Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 1 of 32 1.

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

PURPOSE To establish a routine for any machines and equipments acquiring in accordance with new lines

quality requirements. REFERENCES G35 CS – Working Procedures and Instructions Issuing.

2.

POPRIETY ADVICE: This deed belongs to TRW and is divulged in confidence. No cpies or to thirds divolging permited , unles if authorized by TRW.

3.

DEFINITIONS NONE

4.

REVISIONS CONTROL

Revision No. 00 5.

Date

Requester

Comments

June 30,2009 Manufacturing Engineering Initial Revision REGISTRATION MANAGEMENT Form

6.

Fulfilling Accountable

Origin Place

Retaining Time

Filing place

SYSTEM’S RANGE Services rendering and /or either Machines or Equipments supply shall be governed by this manual

rules as well as by items contained in Decisions’ Analysis (D.A.). Additional conditions discussed at contracting time may be fixed in accordance with service and/or Machines and Equipment Supply features. Partial and or total buildings, machines or equipments reformations, shall be governed by this manual rules. Any alteration, occasionally required by a supplier in projects or specifications given by TRW, shall only be accepted if approved by the accountable for the focused order. All alteration shall be duly documented and shall bear name and signature of the TRW’s employee who accepts the alteration. Beside this manual, Law No. 6.514, dated December 22, 1977 as well as Administrative Directive No. 3214 dated June 08, 1978, where NR 12 governs about Machines and Equipments, COLLECTIVE CONVENTION FOR IMPROVING IN

WORKING CONDITIONS

IN PRESSES AND SIMILAR

EQUIPMENTS, PLASTIC INJECTORS AND GALVANIC SURFACE TREATMENT IN METALWORKING PLANTS IN THE STATE OF SÃO PAULO dated April 04, 2006, Technical Note No. 16 (MTE) shall be observed as well as following NBRs (Recommended Brazilian Standards): •

NBR NM 213 – 1-2 – Machines Safety – Basic Concepts – General principles for projects, parts 1 and 2.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

)RUPDWDGRV0DUFDGRUHVH QXPHUDomR

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 2 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

NBR NM 272 – Machines Safety – Protections– General requirements for fixed and movable

•

protections project and construction. NBR NM 273 – Machines Safety – Interlocking associated to protection devices – Project and

•

selection principles. •

NBR 5410 – Low Voltage electric installations.

•

NBR 13536 – Plastic and elastomers injection machines – Safety technical requirements. •

NBR 13759 – Machines Safety – Emergency Stop Equipments – Operational features – Projects Principles.

•

NBRNM-ISO 13852 – Machines Safety – Safety distance for dangerous zones access impeding to

•

NBRNM-ISO 13853 – Machines Safety – Safety distance for dangerous zones access impeding to

upper limb components.

lower limb components. •

NBRNM-ISO 13854 – Machines Safety – Minimum clearances to human body’s parts smashing.

•

NBR ISO 13855 – Body’s parts approaching speed – Safety distances.

•

NBR 13930 – Mechanical presses – Safety requirements.

•

NBR 14009 – Machines Safety – Risks evaluation principles.

•

NBR 14152 – Machines Safety – Both hands operated devices – Working features and project principles.

7.

•

NBR 14153 – Machines Safety – Safety related control systems parts – General project principles.

•

NBR 14154 – Machines Safety – Unexpected start prevention.

•

NBR 15417 – Pressure vessels – In-service safety inspection.

DOCUMENTATION A Machine or Equipment manufacturing, assembling, installation and delivery time-schedule shall be

supplied within 10 (ten) days counted from the purchase order placement. All manual (operation, programming, maintenance, mechanical, electrical, etc.) shall be in the Portuguese Language. Machine’s or Equipment’s foundations drawings, transportation standards, leveling, as well as templates (models, 1:50 scale) shall be forwarded to TRW, at least 30 (thirty) days before machine or equipment deliver. Should such deeds do not exist, a TRW shall not answer for occasional caused damages. Equipment’s accessories templates, (tank, filters, hydraulic unit, control boards, etc.). shall be supplied in *.DWG (AUTOCAD) format. All Machine or Equipment shall be accompanied by its respective geometric control, which shall be re-done after its installation at TRW. Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 3 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

OBS.: Reports are supplier’s responsibility, under TRW supervision. Clearances shall be informed TRW together with the purchase order. When delivering the Machine or the Equipment, its suppliers shall also deliver a replacement list of those parts considered as being critical and of greater wear, with the technical description of the listed parts as well their Brazilian suppliers contact particulars, as well as MTBF and MTTR analysis. Predictable as well as Preventive Plans Spreadsheets shall be supplied within 2 (two) weeks before Machine or Equipment deliver, contemplating mechanical and electrical items periodicity, Machine’s status for such plan performing and each plan’s activity respective execution time. A Lubrication Plan Spreadsheet shall be supplied within two (2) weeks before Machine or Equipment deliver, with a manual lubrication points lay-out, lubrication periodicity, Machine’s status for such plan performing and each plan’s activity respective execution time. Software as well as communication cable (clp, ihm, pc, etc...) shall be supplied together with the Machine or Equipment. Together with the Machine or Equipment shall also be supplied: •

Pneumatic, hydraulic drawings as well as Electric Diagrams (Monofilar Diagram – NR 10).

•

General Manuals

•

Cycles Diagram

•

Software Commented List

•

Specific mechanisms and devices drawings.

•

CD copy of all software and programs related with the Machine and its equipments/accessories.

•

Should it possess any type of pressure vessel, deeds related with NR 13 and NBR 15417 shall be supplied.

•

ART (Anotação de Responsabilidade Técnica – Technical Responsibility Register) together with collection (payment) receipt.

•

All outlines, manuals, lists, drawings and diagrams shall be supplied in a reproducible CD together

•

In the specific case of Assembly Lines, the supplier shall deliver the operating descriptive flow-

with two printed copies.

chart of each line’s working place for any failure point evaluation aiming further maintenance intervention.

OBS: All supplied mechanical drawings shall be separated by places/operations for items research facilitating. EX: Place No. 1 – Assembly Bench Place No. 1, Op. 20 – Riveting device, Prepared by: Approved by: Bruno Battistella

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 4 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

and so on. ELECTRIC, ELECTRONIC SYSTEM

8.

Inlet required voltage for Assembly Benches shall be 220 Vac / 60 Hz (Three-phased or Bi-phase). Inlet required voltage for Machines shall be 440 Vac / 60 Hz (Three-phase). Control voltage shall be 24 Vac or 24 VCC. One sq. meter or greater surface boards shall enclose fluorescent lamps with door switch and protection fuses, provided with a connection independent from the general control. Boards shall be made with dust-proof gasket, heavy-duty, as well as with 165 degrees frontal doors minimum opening. Board funds shall be removable and shall have 85% maximum use rate. Control circuits shall be made in order to, in voltage return cases, machines and installations may not spontaneously restart, unless clearly required by the general switch operation. All control and motor circuits shall possess a three-phase circuit breaker, for 600V, external handle operation, placed at the frontal door of the electric board, sized for operation under load and provided with padlock hobble. All electric boards shall have a 110 / 220 Vac - 6 A outlet, for instruments connecting, with general switch dependant feeding and a voltage gauge. All components shall be clearly identified, as showed in the electric diagram (conductors’ ringing). Electronic equipments shall be able to work with: •

Net voltage oscillation ± 10 %

•

Room temperature + 5 °C to + 45 °C; an air conditioning appliance shall be installed if needed. Electronic controls must be able to be installed near to cables bearing appreciable current loads or to

welding machines or to other electric controls in general, with no interference suffering. Possibility of inserting electronic control boards in a wrong groove shall be avoided through appropriated safety measures. All Machine or Equipment electric/electronic equipments shall be grounded. Cables shall be flexible, thermoplastic 600 V insulation, obeying to the following color code:

a)

Phases

Black

b)

Grounded neutral

Yellow/Green

c)

Control 110 Vac

Red

d)

Control 24 Vcc

Blue

e) Control 24 Vac Prepared by: Bruno Battistella

Gray Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 5 of 32

Prepared by: Bruno Battistella

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Approved by:

Automotive

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 6 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

All electric conductors shall be clearly identified with numbers and engraving as well as with same denomination used in electric diagrams, which encloses terminals where they shall be connected. Components

Options:

1º

/

2º /

3º /

•

General Circuit Breaker

Moeller / ABB / Siemens / Cutler-Hammer

•

Fuse

Siemens / Legrand / Weg

•

Circuit breakers

Moeller / Siemens / Cutler-Hammer / FAE

•

Contactors

Siemens / Telemecaniq / Moeller

•

Control buttons

ACE / Blindex / Moeller / Cutler-Hammer / Banner

•

Signalization

ACE / Blindex / Moeller / Cutler-Hammer

•

Digital Indicators

Coel / Digimec / Euro-Control / Gefran / Transtec

•

Sensors

Balluf / Sense / Festo / Sick / Banner / Turk

•

CLP / IHM

Moeller / Rexroht / Allen Bradley / Altus

OBS.: For all cases, the software source shall be saved in the memory card.

•

CLP with Redundancy

Pilz

•

CNC Control

Fanuc / Siemens / Mazatrol

•

Inverter/Servomotor

Rexroht / Parker / Wrg

•

End-of-track switch

Euchner / Sick / Banner / Siemens / Telemecaniq (all with positive rupture)

•

Safety Relay (Class 4)

Pilz / Banner / Sick

•

Simultaneity Control (Class 4)

Pilz / Banner / Sick

•

Safety switches (Class 4)

Pilz / Banner / Sick

•

Optical actuating buttons

Pilz / Banner / Sick

•

Electronic screw-driver

CP / Bosch/Rexroht / Atlas Copco

•

Vision system

Vision & Control / DVT/Cognex

Optical barrier

Leuze / Banner / Sick

•

(all Class 4 and 14 mm resolution)

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 7 of 32 •

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

Emergency control buttons Class 4, positive rupture action and feedback, additional safety, should the contact block be not positioned, the machine does not start. For EMERGENCY STOP, it shall be red colored, mushroom shape, blockage equipped, yellow

indication ring and letters in red (emergency) heavy duty and ease of access, placed in the control board as well as in the main service points. For ON/TOUCHES function, it shall be green, heavy duty and ease of access. For CYCLE function, it shall be black, heavy duty and ease of access.

•

Motors They shall all be high efficiency motors. They shall all be fully sealed, with outside ventilation. Motors start shall be: up to 7,5 CV - direct. Over 7,5 CV as needed (star/delta, compensation control,

etc.). Electric cables with inlet voltage shall be directly connected to the General Switch Breaker, at its upper part, and shall not pass through connection terminals. Actuation buttons shall be optical type (equal/similar to SOFT SWITCH of Banner), provided with simultaneity control, upper part protection and obliging the operator to stay with his hands on actuation buttons until the device/machine shall have ended its advancement. Redundant class 4 control and ergonomic actuations (when removing hands from buttons the resources shall block in current position should the work cycle have not started yet). All electric boards shall have an informative panel showing working voltage and general switch; according to board size, following size standard shall be used: 17 X 24 cm or 08 X 12 cm, also applied to remaining actuation controls of size compatible with the board. Presses or similar shall be provided with all controls of both hands actuating, light curtain, emergency buttons, safety switches, maximum redundant safety (class 4) valve vas well as ball-rollers on table base for stamping dies change. OBS: Relays class 4 (curtain, emergency, safety switches, etc.) shall also be load monitoring, i.e., of two positive rupture contactors.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 8 of 32 9.

HYDRAULIC SYSTEM Components:

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Options:

1º

/

2º /

•

Pumps

REXROTH / VICKERS / EATON

•

Filters

HDA / BARRA

•

Gates

REXROTH / VICKERS / EATON

•

Hoses/ Connections

GATES / AEROQUIP

•

Thread standards

GAS / NPT / BSP

Automotive

3º /

OBS: Presses and similar shall possess monitored hydraulic safety gates (class 4) as well as no-return gates.

Hydraulic oil temperature shall not exceed 50 °C in a 24 hours shift. Should this not be assured by the supplier, this shall install an oil cooling system to attend such aforementioned specification. In order to facilitate the working pressures control, as well as to defects find, either pressure gauges in main circuits or a sole pressure gauge with circuit selecting switch shall be installed. The pressure gauges shall possess circuit insulator gate. All equipments shall be identified as shown in the pneumatic diagram. Automatic systems shall inform feedback need, as well as possess an interlocking to avoid machine cycling, in hydraulic missing case, pump failure, etc., i.e., in any system abnormality that may jeopardize the machine operation due to hydraulic oil missing. Refrigeration requiring equipment shall possess individual refrigerating units. Flow control gate that automatically closes or disconnects after a piping/hosing rupture. The noise generated by the hydraulic unit/pump cannot exceed 75 dB.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 9 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

10. PNEUMATIC SYSTEM Components

Options:

1º

/

Automotive

2º /

3º / ..............

•

Gates

SMC / Festo / Ross (Redundancy safety system)

•

Filters

SMC / Festo

•

Conservation Unit

SMC / Festo

•

Pneumatic screw-driver

Deprag / Bosch / Atlas Copco / Desoutter

•

Vacuum Governors

SMC / Schmalz

•

Piping

SMC / Festo

•

Connections

SMC / Festo

•

Pressure Transducers

Smar / Gefran / Wika

•

Vacuum Pump

PIAB

•

Flow and Pressure Drop Gauges

Uson / Ateq / Cincinnatti

OBS: Presses and similar shall possess a safety valve class 4 with dynamic monitoring and pressure switch for minimum and maximum pressure control as well as a no-return gate to keep the devices raised even when a pneumatic system pressure drop would occur. Aiming to make working pressure control easier as well as to defects find, either pressure gauges in main circuits indicating the working range (appropriated for the kind of machine or equipment) or one only pressure gauge with circuit selection switch shall be installed. The pressure gauge(s) shall possess a circuit separating gate as well as a system for the machine or equipment net depressurizing (with a padlock blocking mechanism). The pressure gauge shall possess a colored scale to identify the working pressures range.

OBS: The pressure dropping control shall be near to the operator for easy accessing. All equipments shall be identified as shown in the diagram. Should negative pressure (vacuum) be needed, the Machine/Equipment shall self-generate it. The Machine/Equipment shall be designed for 6 bar maximum compressed air using, save special conditions requested by TRW. The pneumatic circuit inlet shall possess a governor plus filter unit for the line proceeding compressed air. The pneumatic system general valve shall automatically decrease equipment pressure after being closed, shall possess a blockage option (padlock) in the closed position and shall be installed in an operator ease of access place as well.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 10 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

Should there be a need for a “lung” in the pneumatic system, it shall obey all NR 13 (Boilers and Pressure Vessels) requirements, which encloses test certificate and REFERENCE BOOK. Advancement, return and vacuum circuits shall be color distinguished as follows: Advancement circuit: blue hose Return circuit: black hose Vacuum circuit: white hose All double solenoid valves shall be memory type. Use of cylinders and actuating and/or spring operated return valves is not allowed. Should there be cylinders/actuators movements that may put the operator in an electric failure, power dropping and/or pneumatic line depressurization accident risky situation, only either automatic pilot valves or solenoid operated no-return and crossed flow valves shall be used in order to avoid undesired cylinder/device actuation as below shown (crossed flow installation referred).

CONSERVATION UNIT

INTERMEDIARY STOPPAGE

Filter Lubricator Closing valve Progression valve

Cylinder 1 No-return valve with flow governor 2 Valve 5/3 – Open center 3 Gauge with colored scale

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 11 of 32 11.

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

LUBRICATION SYSTEM The lubrication system shall be centralized and automated, with line obstruction indicator, for all

points lubrication requiring within 200 h. The lubricants tank shall be over 200 hours capacity, before re-feeding. The automatic systems shall inform the re-feeding need, as well as they shall posses and interlocking to avoid machine recycling, in case of lubrication failure, pump failure, etc., i.e., any system abnormality that may place in a risky situation the machine operation due to lack of lubricant. The element cascade system may be used provided item 6.3 safety conditions be satisfied. Lubricants containers, lubrication devices as well as Machine or Equipment lubrication instructions shall be in accordance with TRW specification.

Components

Options: 1º

/

2º /

Centralized lubrication system

Eximport / Soned / Sehi

Grease dosing devices

Dopag

3º /

12. MACHINES VISUAL CONTROLS All Machine/Equipment identifications (Buttons, locations, risks, procedures, etc.) shall be in the Portuguese Language, which encloses plates and signalization adhesives. Control components (pressure gauges, pressure switches, thermometers) shall possess working range visual control as well as be located at operator’s ease of access/sight place. Liquid, grease and others tanks shall possess working level visual control (maximum and minimum). Piping shall show content identification (colors) and flow direction. Refrigeration units shall possess a cooling fluid flow checking component. Hand operate\d valves and gates shall possess open and close positions identification as well as padlock blocking option only in the closed position. Belts protections shall be made out from a belt conservation status sight allowing raw material, with no need of belts removal. Gyratory components (motors, pulleys) shall show rotation direction. Nuts/bolts the maker knows may lose during operation shall be visually identified by a marking liner. Machines shall possess Status identification (machine in cycle, machine stopped).

Mechanical risks (movable parts) – shall be provided with mechanical and or electronic protections, operators protecting from existing risks. Should there be any movable mechanical protection, there shall also be an electronic protection, i.e., in open position, the machine/equipment shall immediately enter into emergency situation (it shall not start). Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 12 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

13. NOISE LEVEL The Machines allowed noise level shall be 85 DB (A), slow answer, measured with the measuring device placed 1 meter far from the machine’s ground projection, with the microphone at a height of 1,5 meters from the ground. The greatest values shall be considered in accordance with the Machine emitted sound direction. The maker shall submit to TRW appreciation, for approval, the noise control planning, should the equipment emit noise levels exceeding the specified ones. Allowable noise emission level for Assembly/Test Benches shall be 75 DB (A) -, slow answer, measured with the measuring device placed at 1 meter far from the machine ground projection, with the microphone at a height of 1,5 meter from the ground. The greatest values shall be considered in accordance with the Machine emitted sound direction. The maker shall submit to TRW appreciation, for approval, the noise control planning, should the equipment emit noise levels exceeding the specified ones. MACHINES, EQUIPMENTS AND INSTALLATION PAINTING

14.

Used colors shall be in accordance with NB 54 and NR 26 – Safety Signalization. For piping, movable equipments, ducts, chimneys, stairs, protections, fences, fire fighting materials, civil installations, Signalization – Safety/ SMA 040 Procedure shall be used.

For Machines painting, following standard shall be used: •

Boards:

GRAY

RAL 9002

• •

Structure:

BLUE

RAL 5015

Movable and Protuberant Parts (movements): LARANJA

RAL 2011

•

Protections / Steel plates works:

GRAY

RAL 9002

•

Chip drag:

BLUE

RAL 5015

•

Refrigerating and Hydraulic Units:

BLUE

RAL 5015

Test and Assembly Benches shall be treated in a specific item in this Manual (Item No. 12).

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 13 of 32 15.

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

TRAINING Training shall be operational type ministered. Book of such training shall be issued with all

information needed for a Machine or Equipment appropriated operation and shall point out risks and respective due cares to be adopted during preparation and operation. Mechanical as well as Electronic Maintenance Training shall be ministered. Book of such training shall be issued with all information needed for TRW’s maintenance technicians to have full conditions for a Machine/Equipment intervening. The number of persons to be trained shall be indicated by the maker, taking into consideration the Machine/Equipment complexity as well as the operation difficulty degree, considering, however, a minimum of 3 maintenance workers per area (electric/mechanic). The operational training shall be made together with the TRW plant operation START and shall be up-dated in case of alteration in equipments release. The Mechanical and Electro-electronic training may be made either at TRW or at the maker. It shall be made at the place that may offer the best learning conditions. Operational/Maintenance training Cost shall be enclosed in the Machine/Equipment acquisition. 16. TRY-OUT A try-out shall be made with the TRW inspection team at the maker plant for the Machine or Equipment releasing. 100 parts shall be produced and tested. The supplier shall be prepared for such try-out two weeks before the Machine or Equipment delivery date. Two weeks before the delivery date, an audit of this manual items shall be performed. A second try-out shall be made with the TRW inspection team at TRW’s plant after installation and START. 150 parts shall be produced and tested. After approval, maxim period of time for productivity reaching (parts per hour) as per Purpose shall be 30 days. The at-maker’s plant try-out may possibly not be made should TRW judge it unnecessary through purchase order responsible opinion. OBS: During the try-out removal or inhibition of the machine installed safety resources shall not be allowed. Should they not attend the process requirements, such resources shall be adjusted before starting. Only after such adjustment and work safety area approval, the machine would be released for the due tests.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 14 of 32 17.

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

TEST AND ASSEMBLY BENCHES This item is embodied to the PPRPS as similar and shall attend items listed in the Convention.

Chutes or scrap boxes red painted, sensored, difficult for parts removing through inlet door and difficult for sensor direct actuating by operator. When possible, it should belong to the machine or bench body. Electric cables beds and pneumatic piping. Zinc or nickel plated 25 millimeters steel plate surface benches. Benches assembled with extruded anodized aluminum profiles (Bosch standard or similar). For Assembly Benches Painting follow standard shall be used:

•

Electric boards

Gray

RAL 9002

•

Devices

Chemical Nickel or Zinc Blue

•

Precision or sliding parts

Black Oxidizing

•

Steel plate benches surfaces

Chemical Nickel or Zinc Blue

•

Movable sets and parts

Orange

RAL 2011

•

Safety or protection grids

Orange

RAL 2011

Needed paintings shall be electrostatic powder or similar, provided it does not jeopardize or contaminate the product. To possess an appropriated support for components, related to TRW standard boxes and/or MTM Marfinite standard boxes (that must be properly positioned, i.e., taking into consideration operator’s posture, attending ergonomics requirements). To possess an appropriated TRW standard support for work routines (similar to attached draft):

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 15 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

ISOFLEX FOLDER LETTER SIZE

ISOFLEX FOLDERS SUPPORT

VISUAL IDENTIFICATION LABEL RAIL IN-OPERATION INDETIFIED

Signalizing lamps colors:

Green

Approved parts

Yellow

Parts under test

Red

Faulty or rejected parts

Blue

Cycle initiating condition

White

Energization

Software basic requirement: •

Hand operated or automatic cycle as well as audit for simulated defect standard passing (item No. 13)

•

Programs or products selection;

•

Test periods, maximum and minimum leakage specifications;

•

To allow test results visualizing when made and to file last part data;

•

In a natural manner, to make all cylinders and valves or gates actuations available, being actuation done through IHM by pressing F7 and F9 keys, keeping activated all bench safety controls (optical barrier, safety relays, safety blockage, etc.);

•

Different passwords for hand access and parameterization;

•

Emergency, when actuated, shall stop in current position, automatically fully depressurizing the pneumatic net (to possess no-return valves);

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 16 of 32 •

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

Should light curtain emergency buttons and safety switch be actuated, the machine or equipment shall stop in current position and posses hand operated reset, i.e., reset button shall be actuated in order to relocate the bench in original conditions.

•

Reset shall be hand operated, at blue button (positioning). When actuated, it shall relocate the whole system in cycle initial position (origin conditions;

•

To diagnose with two level alarm message in defects case of mechanical or pneumatic or electric and product failures actuations (rejection, leakages, etc.);

•

All sensors shall be verified on what concerns their status change to assure they are not burned or with glued contact;

•

Pages structure attending according to lay-out shown at item No. 12.16;

•

Any rejected part shall stay bound to the device; red button or “release part” switch actuating needed for rejected parts releasing from device. When possible, the rejected part should automatically be discarded.

•

All production scrap shall be confirmed in sensored chutes or scrap boxes for a new cycle releasing.

•

“APPROVED” and “REJECTED” parts counter;

•

Whenever the assembly or test initial conditions would not be achieved, a red lamp shall blink and a sounding signal emit to call operator’s attention. (e. g.: minimum test pressure or vacuum not achieved); Both-hand actuation shall be done with optical keyboards with simultaneous control safety relay

class 4 (over buttons protections should be available). IHM with alphanumeric keyboard and a display with at least 04 lines; Should a vacuum test application be required, the bench test shall possess equipments able to assure all parameters indicated in test standards; Should pneumatic and or hydraulic cylinders be used for operations performing where pressure variation may alter the final product quality (to rivet, to form, to assemble, etc.,) the bench and or the device shall possess some controls for it to only operate within the pressures parameterized in the IHM (transducers, pressure switches, etc.); Date code engraving machines approved by TRW: Micro punching engraving system: Couth, Telesis and Technifor All with CPU and keyboard for configuration and adjustments. The engraver shall obey NV6-01-01 and TS1-20-02 standards. Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 17 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

Ink-jet engraving system: Willet

Every POKA YOKE device shall obey TRW E-211 – Error-proof Verification specification to be homologated. Leakage standards “calibrated whole type” for simulated defects patterns making as well as for test bench calibration shall be supplied together with leakage/sealing test benches. IHM building reference.

REFERÊNCIA DE ESTRUTURAÇÃO PARA O SOFTWARE DA IHM LIVRE DE SENHA

TELA P/ MANUTENÇÃO SENHA: 1234

PARÂMETROS DE ENGENHARIA SENHA: 0531

LIVRE DE SENHA

LIVRE DE SENHA

TECLA F1

TECLA F2

TECLA F3

TECLA F4

TECLA F5

SELEÇÃO DE PRODUTOS

MANUAL DISP. 1

PARÂMETROS DISP. 1

RESULTADOS DISP. 1

MENSAGENS DISP. 1

MANUAL DISP. 2

PARÂMETROS DISP. 2

RESULTADOS DISP. 2

MENSAGENS DISP. 2

MANUAL DISP. xx

PARÂMETROS DISP. xx

RESULTADOS DISP. xx

VISUALIZAÇÃO DAS ENTRADAS ANALÓGICAS. - TRANSDUTOR LINEAR, - TRANSDUTOR DE PRESSÃO, -CÉLULAS DE CARGA, -OUTROS

MENSAGENS DISP. xx

PARÂMETROS DE MÁQUINA

PEÇAS APROVADAS PEÇAS REPROVADAS

TECLA F6

TECLA F7

TECLA F9

PASSAR PADRÃO, INIBE REFUGO

COMANDO PARA AVANÇAR

COMANDO PARA RETORNAR F7 E F9 SÓ FUNCIONAM NO MODO DE MANUTENÇÃO (TECLA F2)

TELA P/ PRODUÇÃO SENHA: 2222

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 18 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

IHM SOFTWARE BUILDING REFERENCE MAINTENANCE SCREEN ENGINEERING PARAMETERS P ASSWORD PASSWORD 1234 PASSWORD 0531 FREE F1 KEY

Automotive

PASSWORD FREE

PASSWORD FREE

PRODUCT SELECTION

F2 KEY MANUAL DEV. NO. 1

F3 KEY PARAMETERS DEV. NO. 1

F4 KEY RESULTS DEV. NO. 1

F5 KEY ANALOGIC ENTRIES SIGHT

MESSAGES DEV. NO. 1

MANUAL DEV. NO. 2

PARAMETERS DEV. NO. 2

RESULTS DEV. NO. 2

MESSAGES DEV. NO. 2

MANUAL DEV. NO. XX

PARAMETERS DEV. NO. XX

RESULTS DEV. NO. XX

LINEAR TRANSDUCER PRESSURE TRANSDUCER LOAD CELLS OTHERS

MESSAGES DEV. NO. XX

MACHINE PARAMETERS

F6 KEY

F7 KEY

F9 KEY

PATTERN PASSING REJECTED INHIBITION

ADVANCING COMMAND

RETURN COMMAND

APPROVED PARTS

I

REJECTED P ARTS P ASSWORD 2222

Prepared by: Bruno Battistella

PRODUCTION SCREEN

Approved by:

F7 & F9 KEYS ONLY WORK IN MAINTENANCE MODE

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 19 of 32 18.

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

AUDIT An audit at the maker on items contained in this procedure shall be done 10 days before the Machine

or the Equipment deliver. Item not in accordance shall be corrected within the deliver at TRW date. At the delivery, another audit shall be done to check first audit pending items correction. 19

SAFETY Whatever process that could haze, vapors and particulate generate shall possess an exhaust system

as well as specific filters. Whatever machine or equipment or device shall attend ergonomic features, i.e., height, legs room physical endeavor, support points for upper limb components micro pauses, actuations, temperature, components at operator range, etc... Analysis and application of machine or equipment or bench safety controls is of maker’s responsibility.

RISK EVALUATION IN ACCORDANCE WITH NBR 14153 S – Wound severity S1 – Light (revertible) Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 20 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

S2 – Heavy (irreversible) fatal enclosed

Automotive

Categories

Starting point for risk Evaluation of Safety control area F – FREQUENCY AND EXPOSITION TIME F1 – Rarely and or small exposition F2 – Frequent to continuous and or long exposition P – Possibility of danger avoiding (they usually refer to speed and frequency with which the analyzed part moves and the operator distance from it P1 – possible under specific conditions P2 – little possible Law no. 5280 states legislation observance for imported machines.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 21 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

SAFETY STANDARDS IN BRAZIL

Machine and Equipment maker

A Type Standards

NBR NM 213 - 1-2

B T\ype Standards

C Type Standards

B1 Type Standards

B@ Type Standards

Machines Safety

NBR 13862 Continuous conveyors

Safety General Features

Used Components in Safety

Basic concepts, general principles

Project safety requirements

for projects part EN 292 1/2/3

EN 60204-1 Machines safety – Machines Electric

NBR 13761 – Safe distances for

NBR 13759 – Emergency stoppage equipments, functional features,

Alimentary pasta

equipments Part No. 1 General requirements specifications

NBR 14009

project principles (EN 294)

(EN 418)

NBR 13760 – Minimum clearances to avoid human body parts smashing

Risk appreciation principles (EN1050)

NBR 13865

dangerous zones accessing by upper limb components

(EN 349)

cylinders Safety Requirements

NBR 13929 - Interblockage

NBR 13867

devices associated to protectioins

Meat meancers

Projects and selection principles

Safety requirements

(EN 1088)

NBR 14153 – Machines safety: Control systems parts relat

NBR 13928 General requirements for protections projecting and building (fixed and movable)

NBR 13536 – Plastic and elastomerics Injection machines Safety technical requirements for projecting, building

With safety, general project principles (EN 954-1)

NBR 14154 – Machines safety Unexpected start prevention

(EN 953)

and using (EN 201)

NBR 13758 – Safe distance for

NBR 13930

Dangerous zones acessing to lower limb components

(EN 1037)

MechanicalPresses Safety requirementes

(EN 811)

NBR 14152 – Machines safety

(EN 692)

NBR 13996 Blast molding machines for void thermoplastic articles

B oth hands command devices Functoinal featrures and project

Articles. Technical safety requirements for Projecting and building

principles (EN574)

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 22 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

ACCIDENT ACCOUNTABILITIES When work accident accountability was mentioned, it was specifically based on NBR 14153 that at its item No. 8.5, referring to a new or re-built machine approval for production, requires the issuing of an approval deed containing: •

Names of responsible persons for the tests

•

The equipments used in the tests

•

The several tests that were made

•

A list of the failures and their corrections A juridical strong phrase is present in NBR 14153, below transcript: Results must be documented and filed in an auditable manner.

20. PRESSES AND SIMILAR To fully obey the collective convention, technical note No. 16, NBR’s and other legislation. Logic programmable safety controller Class 4: (device in accordance with NBR 13930 item No. 4.10 and NBR 14153 item No. 6.2.5 class 4); Such device’s purpose is to press monitor and control. Having a specific technology for the segment, in accordance with Brazilian and International safety standards, the safety CLP controls all devices related with a press stoppage that are below described: Based on EM 60 204-1 standard, that enhances items related to redundancy, diversity and self-test for safe considered controls, an example may be that of an unit formed by three processors from different makers and an efficient self-test and failures diagnosis. Such configuration only allows to operate one outlet should the three processors present same result. Safety valve (only monitored by the safety PLC) Class 4: For clutch brake coupling control (safety device for presses, as per items No. 4.7 and No. 4.8 of NBR 13930); Redundant safety device. It is self-monitored, therefore assuring the machine safe stoppage (dynamical monitoring), with minimum and maximum pressure switch. Safety switches (Class 4) for monitoring grids and doors that allow risk area access (movable parts); Light curtain 14 millimeters resolution (class 4) – depending upon the process it shall possess the fluctuant blank function – for the risk area access monitoring (class 4, as per NBR 14153 item No. 6.2.5) Active optical safety device type 4 (as per IEC 61496-1, -2 and EM 61496-1, -2). An infrared bi-dimensional radiation protection field is generated between the transmitter and the receiver. Should this protection field be interrupted the CLP and or the safety relay is instructed to operate Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 23 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

in the safety mode where the safety valve is disconnected, which interrupts the movement, therefore protecting the operator from a possible accident. Emergency stop button with positive rupture and feed back (safety additional, should the contact block be not properly positioned, the machine does not start). Its purpose is to do an emergency stop and the CLP and or the safety relay shall monitor such circuit in order that, should either a cable rupture or a short circuit happen the CLP or the safety relay shall immediately do a safety stop. Both hands control (class 4, as per NBR 14152): Bi-hand operation requiring device. The outlet sign will remain active until one hand would be released. As per NBR 14152, items No. 3.5 and 7, the CLP or the safety relay monitors the synchronous action of the bi-hands buttons, therefore assuring the command actuation only if the simultaneous actuation time is smaller or equal to 0,5 sec. Upper and lower dead point control (hummer monitoring): Hummer position monitoring device for LDP (lower dead point) [PMI (ponto morto inferior)] finding and UDP (upper dead point) [PMS (ponto morto superior)]. Only safety CLP monitors this device for safety routine performing.

OBS: Item No. 4.9 of NBR 13930 must be observed Safety wedge: This device is used between tools when small maintenance services are required in them. It shall be interconnected with the machine’s emergency system, i.e., it must be outlet disconnected and placed within the machine range area, so that once it is disconnected, the machine will not work therefore avoiding the risk of starting the machine with the wedge in its range

Front door: Door opening shall be made by means of a pneumatic cylinder and its blockage shall be made my means of safety key.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 24 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

21. AVAILABILITY PLAN / ASSEMBLIES RELIANCE • EQUIPMENT WARRANTY AFTER DELIVERY START TO CUSTOMER. •

ACQUIRED EQUIPMENTS WARRANTY BY NEGOTIATION.

•

AFTER APPROVAL OF FIELD TECHNICAL RELEASE CERTIFICATE.

21.1. •

CRITICAL FEATURES FOR ELECTRO-ELECTRONIC TARGET ACHIEVING TO DELIVER BENCH OPERATION DETAILED FLOW CHART;

•

AUTOMATIC MANUAL CYCLE FAILURES MANAGING SOFTWARE;

•

NOT ALLOWED TO WORK IN CONDITIONS No. 1 AND No. 2 BUT RATHER USE TRANSITION;

•

TO TEST WITH MESSAGE IN IHM EACH SENSOR OF EACH WORKING PLACE SIGNALIZING;

•

TO INDICATE THE NUMBER OF THE ERROR, WRITTEN MESSAGE WITH FAILURE INDICATION (SENSOR OF…..);

•

EVALUATION OF SENSORS PLACES (NEED OF CHANCE OR PROTECTION);

•

TO PRIORITIZE IN IHM THE ERROR MESSAGE THAT CAUSES PLACE STOP;

•

MESSAGES MUST BE DEVELOPED FOR ANY USER LEVEL INFORMING;

•

TO START HELP SYSTEM AT IHM WITH SOFTWARE OPERATION ACCESS PROCEDURES ;

•

TO SUPPLY SOFTWARE SOURCE WITH COMMENTS, COMMUNICATION PROGRAMS AND CABLE;

•

LINE PERIFERALS COURSES BELONG TO TRW (SMAR, ENGRAVERS, TORQUE MACHINE, ETC);

•

CLP MUST HAVE ITS PROGRAM SAVED IN MEMORY CARD;

•

PROCESS / CONTROL PARAMETERS MUST BE INSERTED IN THE MEMORY CARD;

•

WHATEVER ALTERATION ( SOFTWARE / DRAWINGS AND PNEUMATIC, ELECTRIC AND HYDRAULIC DIAGRAMS) MUST BE DOCUMENTED AND DELIVERED TO TRW WITHIN 48 HOURS; OBS: SOFTWARE DELIVER DOES NOT ALLOW UNDER NO CIRCUMSTANCE AT ALL

EQUIPMENT WARRANTY SUSPENSION.

•

IN-FIELD EVALUATION

OF

CABLES

MOVING SYSTEMS

/

PROTECTIONS, ETC..

EFFICIENCY; •

TIME BASED PILOT RUN MUST BE INFORMED TO TECHNICAL PERSONNEL AFTER LINE RELEASING. TWO FIRST PILOT RUINS MUST BE MADE BY THE SUPPLIER;

•

TO INFORM TECHNICAL FEATURES / PARTS, COMPONENTS, SPECIAL ASSEMBLIES, ETC.. SUPPLIER;

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 25 of 32 •

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

SENSORS STANDARDIZE / END OF TRACK KEYS RELATED TO MODEL USED TO FULL EXTENT.

•

TIME BASED PILOT RUN MUST BE INFORMED TO TECHNICAL PERSONNEL AFTER LINE RELEASE, TWO FIRST PILOT RUN.

•

SHALL BE DONE BY THE SUPPLIER (WEARING ITEMS SUCH AS BELTS, SUPPORT POINT, ETC).

23. 21.2 CRITICAL FEATURES FOR MECHANICAL TARGET ACHIEVING •

IN-LINE CHECK CORRECT OPERATION (EFFICIENCY) OF EACH DEVICE;

•

TO PREVIOUSLY INDICATE WEARING COMPONENTS (SPRINGS, PARTS CONTACT, ETC);

•

TO EVALUATE OUTER INFLUENCES IN DEVICES OPERATION (PROCESS DIRTINESS, PARTS CONTACT, ETC.);

•

TO INFORM TECHNICAL FEATURES / PARTS, COMPONENTS, SPECIAL ASSEMBLIES, ETC... SUPPLIER;

•

ALL MECHANICS SHALL BE DIMENSIONED TO WORK Q\WITH PRODUCT TOLERANCES;

•

DEVICES ALIGNMENT (GEOMETRY) VERIFYING STANDARD MUST BE SUPPLIED

•

MOVING DEVICES / SYSTEMS DURATION MUST BE DEFINED (WEARING ITEMS);

•

DURATION MUST BE THE LONGEST AS POSSIBLE WITH NO NEED OF PREVENTIVE MAINTENANCE INTERFERENCE (WEARING ITEMS);

•

ALL FINE ADJUSTMENTS MUST BE DONE IN MECHANICAL KNOCKER (CYLINDERS, LINEAR GUIDES, HYDRA SHOCK ABSORBER, ETC);

•

ALL MOVEMENT SYSTEM MUST HAVE SHOCK ABSORBERS TO AVOID PREMATURE WEARING;

•

ALL DOCUMENTATION MUST BE DELIVERED WITH CONSTRUCTIVE DIMENSIONS;

•

USED BOLTS STANDARDIZING, AS FOR INSTANCE: M5 TO M6 THAT IS MOST USED;

•

CYLINDERS DIAMETER STANDARDIZATION.

•

CYLINDERS LENGTH STANDARDIZING TO MAXIMUM POSSIBLE EXTENT.

•

RODS AMD SLIDING BUSHES STANDARDIZING.

•

ROLLER BALLS USED IN THE LINE STANDARDIZATION TO MAXIMUM POSSIBLE EXTENT.

•

TO TPM METHODOLOGY USE FOR EQUIPMENTS ABD DEVICVES ACCESSING.

•

ALL DEVICE / PART USED IN THE LINE MUST HAVE ITS NUMBER TYPED IN A VISIBLE PLACE (DEVICE NUMBER / DETAIL).

•

POKA YOKES LISTING AND INDICATING / LINE CALIBERS WITH DIFFERENT COLOR (TRW 11 COLORS PROCEDURE).

•

ALL DEVICE / ASSEMBLY MUST BE PINNED AND GUIDED ON THE LINE.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 26 of 32

Prepared by: Bruno Battistella

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Approved by:

Automotive

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 27 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

CHECK LIST – SAFETY AND ENVIRONMENT AUDIT - TRY-OUT

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 28 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

TRW Automotive Ltda

Prepared by: Bruno Battistella

Automotive

Machine or Equipment try-out Safety Audit

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 29 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

Items to be audited description – 1 PHYSICAL Noise – Is sonorous power (noise) produced over 75 dB/A? Is it of excessive vibration? Should it emit ionizing or non –ionizing radiation has it enough protection And is it CNEN No. 27/04 Resolution limit off (when needed due documentation must be required from supplier) Is there heat or has it hot parts with burning risk?

Yes

No

N.A.

Items to be audited description – 2 CHEMICAL Does it humidity generate? Does it dust emit ? Does it fume emit? Does it mist emit? Does it gas emit? Does it fog emit? Chemical compounds or substances use in general? (describe the risk)

Yes

No

N.A.

Items to be audited description – 3 B BIOLOGIC May it generate viruses, protozoas, bacilluses or parasites proliferation? May it provoke bacteria or funguses proliferation?

Yes

No

N.A.

Items to be audited description – 4 ERGONOMIC Does it require intense physical effort? Does it require weight manual raising and transportation? Does It require inappropriate posture? Does it require tweezers taking > 1 kg with > 10 sec. or > 30X/min. duration? Does it require taking effort > 5 kg with > 10 sec. or > 30X/minute duration? > 5 kg parts handling is it done with lifting equipment Are there taking points beyond taking area (range) without protruding shoulder ahead? Is it there any operation point beyond comfort area? Does it require radial deviation > 20o and wrist angle > 30o> >10 sec. or > 30X;min.? Does it require wrist flexion or extension > 45o >10 sec. or > 30X;min.? Does it require arm rotation (pronation and supination) > 150o or > 5kg or 3X/min.? Does require arm positioning to the back? Does it require raising hand/arm over shoulder line? Does it require neck inclination > 20o or > 10 sec. or > 2X/min.? Does it require column inclination > 20o or > 10 sec. or > 2X/min.? Does it require column twist (rotate) > 30o ? Does it require lateral column inclination? Does it require knees bending > 30% of the day or > 2X/min.? Does it require toy be upstanding > 30% of the day or > 2X/min.? Does it require to raise > 20 Kg? Does it require to take 10 kg in less than 5 minutes? Is operation point at elbow’s navel height? Does it require static effort from operator (body partially rigid or stopped)? Does it require repetitive movements? Are feet fully supported? Is it there employee’s body parts mechanically compressed? Does it require to work with raised shoulders? Does he stay with the arms elevated or semi-elevated with no support? Has it polished faces that may provoke reflex? Are handles anatomic and do handle allow full contact with hand? Has operator place room for legs? Does operator place possess support point for micro-pauses of upper limb components with no protruding corners (saliencies)? Are TRW standard boxes supports heights ergonomic?

Yes

No

N.A.

Items to be audited description – 5 ACCIDENTS – 1 NR-10 Is electrical installation in accordance with NR-10? Has it an electric diagram? Is command actuating duly signalized on boards? Are phase cables flexible with thermoplastic insulation 690V and are they Black? Are neutral grounded cables flexible, thermoplastic insulated and Yellow / Green? Are 110 Vac command cables flexible thermoplastic insulated 600V and Red? Are 24 Vcc command cable flexible thermoplastic insulated 600V and Blue? Are 24Vac command cable flexible thermoplastic insulated 600V and Gray?

Yes

No

N.A.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 30 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

Items to be audited description – 5 ACCIDENTS – 1.1. Main switch Has it main switch? Is it signalized (main switch and voltage)? Easy of access? Does it allow blockage (padlock hobble)? Has it 70 cm free space beyond open door?

Yes

No

N.A.

Items to be audited description – 5 ACCIDENTS – 2 Simple actuation Is it there accidental actuation risk? Has it a protection? Are actuating ergonomic? Does it require strength to keep it pressed (DORI)? Are hands free before cycle end? Has it shock when starting? Are there more irregularities at start?

Yes

No

N.A.

Prepared by: Bruno Battistella

Approved by:

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 31 of 32

Prepared by: Bruno Battistella

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Approved by:

Automotive

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering

Date: June 30, 2009 Revision No.: 00 Resp.: João Mendonça File : EM_08.doc Page 32 of 32

EM 08 MACHINES AND EQUIPMENTS AQUISITION

Automotive

Items to be audited description – 5 ACCIDENTS – 11 Others Yes Has it manual and is it in the Portuguese Language? Has it safety recommendations and instructions? Have pressure vessels Reference book, safety book, hydrostatic test and + as per NR 13? Has it a flow control valve should the hopes break off? Have all air discharge point noise reducers? Has hydraulic, pneumatic system general gate blockage placing option? Does it use combustible or inflammable products?

No

N.A.

Items to be audited description – 5 ACCIDENTS – 11 Others Yes Are moving parts, pistons, protruding parts, recessed parts, pressing, gyratory, pulleys, gears all protected? Have them protection against chip, particles and oil projection? Does safety switch actuating to current situation automatically depressurize the system? Does safety switch (of side doors) actuating to current position automatically system depressurize Does belts protection allow sight of their status without protection removing? Have fog, vapors, particles and gases generating systems exhaust system and filters? Have dies / heavy tools replacing table balls on their surfaces

No

N.A.

Resp.

Term

OBSERVATIONS ALL ITEMS IN GRAY FIELDS MUST BE CORRECTED ACTIONS Item

Description

Evaluation And approval by partakers

Supplier (name) Manufacturing (name) Maintenance (name) Quality Production (name) Work safety (name)

Prepared by: Bruno Battistella

Approved by:

Obs.

Signature Signature Signature Signature Signature Signature

Issued by:

Jacques Mambro / Marcio Bueno

ELECTRONICALLY VALID DEED

Manufacturing Engineering