaimlerChrysler‘s approval within four (4) weeks of receiving a purchase order. Upon job completion, the OEM shall ship one (1) set of as built drawings with the machine, and supply one CD to the responsible AMEPT Engineer .Three (3) sets of operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. shall be shipped directly to the plant, per AMEPT instructions.

B.DaimlerChrysler will supply the brass tag and drawing numbering system when the purchase order is issued.

C.All floor plan drawings must show the complete plan view of the entire machine as it sets on the floor. Its base, including projections for leveling or anchoring, shall be shown in heavy dashed lines. Heavy solid lines shall be used for any and all projections above the base including tanks, housing, platforms, conveyors, load and unload locations, panels or any other part of the machine. Clearance for service, including panel and access doors (open position) shall be shown in the proper location. Show all locations of piping, drains, exhaust stacks, and air intakes. Ancillary equipment such as electrical panels and filters shall be shown in correct relation to machine and dimensioned. Equipment shall be located to allow for ease of access for service or repairs of any component of the machine or ancillary equipment.

D.The scale floor plan drawings shall be updated each time a revision is made and submitted for approval to DaimlerChrysler prior to altering the machine, ancillary equipment or orientation.

E.All engineering drawings shall be developed using the CAD software and version agreed upon in Cad Administration Agreement (CAA). All engineering drawings, upon successful completion of this project become the property of DaimlerChrysler Corporation.

F.Maintenance Manuals in Englishshall also be developed in an electronic format utilizing Microsoft Word or Adobe Acrobat. All graphics must be embedded into the document, not linked. Preventative Maintenance Manuals must include procedures and frequencies.

G.The OEM shall provide a recommended spare parts list of this machine. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per DaimlerChrysler TMS electronic format (contact DaimlerChrysler plant engineer).Note- spare parts shall be available from sources within the country where the equipment is intended for use.

PART 2 - PRODUCTS

2.1WASHER EQUIPMENT SPECIFICATIONS

  1. Washers are required to ensure that all parts that are processed through them are clean & dry, in machining, such that the coolant and/or chips on the parts do not cause damage and contamination to the tooling and/or in the downstream process.
  2. Washers shall as a general rule, be flexible and configurable for all parts within the defined envelope. Standard washers will be considered and accepted. If non-standard equipment is ordered, the OEM shall have a request for deviation form approved.
  3. The following sections are guidelines that the OEM shall follow. However, if an OEM feels that any part or section of this specification can be improved with changing technology, the OEM may suggest changes to the specification in writing, with the reasons why the changes would better the equipment/product quality, reliability, cost and lead-time. Only approved suggestions will be amended to the specifications.

2.2SYSTEM DESIGN CRITERIA AND BASIC MACHINE DESIGN

  1. The following are basic washer equipment requirements that shall be incorporated by the OEM, unless expressly approved otherwise.

1. Each station within the washer shall automatically handle the parts(Refer to Controls Engineering“System Integration” section for parts handling automation).

2.The OEM shall design equipment to support modularity, such that all accessory equipment can be installed at the Purchaser’s manufacturing facility in less than 2 days (use of plug and pin cable methods, one piece units, etc…)

3.Washer layout shall be optimized to utilize the least amount of floor space, while maintaining safety, quality, reliability and maintainability.

4.The OEM shall provide cycle time breakdown, for all operations within equipment supplied. This may include, but not be limited to, loading/unloading, clamping, rotating, metering, etc.

5. The OEM shall provide a process flow sheet that describes the part as it is processed through the washer, and shall be located near or on the main operator panel or operator aisle, and shall be oil/water resistant.

6. Minimized start-up sequence on the HMI. Start up sequence to be on the 1st or 2nd page .

7.Location of HMI shall be placed such that, to provide the operator/maintenance personnel ease of access to both the washer and HMI.

8.There shall be a “Manual Run Out” mode included to manually run-out the washer of parts for operator/maintenance inspection.

  1. There shall be an “Automatic Run-Out” mode incorporated such that, while in automatic mode, the washer is blocked for a specified amount of time (adjustable via the HMI), the washer will run-out the parts within the washer and not load any more parts until blocked condition is cleared. This is done while the washer is in automatic mode. The washer will also indicate when it is in this mode. This dictates that the unload automation shall have high level set that it could take up to a maximum number of parts in the washer, after high level is achieved and not have any binding conditions.

10. The equipment shall have automaticand manual mode(See AMEPT Controls Specifications for Mode definitions).

11.Exhaust Fan shall have a separate disconnect, to allow for proper ventilation of washer chambers during maintenance.

  1. OEM shall ensure that the washer is designed such that the wash & rinse fluid is directed in a manner to force any chips, that may come out of the parts, out to the filter system. This affects the sizing of pumps and the design of reclamation system inherent to the design of the washer.
  2. All gauges (pressure, temperature, level indicators, etc…) shall have a transparent green colored tape installed, to indicate normal operating pressure and, where applicable, a tag to indicate what the pressure should be set at for normal operation.
  3. The washer shall be designed for top of finish floor installation. Drip pans shall not be used, however, the washer shall be designed to be dry floor guarded.
  4. All motions within the washer shall be electromechanically actuated and mounted outside the wash and rinse zones.
  5. The design of the individual chamber, and the washer equipment in general, shall be such that, to avoid creating “confined space” areas. If this can’t be prevented, written approval must be acquired from the purchaser.
  6. The general guideline for part discharge temperature out of a washer shall be approximately plant ambient temperature, 75°F (+20°F/-5°F). This temperature guideline applies to parts discharged from a primary washer. For a part discharging from a finish washer the discharge temperature shall be, 75°F (+10°F/-5°F). This guideline shall be used, if the Purchaser gives no other specification.(Note if an automatic gage resides beyond a washer, provide temperatures within gage limits).
  7. If discharge temperature cannot be met, it shall be the OEM’s responsibility to design and implement a cooling method using chilled water if available or other cooling method approved by Purchaser. The OEM’s standard cooling method is preferred, however the method will have to be approved by the Purchaser.
  1. For washer cleanliness requirements [see Appendix A]

20.External heat shall not be used to assist in drying the part. If required dryness cannot be achieved by traditional blow-off conventions, then an alternate drying method such as a vacuum system shall be incorporated, and shall be identified as such at the time of quotation by the OEM. Failing this the OEM shall provide the supplemental drying system at no additional cost to the Purchaser.

2.3PART TRANSFER AND ROTATE MECHANISMS

A.The washer shall be designed so that it is integrated both mechanically and electrically with the preceding and post-processing equipment. (Refer to AMEPT Controls Specifications for interlocks).

B.Hydraulic, pneumatic or electrical transfer mechanism components shall be kept out of the wash, rinse, or blow-off sections of the washer. Transfer mechanism pivot points or other components required for the operation of the transfer mechanism shall also be kept out of the wash, rinse, or blow-off sections. All exposed components shall be protected from moisture, heat, and corrosion. Protect these components or areas with waterproof shields, boots or covers.

C.All components subjected to wear shall be hardened to a minimum of Rockwell 55 and finish ground.

D.The transfer mechanism shall be designed so that the parts are securely held in place as they go through the washer. The transfer mechanism shall also have guide rails for keeping the parts aligned and in position.

E.All electrical, hydraulic, and pneumatic components utilized in the transfer mechanism must be from DaimlerChrysler-approved sources. Reference the controls fluid power specifications.

F.The part, if required, shall be rotated to ensure that all required areas are clean. The preferred method is to acquire required cleanliness and dryness without disturbing the part. If the part is required to be re-oriented through the process, the OEM shall then ensure that the orientation of the part is maintained, as specified, when it is discharged from the washer.

2.4PUMPS FOR WASH AND RINSE SYSTEMS

A.Each wash and rinse section shall have its own pump set up.

B.Smaller parts washers shall incorporate barrel mount top pull-out vertical end suction centrifugal pumps. Reference the ‘Approved components summary list’.

C.Larger parts washers such as cylinder blocks and cylinder heads shall incorporate vertical turbine pumps. Reference the ‘Approved components summary list’.

D.The pump capacity shall be governed by nozzle requirements.

E.The pumps shall be furnished complete with all necessary piping and fitted with non-clogging spray jets and double screens for screening water before entering intake of pumps. Manifolds, headers, and specially designed jets shall be arranged with indicators and stops so that they can be dismantled and reassembled in the correct position as indicated on the header drawings. All headers shall be supported to prevent shifting.

F.Each pump discharge outlet shall be provided with a pressure gauge.

G.Each pump discharge outlet shall have a pressure switch to detect pump failure. The pressure switch shall be tied to washer's alarm system.