Mastering the Machine

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2 Table of Contents 1 INTRODUCTION 3 2 CONCEPTING THE SYSTEM Establishing System Requirements Selecting a Method Applications Vendor Selection 7 3 DESIGNING THE SYSTEM AND MACHINERY Project Review Mechanical Design Electrical Design Controls and Software Design Safety and Risk Analysis 15 4 BUILDING THE SYSTEM 16 5 ACCEPTANCE AND RUNOFF 17 6 FINAL DOCUMENTATION 18 Appendix A Design and Documentation Checklist 20 2

3 Mastering the Machine A Step-by-Step Guide to Planning, Building and Documenting 1 Introduction Planning and building a production line is a process that can take many months or even years to accomplish. Whether it is a simple machine with a few peripheral material handling sections or a complex multi-million dollar system, it is critical that the process is carefully executed so that it meets budgetary, schedule and performance requirements. There are three common methods a manufacturing company can employ to achieve this goal. The first is to use a company that offers turnkey projects, handling everything from design and scheduling to installation. The second is to purchase all of the elements of the production line separately and assemble them on the plant floor, possibly with the help of a systems integrator. The third is to build the machinery in-house, possibly purchasing some specialty equipment from outside vendors. Many steps among the three methods may overlap, but the delegation of responsibilities differs in each method. This comprehensive guidebook describes all of the stages and steps required for each method in order for a manufacturer to successfully implement a production line. This book will also help guide its readers through the complex maze of documentation and design tools required to accomplish this task. Take note! The following legend is crucial for understanding the documentation process. While secondary and tertiary documents are not optional, there is a sequence to the order of documentation. Listed beneath each subchapter is a list of color-coded requirements in each phase. Here is what the colors represent: 2 Concepting the System Manufacturers usually have a rough idea of the type of system they want, or at least the expected results. They may have an existing production line or machine that is already making product, or they may have a process in mind that will achieve the desired result but that has never been tested. Alternatively, they may 3

4 have no idea at all how to achieve their goal. Regardless of the manufacturer s starting point, this is the phase in which the idea for a machine or process starts to become reality. 2.1 Establishing System Requirements Requirements Documentation Product Specifications Plant Specifications In order to define the system, the basic requirements must be outlined. The resulting requirements documentation should include a description of the product being manufactured, the specifications that must be followed in its manufacture, and an outline of the purpose and scope of the project. The document should not define the technical solution that will be used to produce the product. The first step in developing a concept for a new production system is to determine the required output over time. This can be expressed as parts per period or, in the case of a continuous process, as volume or weight per period. As requirements for the product and process are developed, a manufacturer should also attempt to determine whether the project is viable. In other words, is there justification for proceeding with the project? This is often linked with the cost of labor (number of operators), energy (electricity, water, gas) and new equipment. The individual components used to make up the product itself are also identified at this stage, along with consumables such as adhesives or packaging materials. Most manufacturing companies also have specifications for electrical and mechanical equipment already developed. This may include preferred brands for components, required materials to be used or avoided, fabrication and assembly techniques and any other standards that vendors must adhere to. All of these standards should be referenced in the requirements documentation, which may then be used to provide potential vendors with sufficient information to quote the system or their portion of it. The amount of space available on the factory floor may also be included in the documentation. If floor space has already been designated for a new production line, information such as square footage, maximum equipment height and available utilities may be described here. 2.2 Selecting a Method Quote Requests Vendor Qualification After establishing the production machinery requirements, the method used to implement the project must be determined. A manufacturer may already have vendors the company has worked with in the past. If so, documentation of those companies capabilities, histories, financial conditions and references should already exist in the manufacturer s records. If not, information can be obtained from the vendors themselves, sourced from a questionnaire, website, Dunn and Bradstreet report or other trade resources. 4

5 Figure 1 - Vendor Solution Spectrum As illustrated in figure 1, there is a range of possibilities for implementing a production line. Some manufacturers have a great deal of in-house capabilities when it comes to designing, building and commissioning a new system. Even then special equipment such as packaging machinery, conveyors, test equipment and vibratory bowls are usually purchased from vendors. Other manufacturers may choose to engage an engineering firm or large custom machine builder to deliver and install a turnkey system. In this case, the vendor is taking on the responsibility of ensuring the entire system performs as specified in exchange for an increased margin on all of the associated equipment used for the project. Many systems fall somewhere in between. Even when a large system is designed and built by a custom machine builder, utility connections and millwright services may be handled in-house or by using contractors. Packaging machinery, test equipment and material handling may be purchased separately and integrated into the system. Project management is a key requirement for the manufacturer. The purchaser of the production line usually has a certified project management professional (PMP) in overall control of the project regardless of the method selected. The project manager keeps a master schedule or Gantt chart that includes the work breakdown structures of all the project vendors, dependency relationships between processes and the durations of the design and build stages. Project managers are also tasked with monitoring the budget and scope of the entire project. Vendors may or may not have project managers for their part of the project. Even large machine builders and engineering firms rarely have certified PMPs. Typically an engineer is assigned to these duties. They will likely be able to provide Gantt charts and reports for their part of the system; however, budget and project details may not be easily accessible to the manufacturer/purchaser. 2.3 Applications Proposal Quote Spreadsheet System Architecture Solid Models or Drawings Process Description 5

6 Requirements Documentation Plant Specifications Product Drawings and Samples The proposal and preliminary design of a system is usually handled by an applications engineer or department. In many cases, a sales representative from a vendor has already been in contact with the customer and provided preliminary information to the vendor. This information may include a rough description of a proposed solution as well as the requirements and product specifications outlined in chapter 2.1. Applications engineers often work with designers and other personnel to narrow down methods of processing the product. They may be in direct contact with the customer, typically through the vendor s technical salesperson. In some smaller companies, the role of an applications engineer may also encompass technical sales or design engineering responsibilities as well. Ideally, an applications engineer will want a sample of the product as well. As the proposed solution is designed, a quote spreadsheet is typically used to break down component costs and estimations of labor. A common method used to organize this document is to assign each sensor, actuator, HMI screen and auxiliary device a number of labor hours by discipline. Mechanical and electrical design, PLC and HMI programming and assembly hours can all be handled in this way. Most standard components are not broken down into actual quoted prices from the distributor, but are instead treated as generic items. Test equipment, fastening tools and other auxiliary equipment may be quoted by third parties or historical pricing data used in the spreadsheet. This method of estimating cost though somewhat imprecise saves time when generating quotes. An additional margin is added for purchased devices and riskier parts of the application. Labor costs are generated by discipline, breaking down loaded costs for engineering, assembly, documentation and project management. Machine framing, guarding and structural steel may be calculated by weight or square footage. Fabrication and machining hours are also sometimes handled in this way. 6

7 Figure 2 - System Architecture Concept and system architecture drawings are also generated for inclusion in the proposal. Many companies use solid models to paint a picture of what different parts of the system will look like. Other graphics programs, such as AutoCAD or Microsoft Visio, may be used to generate architectures and other diagrams. The end result of the applications process is to generate a written proposal with firm pricing and scheduling for the customer. 2.4 Vendor Selection Purchase Order Contract and Terms Gantt Chart Team/Contact Info After vendors have been selected, purchase orders are issued for equipment. Payment terms can vary widely, but usually an initial deposit is billed upon receipt of the order, an additional billing occurs after a certain amount of design has occurred or parts are ordered, a third billing takes place after a successful 7

8 runoff at the builder s location (Factory Acceptance Testing or FAT), and final billing occurs after runoff at the purchaser s facility (Site Acceptance Test or SAT). Percentages for these milestones are often negotiated beforehand since requested terms often differ between vendor and buyer. A contract is often signed with stipulations in case of late delivery, order cancellation or other clauses. These contractual provisions may be required in addition and prior to the generation of a Statement of Work (SOW). If a turnkey solution is used for a large system, this process is often repeated among the main contractor, subcontractors and OEMs. This can be repeated several layers deep to the point where it is difficult for the purchaser to see all of the scheduling details at every level. Communication among all levels of project implementation is a key component of a project s success. Figure 3 - Project Schedule Gantt Chart After the project manager has created a master Gantt chart for the system, it is important that it is updated regularly. As subcontractors update their charts typically on a weekly basis results need to be reflected on the master chart of the customer s project manager. To help facilitate communication among all of the team members involved in a project, a chart or list is often generated with contact information including names, titles, s and phone numbers. Putting this in a chart format can be useful to help illustrate each member s position and responsibilities within the organization. Team contact information may include subcontractor personnel also, but aside from qualification purposes, subcontractor personnel are usually not contacted directly by the purchaser. 8

9 3 Designing the System and Machinery After the purchase orders are placed and contracts signed by the appropriate representatives, a formal Statement of Work (SOW) is usually issued. This can be considered as the beginning of the design process. A kickoff meeting is often held at the beginning of the project to acquaint team members and review the project. This meeting is usually scheduled to give team leaders adequate time beforehand to review specifications and preliminary design information. 3.1 Project Review Statement of Work (SOW) Proposal Project Schedule Before and during the project kickoff meeting all parties involved review the existing project documentation. Negotiations concerning details of the project should be captured in the SOW document generated by the purchaser. The Statement of Work encapsulates the deliverables and work activities as detailed in the proposal generated by the vendor. The project schedule should be updated and reflected accurately in the SOW, and details of the requirements documentation may also be reiterated at this point. A common mistake that is often made when creating the SOW is that the manufacturer does not capture and align differences between the requirements documentation and the vendor s proposal. The SOW is usually considered a formal binding contract between vendor and purchaser, so if differences between the proposal and SOW exist, litigation will usually side with the SOW since the document was created later in the process and is, therefore, considered more final. Revisions to the SOW are not uncommon even after the kickoff meeting. Representatives of both parties should sign the SOW and all its revisions to bind the agreement. The project schedule often changes for many reasons engineering changes, part availability and unforeseen occurrences can all affect the schedule. The purchaser and vendor must both agree to clauses that address these circumstances. 3.2 Mechanical Design Timing Chart Solid Models 2D Prints (Assembly Drawings) Stress/Load Analysis Motor Sizing Pneumatic, Hydraulic and Piping Sizing Mechanical BOM Proposal Statement of Work Concepts outlined in the proposal may have changed during the project review. These are not necessarily reflected in the SOW unless they impact the cost or procedural aspects of the project. As mentioned in the applications section of this book, solid models may have been created as part of the proposal. If the 9

10 project description has not changed drastically, these solid models can serve as the basis for the mechanical design. If the manufacturing method has changed since the proposal, a new description of the process should be contained in the SOW. The first step many designers take is to create a rough outline of what the system will look like. A sequential list of operations is generated and actuators identified. This becomes the basis for a timing chart, which shows a graphical representation of machine operation. The timing chart is an important means of communication among the mechanical, electrical and controls engineering teams since it creates the names of many of the machinery actuators and processes. Because of this, all teams should have input into the contents of the timing chart. Figure 4 - Mechanical Timing Chart Solid modeling software allows a designer to simulate actuator movement, check for interferences and sometimes even calculate forces and stresses for machinery. There are also other simulation software products used to calculate stress and strain for mechanical systems and finite element analysis. Structural weights can be easily calculated since the type of material is usually designated in the model properties. Solid modeling software is also used to generate two-dimensional (2D) prints for machinists and assembly technicians. These prints may be used to generate CNC programs or maintained in a folder for reference. Mechanical designers usually size motors since the weights and inertias are easily generated by the solid modeling software. After being sized, the actual components are generally selected with input from the electrical designers. Servo motor sizing is usually done with motion analysis software external to the solid modeling tools. This is because gearboxes and motors have often been tested in applications by the vendor using various custom criteria. Therefore, the servo manufacturer usually provides the servo modeling software. Pneumatic and hydraulic actuators are also sized based on calculated speeds and tooling weights obtained from solid models. While actuators may be selected by a mechanical designer, valves and other devices 10

11 are primarily selected by electrical designers, and piping for process and flow applications is usually sized by mechanical or process engineers. Again, special software is often available from the vendors of related equipment, and many engineers have spreadsheets developed for this purpose also. As commercial components are selected for the machine, a Bill of Materials (BOM) is generated. Solid modeling programs have the capability of linking these BOM part numbers to assemblies within the model. Solid models or AutoCAD (.dxf or.dwg) files for many commercial components are available from the manufacturer. 3.3 Electrical Design Single Line Drawings Fusing and Circuit Breakers I/O List Electrical CAD Cable Schedule Electrical BOM P&ID Instrument Index Utilities Motor Sizing Mechanical BOM Proposal Statement Of Work Electrical design typically lags behind mechanical design by several weeks or even months. Before components such as circuit breakers, fuses, valves and motor starters can be selected and sized, the mechanical designer must provide information on the elements of the system. Once voltage and current requirements for equipment are known, the electrical design process can begin. Usually a set of single line drawings is generated to show the major components and branch protection for power distribution. This forms the basis of the electrical schematic package. 11

12 Figure 5 - Single Line Diagram Electrical drawings are created using a CAD package such as AutoCAD. Advanced software packages have the ability to create a BOM as components are drawn, attaching properties to the elements for easy reference. Unlike mechanical drawings, where physical components need to be scaled to dimensions, electrical schematics often use boxes or symbols to represent components. For PLCs or other controllers, an I/O list is created by assigning all of the sensors, buttons and actuators to input and output points. This is often done by the project engineer or programmer for reasons that will be discussed later. The I/O list is used to generate individual pages for each card or I/O device. Architectural drawings are updated to reflect the SOW. These can be used as the basis for communications layouts, which are also drawn in the schematics. As all of the required electrical and mechanical components are determined during the design phase, the BOM is updated. Advanced CAD packages will also help determine the number of terminal blocks and other power distribution devices to be used in the control panel. Physical drawings of the control components are obtained from the vendor s website or a CAD library and used to create a panel layout. A typical electrical schematic package includes a table of contents, device and symbol page, single lines, power distribution, communications, I/O structure and physical layout including panel drawings. A cable schedule listing interconnections between electrical enclosures and devices is often generated for electricians during installation. Information on the physical layout of the system is required for this document to determine lengths. 12

13 For process applications with distributed I/O and instrumentation, a P&ID (Piping and Instrumentation Drawing) is created with the information contained in electrical and mechanical designs. These drawings are not typically used for machinery but may be required by some engineering firms or purchasers of manufacturing equipment. P&IDs can be extremely helpful when troubleshooting systems. Figure 6 - Piping and Instrumentation Drawing (P&ID) After the creation of P&ID documents, an instrument index may also be required. This is a list that acts as a cross-reference among P&ID device numbers, manufacturer part numbers and electrical schematics, indicating the specific page numbers on which devices are located. If component or instrumentation cut sheets are combined into a single document, the instrument index can also be used to locate the sheets. 3.4 Controls and Software Design Flow Chart/GRAFCET I/O List/Tag Generator HMI Screen Flow Diagram Equipment Interfaces Controls Program 13

14 HMI Program SCADA/Data Collection Program Proposal Statement of Work The type of controllers used in an automation project will vary depending on the type of application and customer specifications. The selected controllers and manufacturer will then determine what method of programming and software will be required. Most software design processes use some kind of flowchart to lay out the program. A common tool for presentation of software flow is GRAFCET, a stage transition command graph and programming method. Figure 7 - Flowchart and GRAFCET Software Design The I/O list that was used as a basis for the electrical schematics is also used in flowcharting the program. Transitions or decisions are often based on input status, while steps represent the actuation of outputs. The I/O list can also be used as the basis for a spreadsheet that generates tags for the program; names for I/O variables, HMI component names, machine faults and many other program elements can be automatically created using spreadsheet functions. This allows for standardization and saves a great deal of time during program and system development. Flow charts are used to develop controls programs in a variety of languages. Common programming methods include ladder logic (LD), structured text (ST), sequential function charts (SFC), instruction list (IL), and function block diagram (FBD). These languages are used for programming PLCs and some motion control systems and are detailed in the IEC standard for the programming of programmable controllers. Because these programs can be very long, they are not typically printed for use in a manual but are maintained as software files with embedded comments. Development software is required for opening these software files and is not compatible between different brands, so it is important that the purchaser of the production machinery specifies the software and control platform. The programming software is not usually included with the machinery and can cost several thousand dollars. 14

15 Other types of controllers are often used for process control including DCS (Distributed Control Systems), personal computers and embedded controllers. These may be programmed in proprietary languages from the manufacturer or more standard open languages like C++. DCS control is often used when there are a large number of analog points such as in process control. Software developers also often develop a map of HMI screens for customer and peer review. As with programming software for the controller, the development software is not usually included with the purchase of the system unless specified. HMI programming documentation rarely extends much beyond this since the software is graphical in nature. SCADA (System Control and Data Acquisition) programs generally reside on standard computers (PCs). They are usually programmed in proprietary languages or high level computer languages like C, C#, C++ or the like. Documentation and commenting of the program is important but, like other control programs, are rarely printed. 3.5 Safety and Risk Analysis Hazard Worksheet/Safety Classifications Failure Mode Effects Analysis (FMEA) Seismics RoHS and ESD Compliance Clean Rooms MSDS, SDS, PSDS Mechanical Design Documents Electrical Design Documents Software Design Documents As the mechanical and electrical designs proceed, potential physical hazards to operators or equipment must be identified and documented. Hazards to personnel are classified by the severity of the potential injury, frequency of exposure and distance from the hazard. Worksheets are used to determine what type of safety devices must be used to guard or deactivate equipment. Doors with safety switches, emergency stop cables or buttons, and light curtains or safety scanners are common devices used in machine safety systems. Separate controllers dedicated to safety are also becoming more common. Hazard spreadsheets are also useful in automatically classifying hazards and recommending solutions based on the information entered. Safety classifications and approvals vary among different industries based on the level of hazard inherent to the substances used, severity of electrostatic discharge or environmentally harmful emissions, and the potential risk involved to operators and end-users. A Failure Mode Effects Analysis (FMEA) is a technique used to identify potential causes of failure in components, assemblies and subsystems. Reliability and quality engineers use this technique to reduce or eliminate the root causes of failure and their effects on system operations. This technique is most often used in government-related jobs or by large engineering firms, but it can also surface in some industrial projects. 15

16 Seismic calculations are also sometimes required for government-related projects or systems with special requirements. Dimensions of control cabinets and mechanical structures, as well as the method of securing equipment to the floor or ground, are relayed to companies that specialize in these calculations for evaluation. These specialists sometimes require design approval prior to the system s installation. Other approvals may include compliance with RoHS (Restriction of Hazardous Substances) and ESD (Electrostatic Discharge) requirements. Circuit board and electronics manufacturers have special requirements related to their manufacturing processes that include these certifications. Pharmaceutical and medical device manufacturers have additional machinery requirements in order to consistently produce and deliver a product that meets its predetermined and specified attributes. Often, equipment will have specific material and clean room requirements included in their specifications. Clean rooms have certification procedures that ensure a low level of environmental pollutants. Equipment that is located in clean rooms must be designed to generate minimal air contamination. Compliance with IEC, OSHA and FDA regulations related to specific products is required for manufacturers. For this reason, machine builders who specialize in this type of equipment are often selected. Food service equipment also requires special material and manufacturing techniques that ensures biological contaminants are minimized and equipment can be easily cleaned. Again, these specifications should be included in the purchaser s documentation, and there are usually companies available that specialize in this type of machinery. Machines that use consumables such as adhesives or other liquid substances must be accompanied by Material Safety Data Sheets (MSDS), which describe storage, disposal and spill-handling procedures. Closely related are Safety Data Sheets (SDS) for chemicals and Product Safety Data Sheets (PSDS) for certain manufactured products. These documents must be located near the point of use for the substances or devices. 4 Building The System Engineering Change Order (ECO) Red-lining Power-on Checklists Mechanical Design Documents Electrical Design Documents As stages of the design process are completed, drawings are released to machinists, technicians and assemblers for fabrication. There are no specific documents required during this stage outside of updating design drawings. Checklists and other internal documents are often used to ensure completion of required activities and to ensure personnel are aware of the correct procedures. During the design process, changes are often made to the system. If these changes fall outside of the original scope of the project, an Engineering Change Order (ECO) is issued. ECOs may consist of simple changes to the existing design or more complex stations that contain all the elements of a small machine. 16

17 Oversights in the original design may also prompt additional changes to the design documents. Assembly personnel may find that parts don t fit correctly or electricians may discover that wiring changes need to be made. A common method used to capture these changes is to manually red line the drawings. A red pen is used to mark up drawings showing the way that a task was done. The initials of the person making the red line, along with the date is written next to the change. This can be easier than constantly going back to the designer to update drawings; changes are captured on the shop floor and passed back to the designers at a later time. For this reason, it is important to maintain only one master set of printed drawings on the floor at a time. These are typically stamped approved so they are not confused with other working copies that may be present. Updated drawings are returned to designers who make revisions to the original schematics or prints. Revision numbers are sequenced in the title block of the drawings along with the date of the revision. Notes are also placed on the drawing explaining the change, revision number and date. Powering up a machine or line for the first time requires a number of safety checklists and briefings for personnel working around the machinery. Guard devices are often bypassed and machine operation has not been tested, so extra care must be taken when working on equipment. 5 Acceptance and Runoff Dry Cycle Production Run Validation Factory Acceptance Test (FAT) Report Site Acceptance Testing (SAT) Proposal Statement of Work After the startup and debug of machinery is complete, there is often a period of time where the machine will run continuously with no parts. This phase, often known as dry cycle, is used to put run time on mechanical and electrical components. Loose wiring and bolts are often found at this time as the vibration of machinery exposes these oversights. This procedure should be noted in the SOW if required since machinery often requires parts to operate; a special mode must be designed into machinery to accomplish this task. Factory Acceptance Testing or FAT is performed wherever the equipment is manufactured to verify whether the system and its safety instrumentation operate correctly. The FAT can be used as an integration test confirmation or during validation. After disassembly, shipping and reassembly of machinery, a Site Acceptance Test (SAT) is performed. Before machinery is accepted as complete certain requirements must be achieved. These requirements may include a certain output rate, percentage of accepted or correctly manufactured product or a minimum overall equipment effectiveness (OEE). 17

18 6 Final Documentation Recommended Spare Parts Bills of Material Product Cut Sheets As-Built Mechanical Drawings Final Electrical Schematics Operator Manual Maintenance Manual Controls Program Software Validations and Certifications Warranty Mechanical Solid Models and Drawings 18

19 Electrical Drawings Mechanical BOM Electrical BOM As part of a completed production line, a full set of documentation must be supplied to the end-user. This may be in printed or electronic form, but it is usually a combination of both. Much of the documentation presented to the customer comes from information contained in the documents previously discussed in this book. The recommended spare parts list is generated by analyzing the bills of material generated during the design of the machine or system. It is important that updated BOMs are used to encapsulate all of the items required. Recommended spare parts should include items such as fuses, control components like I/O cards and processors, sensors and wearable tooling. If a component is subject to breakage or wear, it should be considered for the recommended spare parts list. Some major components may have long lead times from the factory. Assessment of downtime potential needs to be weighed against the cost of the parts. In some cases, suppliers may have programs to keep items on the shelf at all times for emergencies. In addition to the recommended spares list, a full bill of materials should be included for all purchased components. This list should include the manufacturer s name and part number at a minimum, and, ideally, contact information for the manufacturer and vendor should also be included. Many purchasers of automated equipment will also require cut sheets for some components, which contain technical specifications and setup information for electronic devices. Most of these sheets are easily obtained online or may be photocopied from a catalog. Instruction sheets are also usually packaged with components and should be saved when the system is being fabricated. Mechanical and electrical drawings and schematics should be updated with all engineering changes and redlines performed during the build process. Title blocks should be modified to indicate the revision number and final or approved status of the drawings. Electrical drawings should show all wiring connections and panel layouts with complete wiring numbers and physical panel layouts cross-referenced to the electrical BOM. Mechanical drawings should include 2D drawings of removable tooling and replaceable or wear items. Some customers may also require solid model files. Operator manuals give step-by-step instructions on how a machine operates. The manual often has many illustrations of different parts of the machine and screen prints of the operator interface. Because of this, digital photographs need to be taken of machinery before it is disassembled and shipped. Close-ups of critical sensors, major assemblies and safety devices should be taken along with pictures of control panels and peripheral machinery. The purpose of these photographs is to give operators and maintenance personnel a clear indication of where things are located. Maintenance manuals describe procedures used to remove components, lubricate and adjust mechanical devices, and replace worn tooling. Setup and calibration of measurement devices and sensors are also often covered here. Like the operator manual, pictures are generally used to locate parts on the machine or system. Maintenance manuals may also contain additional cut sheets or manufacturer specifications for purchased assemblies. Recommended schedules for equipment maintenance are usually included in this manual. 19

20 Controls software and other program documentation is usually saved onto a CD or DVD ROM. Physical printouts of controls programs are rarely included in the documentation due to the length of code, however a.pdf copy may sometimes be included for customers who do not have the programming software. Controls software programs should be well documented so technicians can easily interpret the code. Additionally, a read-me file is often a good idea to describe what types of programming software may be needed to open controls or device programs. This text file may also be a good place to record software version or revision numbers. Validation documents, records of machine runoff and certifications of instrumentation or device calibration are also usually included in the final documentation, as well as a record of the warranty or service agreements made at the time of original purchase. Due to the volume of paper required to print all of the required documentation, much of it may be saved in electronic format. Operator and maintenance manuals and electrical schematics are usually printed and kept with the machine. 20

21 Appendix Design and Documentation Checklist Master Documentation Checklist Company: Project Number: Project Name: Date: Requirements Documentation (Purchaser) Documents Yes No Not Required Comments Product Specifications Plant Specifications Requirements Document Vendor Selection (Purchaser) Documents Yes No Not Required Comments Quote Requests Vendor Qualification 21

22 Applications (Vendor) Documents Yes No Not Required Comments Proposal Quote Spreadsheet System Architecture Solid Models or Drawings Process Description Initial Project Layout (Purchaser/Vendor) Documents Yes No Not Required Comments Purchase Order Contract and Terms Gantt Chart Team Contact Information Project Review (Purchaser/Vendor) Documents Yes No Not Required Comments Statement of Work Proposal Project Schedule 22

23 Mechanical Design (Vendor) Documents Yes No Not Required Comments Timing Chart Solid Models 2D Prints (Assembly Drawings) Stress/Load Analysis Motor Sizing Pneumatic, Hydraulic and Piping Sizing Mechanical BOM Electrical Design (Vendor) Documents Yes No Not Required Comments Single Line Drawings Fusing and Circuit Breakers I/O List Electrical CAD Cable Schedule Electrical BOM P&ID Instrument Index 23

24 Controls and Software Design (Vendor) Documents Yes No Not Required Comments Flow Chart/Grafcet I/O List/Tag Generator HMI Screen Flow Diagram Equipment Interfaces Controls Program HMI Program SCADA/Data Collection Program Safety and Risk Analysis (Purchaser/Vendor) Documents Yes No Not Required Comments Hazard Worksheet/Safety Classifications Failure Mode Effects Analysis (FMEA) Seismics RoHS and ESD Compliance Clean Rooms MSDS, SDS, PSDS 24

25 Building the System (Vendor) Documents Yes No Not Required Comments Engineering Change Order (ECO) Red-lines Power-on Checklists Acceptance and Runoff (Purchaser/Vendor) Documents Yes No Not Required Comments Dry Cycle ( hrs. continuous) Production Run Validation Factory Acceptance Test (FAT) Report Site Acceptance Testing (SAT) 25

26 Final Documentation (Vendor) Documents Yes No Not Required Comments Recommended Spare Parts Bills of Material Product Cut Sheets As-Built Mechanical Drawings Final Electrical Schematics Operator Manual Maintenance Manual Controls Program Software Validations and Certifications Warranty 26