General Delivery Specifications for Machinery and Equipment - Bosch

General Delivery 

Specifications 

for 

Machinery and Equipment 

Machinery and Equipment (MAE) General Delivery Specifications 

can also be found at 

www.boschnasuppliers.com 

Reference: - OP4.7.04.004 

Robert Bosch Corporation 

April, 2005

April 

2005 General Delivery Specifications

General Delivery Specifications 

for Machinery and Equipment 

Sections 1 - 9 

Revision 4 - April, 2005 

All prior editions are obsolete and should not be used. 

This document is controlled by: 


ChW/BPS-LS (Industrial Engineering) 

8101 Dorchester Rd. 

Charleston, SC 29418 

(843) 760 - 7659 

wolfgang.hasper@us.bosch.com 

It is the user's responsibility to assure that only the latest revision of this standard is used. 

SUPANAGEMENT

BOSCH General Delivery Specifications for Machinery and Equipment 

CHANGES MADE TO THE GENERAL DELIVERY SPECIFICATIONS SECTIONS 1-9 

Page Section Changes 

April 1, 2005 

2-3..5 2.2 Restructured section in order to match the Review 

Checklist. 

2-3 2.2.1 Moved Lean Manufacturing statement (BPS) to 2.2.2a. 

2-4 2.2.2 Added review of special attention points. 

4-3 4.1.2 Added awareness statement (AC has some different 

drawing standards). 

5-2 5.3.1 Additional information on drawing formats 

5-2 5.3.2 All software shall be licensed 

5-3 5.5.2 Additional b) transformer capacity (deleted in 5.5.5 a)) 

5-4 5.5.5 c) Restated receptacle requirements 

5.5.5 Added f) Safety awareness statement. 

5-5 5.6.3 Entire paragraph rewritten. 

5-5 5.6.6 Added: stranded copper, calibration fluids 

5-6 5.6.7 Plants can have different wire colors as per NFPA 79. 

5-6 5.8 Added Data Management and Networking. 

6-3 6.3.2 Entire paragraph rewritten. 

6-4 6.5.2 Changed changeover time according to BPS. 

6-5 6.7.1 Deleted modem, added Remote Access requirement. 

3 Sec. 7 Restructured Check Sheet: added numbering column and 

reference column, separated “yes” column for Pre and Final 

Acceptance 

4 Sec. 7 Moved electrical cabinet clearance to Electrical Design. 

7 thru 10 Sec. 7 Section 5: Electrical Design completely revised. 

9 Sec. 7 Added Data Management and Networking. 

9 Sec. 7 Added to Gage Capability: alternatives a) and b). 

Sec. 9 

Sec. 9 

Sec. 9 

Sec. 9 

Sec. 9 

Sec. 9 

Appendix 2.1 - Deleted Modem, added Network 

requirements. 

Appendix 2.2 - Changed 1.1 to BPS Assessment. 

Appendix 2.3 - Replaced by BPS Investment Assessment. 

Appendix 4.1 - Added contact for Bosch Rexroth and 

Bosch Power Tools. 

Appendix 5.2 - Added Special Attention Points for 

Equipment Suppliers. 

Appendix 6.2 – Added information regarding latest 

German/English issue. 

Changes 

Page 1 of 1

BOSCH General Delivery Specifications for Machinery and Equipment Apr. 1, 2005 

Other pages of the GDS available for viewing: 

- COVER PAGE 

- SECTIONS 1-9 OWNER’S PAGE 

- CHANGES MADE TO SECTIONS 1-9 

TABLE OF CONTENTS 

SECTION 1 - GENERAL PROCEDURES 

Page 

1.1 Preface........................................................................................................... 1-2 

1.2 Formal Quotation Requirements................................................................. 1-2 

1.3 Order and Alterations .................................................................................. 1-6 

1.4 Work on Buyer’s Facility ............................................................................. 1-6 

1.5 Payment Schedule......................................................................................... 1-7 

SECTION 2 - PROJECT MANAGEMENT 

2.1 Project Timing .............................................................................................. 2-2 

* 2.2 Design Review Requirements....................................................................... 2-3 

SECTION 3 - SAFETY AND HEALTH STANDARDS 

3.1 General ......................................................................................................... 3-2 

3.2 General Standards........................................................................................ 3-2 

3.3 Noise Standard.............................................................................................. 3-3 

3.4 Environmental Considerations .................................................................... 3-3 

Table of Contents - i


SECTION 4 - MECHANICAL DESIGN 

Page 

* 4.1 Mechanical Design Guidelines ..................................................................... 4-2 

4.2 Floor Plan Layout......................................................................................... 4-5 

4.3 Ergonomic Guidelines .................................................................................. 4-6 

4.4 Pneumatic Controls ...................................................................................... 4-7 

4.5 Lubrication ................................................................................................... 4-9 

4.6 Paint .............................................................................................................. 4-9 

SECTION 5 - ELECTRICAL DESIGN 

5.1 Standards ...................................................................................................... 5-2 

5.2 Control Systems Overview ........................................................................... 5-2 

* 5.3 Documentation.............................................................................................. 5-2 

5.4 Functional ..................................................................................................... 5-2 

* 5.5 Equipment..................................................................................................... 5-3 

* 5.6 Wiring Methods............................................................................................ 5-5 

5.7 Programmable Logic Controllers and Computers ..................................... 5-6 

* 5.8 Data Management and Networking............................................................. 5-6 

SECTION 6 - QUALITY STANDARDS & RUN-OFF CONDITIONS 

6.1 General.......................................................................................................... 6-2 

6.2 Guidelines for Statistical Evaluation ........................................................... 6-2 

* 6.3 Gage, Process and Machine Capability....................................................... 6-3 

6.4 Gage Scale and Signal Output ..................................................................... 6-3 

* 6.5 Equipment Effectiveness and Durability Demonstrations ......................... 6-4 

6.6 Run-off Conditions ....................................................................................... 6-4 

* 6.7 Software Validation...................................................................................... 6-5 

SECTION 7 - PRE/FINAL ACCEPTANCE 

7.1 General.......................................................................................................... 7-2 

* 7.2 Pre/Final Acceptance Checklist ................................................................... 7-3 

Table of Contents - ii


SECTION 8 - DOCUMENTATION & SHIPPING INSTRUCTIONS 

Page 

8.1 Machine Documents ....................................................................................8-2 

8.2 Shipping Instructions ..................................................................................8-3 

8.3 Ocean Freight Shipping . ............................................................................8-3 

8.4 Package Identification .................................................................................8-4 

8.5 Shipping Documentation.............................................................................8-4 

8.6 Invoicing.......................................................................................................8-5 

SECTION 9 - APPENDICES 

* 

* 

* 

* 

* 

* 

• Appendix 1.1 











General Terms and Conditions for the Purchase of Capital 

Equipment 

Machine Data Sheet 

Design Review Checklist 

Investment Assessment 

US Contacts for Bosch Products 

Workplace Measurements 

Control Systems Overview form 

Special Attention Points for Equipment Suppliers 

Parts to Produce for Total Test, Sample Size 

Technical Availability 

Documentation 

SECTION 10 - ATTACHMENTS (PLANT SPECIFIC) 

(See Section for details) 

Table of Contents - iii




1.1 Preface. ...................................................................................................................1-2 

1.2 Formal Quotation Requirements ...........................................................................1-2 

1.2.1...... General.......................................................................................................1-2 

1.2.2...... Parameters of Quote for Machinery and Equipment ...................................1-3 

1.2.3...... Itemized Prices...........................................................................................1-4 

1.2.4...... Proposal Description ..................................................................................1-5 

1.2.5...... Project Completion.....................................................................................1-5 

1.3 Order and Alterations ............................................................................................1-6 

1.4 Work at Buyer’s Facility ........................................................................................1-6 

1.5 Payment Schedule...................................................................................................1-7 

Page 

General Procedures - 1 - 1



1.1 Preface 

This specification has been written to present Robert Bosch Corporation/Affiliate’s 

(hereinafter referred to as ‘Bosch’) requirements for industrial equipment in an orderly 

manner. 

Supplier and any subsequent suppliers shall comply with this specification and with "General 

Terms and Conditions for the Purchase of Capital Equipment" (see Appendix 1.1). 

It is not intended to limit or inhibit development in industrial equipment design. Functional 

design of equipment shall be the equipment supplier’s responsibility. The application of 

"Lean Equipment Design" principles is required. 

If the supplier interprets the requirements of this document or any Bosch specification to be 

in conflict with Federal or State regulations, it is the supplier’s responsibility to get 

clarification from Bosch’s Project Engineer. 

Deviations to specifications provided herein may be allowed when necessary, and agreed 

upon in writing by Project Engineer. Copy to Purchasing. 

Individual locations may have plant specific requirements which can be found in 

Section 10. 

1.2 Formal Quotation Requirements 

1.2.1 General 

Request for Quotations (RFQ) are originated by the Project Engineer and transmitted 

through the Purchasing Department to the equipment supplier. The Project Engineer 

shall provide process and equipment specifications adequate to define Bosch's 

requirements for the particular equipment under consideration. Quotes must be 

returned to Purchasing Department and must have Bosch RFQ 

number. All paper quotations must be submitted in triplicate. Electronically 

submitted quotes need buyer's permission. 



1.2.2 Parameters of Quote for Machinery & Equipment 

a) All production machinery must comply with General Delivery 

Specifications. 

The quotation must include this statement: 

“We agree to conform to Bosch’s General Delivery Specifications - for 

machinery and equipment”. 

If this is not possible, a request for specific deviations must be included in 

the quotation and written approval of the deviations requested must be 

obtained from the Project Engineer or his/her immediate supervisor before 

an order can be accepted. 

b) The following information to be included: 

• Bosch RFQ Number 

• Part name(s), number(s), and/or identification number. 

• Name of Project Engineer requesting the quote. 

• Machine tool equipment supplier’s quotation number and date. 

c) The quotation shall include firm delivery dated from the date of purchase 

order. 

d) Document requirements: 

All drawings, documentation, etc., as per Section 8 shall be supplied in 

English. 

e) Must provide special foundation or other site requirements in quote. 

f) A basic timeline containing critical milestones is to be provided with the 

quote. 



1.2.3 Itemized Prices 

The following shall be itemized and separately priced on the quote: 

a) Basic machine 

b) Special Machine Options 

c) Fixtures/Workholding 

d) Perishable Tools (if requested). 

e) Charges, if any, for engineering, source code, drawings, or service 

information. 

f) Auxiliary equipment of a separable nature, such as: Hydraulics, Air 

Handling, Coolant Filtration, Conveyors, etc. 

g) Environmental and health control devices. This would include but not be 

limited to chip removal, mist, and vacuum equipment. 

h) Electrical and electronic controls. 

i) Automatic gaging and size control (if requested). 

j) Spare parts package. 

k) Machine run-off costs. 

l) Service and installation charges (if required). 

m) Cost of training. 

n) Warranty Information. 



1.2.4 Proposal Description 

1.2.4.1 The items quoted shall be accurately described by proposal drawings 

and/or text. Data on obtainable production rates, (in pcs./hr. @ 85% 

utilization), estimated power consumption, maximum change-over times, 

buffer capacity between stations, and process and gage capabilities shall be 

included where applicable. Complete cycle detail is required on each 

station. Estimated coolant, water, steam, compressed air, gas, etc., 

consumption and/or flow rates required at machine must be included. 

1.2.4.2 Number of pieces that will be run-off for each part number is defined in 

Appendix 6.1. These are the quantity of parts that will be run at no charge 

as part of the quote package, and are expected to be good parts per Bosch’s 

requirements. Pieces required for set-up, tryout, or to qualify equipment 

shall be supplied by Bosch. 

1.2.4.3 Information required for Control System Overview (Appendix 5.1) should 

be included in proposal as much as possible. Information not available at 

time of proposal must be submitted along with concept approval drawings. 

1.2.4.4 The supplier shall inform the Project Engineer of any known or suspected 

by-products of machine fluids used which may be hazardous to health. 

1.2.5 Project Completion 

At the completion of each project, parts, drawings and support documentation 

belonging to Bosch to be entirely returned. 



1.3 Order and Alterations 

1.3.1 Purchase orders and amendments to purchase orders are issued by Bosch through the 

Purchasing Department only. No statement of intent to purchase or to amend an 

existing order is a commitment by Bosch until issued by the Purchasing Department. 

1.3.2 When the product design is changed, new prints will be submitted to the equipment 

supplier by the Project Engineer, with a written request to quote modification of the 

equipment under construction required to comply with the revised product design; 

including changes to price and delivery. After approval of the proposed modification 

by Bosch, an amendment will be issued by the Purchasing Department to cover the 

additional costs. 

1.3.3 Acknowledgment of the order acceptance and confirmation of delivery or price shall 

be received by the Bosch Purchasing Department and the Project Engineer 

responsible as soon as possible, but not later than three weeks after receipt of 

purchase order by the equipment manufacturer. 

1.4 Work at Buyer’s Facility (See also Section 9: General Terms and Conditions for the 

Purchase of Capital Equipment (Appendix 1.1)) 

1.4.1 Equipment supplier to provide installation supervision or instruction to assure that 

equipment is installed properly and fulfills requirements of the warranty. 

1.4.2 All equipment suppliers must sign and adhere to each facilities’ Contractor Safety 

Declaration. This requires the supplier to follow plant-specific lock out, tag out 

requirement, confined space entry, etc. 

1.4.3 Welding, cutting, soldering jobs, heating and thawing with welding torches, gasoline 

or gas burners, etc., are forbidden unless specific permits are obtained from Bosch. 

1.4.4 Bosch draws particular attention to the fact that smoking may be restricted or 

forbidden in certain areas of our plants. Safety glasses and appropriate working attire 

and footwear are required within all Bosch facilities. Other safety equipment is as 

required by OSHA regulations. 



1.5 Payment Schedule (See also Section 5 and 7.3 of General Terms and Conditions for the 

Purchase of Capital Equipment (Appendix 1.1)). 

1.5.1 Robert Bosch Corporation payment schedule for the Purchase of Capital Equipment 

is as follows: 

80% Net 30 of complete purchase price upon Delivery of equipment to specified 

Bosch Facility. 

20% Net 30 of complete purchase price upon Final Acceptance at specified Bosch 

Facility. 

(See Section 7 for Pre-Final Acceptance Checklist.) 





2.1 Project Timing ........................................................................................................2-2 

Page 

2.2 Design Review Requirements.................................................................................2-3 

* 2.2.1...... Design Reviews .........................................................................................2-3 

* 2.2.2...... First Design Review...................................................................................2-3 

* 2.2.3...... Final Design Review ..................................................................................2-4 

Project Management - 2 - 5



2.1 Project Timing 

2.1.1 To ensure equipment delivery meets critical timing phases and final shipment dates, 

it is the responsibility of the supplier to provide and maintain a project time line and 

tracking system. 

2.1.2 A draft of this time line is to be provided with the quotation. 

The final time line is to be provided to the project engineer within 2 weeks after 

receipt of a formal purchase order. 

2.1.3 The project time line must be detailed enough to show all critical milestones and as a 

minimum include the following items: 

a) Kick-off meeting 

b) Process flow chart 

c) Process FMEA review 

d) Preliminary design (mechanical and electrical) 

e) Preliminary design review 

f) Purchase of critical long lead-time components 

g) Final design (mechanical and electrical) 

h) Final design review 

i) Purchase of remaining material 

j) Equipment control programming 

k) Equipment control program review 

l) Receipt of purchased/produced components 

m) Floor plan layout and foundation requirement 

n) Equipment build/assembly 

o) Tryout part availability 

p) System tryout and debug 

- manual mode 

- automatic mode 

q) Measurement system calibration 

r) Preliminary gage capability study 

s) Preliminary process capability study 

t) Documentation review 



u) Pre-acceptance at supplier 

v) Package & ship 

w) Installation at Bosch 

x) Tryout and debug at Bosch 

y) Final capability studies 

z) Final acceptance sign-off 

2.1.4 The project time line is to be updated and submitted to the project engineer every two 

weeks throughout the project life. It is the equipment supplier’s responsibility to 

provide any action plan to correct problems that are causing significant shifts in the 

time line. 

2.2 Design Review Requirements 

2.2.1 Design Reviews 

* A minimum of two design reviews will be held to insure that the project goals and 

specifications are being met. The actual number of design reviews will be 

determined by the project engineer. 

* 2.2.2 First Design Review 

The first design review will be a comprehensive concept design review and 

preliminary PFMEA (Process Failure Mode and Effect Analysis) review. 

The following points are to be discussed, whereby the supplier must make available 

necessary documents: 

* a) Review of relevant topics of the BPS (Bosch Production System) Assessment, 

Appendix 2.3. 

b) A concept drawing of the overall machines. This drawing must show the 

overall completed machine or assembly. It must have at least two views, a 

plan or top view, and one side or elevation view. Sufficient detail must be 

shown to convey the overall completed appearance of the equipment including 

control panels. It must be drawn to scale and show overall dimensions of 

height, width, length, location and dimensions of auxiliary control cabinets, the 

location of the work piece or part, and the direction of index travel. 

c) Additional concept drawing(s) of all equipment operations and processes. 

Sufficient detail must be shown to communicate the operation(s) of the 

machine. Main components must be shown and labeled. 



d) A control system overview which will contain a listing of major components. 

e) Material handling overview. 

f) Review of Ergonomics. 

g) Hazard assessment of robots and hazardous material (MSDS). 

* h) Review of Special Attention Points, Appendix 5.2. 

i) Machine guarding. 

j) A completed Machine Data Sheet, Appendix 2.1. 

k) Literature and specifications for any major machine components that were not 

elected from the recommended parts list(s). 

l) Approval Prints 

The supplier must provide two copies of all of the above documentation. At 

the design review, the project engineer and the supplier will sign and date each 

copy of the approval prints to indicate that the concepts have been approved. 

Any changes or modifications that are required will be noted on the prints. 

A follow-up review may be required to evaluate modifications. 

m) Completion of Design Review Checklist, Appendix 2.2. 

* 2.2.3 Final Design Review 

The final design review will be a review of all engineering documentation and 

PFMEA. This review will be completed before construction of the equipment 

begins. 

The supplier must provide the following: 

a) Mechanical Assembly and Subassembly Drawings 

b) Detail Drawings and Parts Lists 

c) Pneumatic & Hydraulic Schematics and Parts Lists 

d) Control System Functional (Sequence) Plan 

e) Electrical Control System Diagrams, Drawings, & Parts Lists 

f) Critical and Proprietary Parts 



g) Updated Machine Data Sheet 

h) Hazardous Material List 

i) Foundation Drawing 

j) Approval Prints 

k) Anticipated PM Requirements (Labor, Material, & Frequency) 

2.2.4 The supplier must provide two copies of all of the above documentation. At the 

design review, the project engineer and the supplier will sign and date each copy 

of the approval prints to indicate that the concepts have been approved. Any 

changes or modifications that are required will be noted on the prints. A followup 

review may be required to evaluate modifications. 





Page 

3.1 General ...................................................................................................................3-2 

3.2 General Standards..................................................................................................3-2 

3.3 Noise Standard........................................................................................................3-3 

3.4 Environmental Considerations ..............................................................................3-3 

Safety and Health Standards - 3 - 1



3.1 General 

Equipment must meet the requirements of the Occupational Safety and Health Act (latest 

amended edition). The OSHA standards are to be interpreted as minimum requirements. 

3.2 General Standards 

3.2.1 In view of constantly changing laws, regulations, codes, and standards, it is the 

responsibility of the supplier to comply with all regulations. 

The latest version and applicable sections of the following standards in effect at the 

time of the order’s acceptance: 

a) Occupational Safety and Health Administration, Department of Labor, General 

Industry Standards, Series 1910 (latest revision). 

b) American National Standards Institute Codes. 

c) National Fire Protection Association (NFPA) Regulations. 

d) National Fluid Power Association “Systems Standard for Industrial Machinery”. 

3.2.2 Equipment must be designed to accept lockout devices on all energy sources (i.e. 

pneumatic, hydraulic, electric) and must be labeled. 

3.2.3 Additional safety requirements are included in the specific sections for electrical, 

hydraulic, pneumatic, and machine design. 

3.2.4 A written risk assessment as per latest ANSI/RIA R15.06 is required for all robots 

prior to final acceptance. 

3.2.5 No asbestos containing materials (ACM) shall be used. 

3.2.6 Equipment with lasers shall be classified and certified to meet applicable Standards 

(21 CFR 1010-1050), provide “Laser Product Report” and accession number from 

the Center for Devices and Radiological Health (CDRH). 



3.3 Noise Standard 

All steady state or cyclical noise levels produced by machinery or equipment shall not exceed 

80dB(A), when running under all anticipated operating conditions while producing parts. 

The noise measurement shall be made along the perimeter of the machine at a 3 foot distance 

and also at the operator(s) position(s). 

3.4 Environmental Considerations 

(Gases, Fluids, Coolants, Cleaning Solutions, Paints, etc.) 

3.4.1 In response to increasingly stringent controls on the use and disposal of waste 

materials, the supplier shall conform to the following provisions: 

a) ISO 14000 Environmental Management System. 

b) Material Safety Data Sheet in English must be submitted to the Project Engineer 

for approval of all material to be used in the machine prior to Preliminary Design 

Review. Usage rates of environmentally sensitive chemicals need to be indexed 

to some criteria such as production rates. 

c) Materials containing PCB (polychlorinated biphenyl) are not allowed 

(e.g. capacitors, oil in transformers, and certain hydraulic fluids). 

Mercury containing switches/devices are not permitted. 

Use of leaded paint is not permitted. 

d) The supplier shall notify the Project Engineer of any anticipated levels of 

emission from radiation, gases, vapors, fumes, dusts, and mists. 

e) All chemicals must be recertified to be on the EPA TSCA inventory. 

f) Equipment shall be designed to contain all process fluids (oil, coolant, etc.) with 

no leaks or splashing onto the operator or floor. 

3.4.2 An approved material list is available from the Project Engineer upon request. 

3.4.3 All equipment that requires ventilation for oil/coolant MUST use filtration 

equipment. The mist density must not exceed 0.2 mg/m3 at the equipment exhaust. 

Equipment manufacturers must utilize the filtration technology specified by Bosch. 

(See plant specific requirements, Section 10 - Attachments) 






Page 

4.1 Mechanical Design Guidelines ...............................................................................4-2 

4.1.1...... Components ...............................................................................................4-2 

* 4.1.2...... Drawing Standards.....................................................................................4-3 

4.2 Floor Plan Layout...................................................................................................4-5 

4.2.1...... General Requirements................................................................................4-5 

4.2.2...... Floor Layout Drawings...............................................................................4-5 

4.2.3...... Machine Leveling.......................................................................................4-5 

4.3 Ergonomic Guidelines ............................................................................................4-6 

4.3.1...... Workstations ..............................................................................................4-6 

4.3.2...... Workplace Measurement............................................................................4-6 

4.3.3...... Task Lighting .............................................................................................4-6 

4.3.4...... Controls and Indicators...............................................................................4-6 

* 4.3.5...... Lifting ........................................................................................................4-6 

4.3.6...... Access........................................................................................................4-6 

4.4 Pneumatic Controls ................................................................................................4-7 

4.4.1...... General.......................................................................................................4-7 

4.4.2...... Equipment Requirements ...........................................................................4-7 

4.4.3...... Safety.........................................................................................................4-7 

4.5 Lubrication..............................................................................................................4-9 

4.6 Paint .... ...................................................................................................................4-9 

Mechanical Design - 4 - 1



4.1 Mechanical Design Guidelines 

4.1.1 Components 

a) Use of BOSCH Products: 

The use of BOSCH products is required for special purpose machines. For 

Information and Service, contact responsible BOSCH group (see Appendix 4.1) 

for product overview and addresses. If the use of BOSCH products is not 

possible, exceptions must be noted at the time of quotation, in exceptional cases 

at latest during preliminary design review. 

b) Preferred Mechanical/Pneumatic Components: 

The use of components readily available within U.S. is required. 


c) Measurement Instruments: 

Selection of measurement instruments and systems has to include consideration 

of calibration requirements. Prior to final selection, the equipment supplier must 

communicate to the Project Engineer the necessary procedures, equipment and 

masters. For masters and gages, a certification of calibration and traceability to 

a standard has to be supplied by the equipment supplier. Masters must be 

delivered with the equipment. 


d) Metric Hardware is required. Deviations require approval by the project 

engineer. 



4.1.2 Drawing Standards 

* See plant specific requirements, Section 10 – Attachments. 

a) Language: 

All documentation, including drawing remarks, schematic diagrams, parts lists, 

PLC programs, etc., must be in English. 

b) Dimensions: 

To insure uniformity of machine and tool design, details should conform to the 

International System of Units (SI). English equivalent may be shown in 

parenthesis adjacent to the metric dimension. Geometric Dimensioning and 

Tolerancing is preferred. 

c) Sizes: 

• Mechanical Drawings: 

Assembly and detail drawings should be drawn on ANSI D or DIN A1. 

Multiple detail drawings should be placed on one sheet. 

• Parts List (Bill of Materials): 

Separate parts lists should be on A size. 

d) Drawings Numbers: 

Drawings shall contain a BOSCH assigned drawing number in the title block. 

Contact Project Engineer for numbers. 

e) CAD-Drawings: 

CAD-drawings are preferred over hardcopy originals. For format of CAD files 

see plant specific requirements, Section 10 - Attachments. 

f) Content: 

• Mechanical Drawings - consist of the following: 

- Main Assembly Drawing 

- Assembly Drawings 

- Subassembly Drawings 

- Detail Drawings 

- Parts Lists 



• Pneumatic & Hydraulic Drawings - consist of the following: 

- Schematic Diagrams 

- Parts List 

• Main Assembly Drawing 

The main assembly drawing should show the overall completed machine or 

assembly. It should have at least two views: plan or top view, and one 

elevation or side view. Sufficient detail is required on these drawings to 

convey the overall completed appearance of the machine, including control 

panels. It is mandatory that these drawings be drawn to scale and show 

overall dimensions of height, width, and length, location and dimensions of 

auxiliary control cabinets, the location of the work piece/part, the direction of 

index travel, and operator location. 

• Assembly and Subassembly Drawings 

It is essential that equipment and machine drawings be broken down into 

logical assembly and subassembly drawings for clarity. Each detail shown on 

an assembly drawing should have a position number assigned and a leader 

line pointing to it. The position number corresponds to the same number in 

the bill of material/parts list. 

• Detail Drawings 

Detail drawings show all dimensions and tolerances necessary to manufacture 

the part. Materials must be designated as per standard designations such as 

AISI, SAE, etc. Heat treatment and surface finish requirements need to be 

shown in universally accepted designations. 

• Parts Lists (Bill of Materials) 

All assembly, subassembly, schematic, and panel layout drawings, have a 

corresponding bill of materials or parts list. The parts list is a list of all 

manufactured and purchased parts required to complete the “assembly”. 

The name and part number of the original manufacturer must be shown on 

the parts list. 



4.2 Floor Plan Layout 

4.2.1 General Requirements 

The supplier shall be required to furnish preliminary and final layout drawings that 

define the overall equipment/machinery configuration which shall include but not 

limited to the following considerations: 

• Overall dimensional size of equipment/machinery (L x W x H) 

• Location, size, range of movement, and direction of movement of doors for all 

• Electrical panels 

• Access areas 

• Access to the required lubrication points (fluid tanks fill and drain points, etc.) 

• All necessary clearance dimensions shall be shown. 

• Location and size of support equipment (e.g. filters, pumps, chip carts, mist 

collectors, drip pan, etc.). 

• Location and size of part loading and unloading devices. 

4.2.2 Floor Layout Drawings 

Within thirty (30) days after final drawing approval, the equipment supplier shall 

transmit to the Project Engineer a print or a CAD file. For format of CAD files see 

plant specific requirements, Section 10 - Attachments. 

4.2.3 Machine Leveling 

Machine leveling devices must be supplied with equipment. 



4.3 Ergonomic Guidelines 

4.3.1 Workstations 

a) If feasible both technically and based on the scope of work, operators should be 

given the option of either sitting or standing while performing their work. 

b) Workstations which accommodate a sitting operator should be equipped with an 

adjustable chair and adjustable footrest. 

c) If a conveyor is in front of a workstation where a person is seated, adequate 

clearance must be provided under the conveyor for the person’s legs. 

4.3.2 Workplace Measurement 

Recommended measurements for working height, distance to work area, leg room 

and area of free movement per workplace are provided in Appendix 4.2. 

4.3.3 Task Lighting 

a) The following light intensities are required: 

• 1,000 lux for testing and adjusting delicate components. 

• 1,500 lux for assembling delicate parts and electronics. 

b) Reflecting workstation surfaces should be avoided. 

4.3.4 Controls and Indicators 

Placement of Controls and Indicators should be within operator’s normal reach and 

field of vision. See also Appendix 4.2. 

4.3.5 Lifting 

* In general, any manual lifting >30 lbs. should be avoided. All heavy or repetitive 

lifting (tools, fixture changes, loading, unloading) must be evaluated using the 

NIOSH lifting guide. If above the action limit (AL), mechanical lifts are required. 

The plant will specify the systems that may be used (supplier, make and model). It 

should be quoted separately. 

4.3.6 Access 

a) When a person has to reach a full arm’s length, clearance for the body shall be 

provided to allow both hands to reach the tools without placing the operator in an 

uncomfortable or hazardous position relative to the surrounding conditions. All 

tool changes must be accomplished with both feet of the operator on normal 

floor level. 

b) The layout of the workstation should provide easy access for maintenance, 

cleaning, housekeeping, material handling, etc. 



4.4 Pneumatic Controls 

4.4.1 General 

4.4.1.1 Non lubricated compressed air shall be used wherever possible. 

4.4.1.2 All types of pneumatic control logic are subject to approval by Project 

Engineer. Electrical logic controls are preferred. 

4.4.1.3 Pneumatic circuit should be designed to function at minimum 4.5 bar. 

6 bar (85 PSI) is standard plant pressure. 

Control voltage for solenoid air valves shall be 24V DC. 

4.4.2 Equipment Requirements 

4.4.3 Safety 

4.4.2.1 Components 

a) Filters, separators, pressure regulators, and dryers must be part 

of the pneumatic circuit. Automatic water dump traps shall be 

used to drain air line filters and lubricators. 

b) All air cylinders that bottom in rapid travel must be cushioned 

to prevent pounding. Deceleration valve shall be used when 

cylinder does not bottom in either direction. 

c) Lubricators shall be used only when approved by project 

engineer. If lubricators must be used, they shall be so mounted 

as to assure ample downstream lubrication to those parts being 

served by the lubricator. 

d) Air discharge to atmosphere shall be provided with mufflers of 

sufficient capacity to reduce noise readings to 80 dBA or less 

at point of discharge. 

4.4.3.1 The main air and hydraulic inlet valves should provide a quick means 

of shutting off the supply and exhausting the downstream system. It 

must be in easy reach of the operator and designed to be locked out in 

the closed position. 



4.4.3.2 Independent of the energy (e.g. electric or pneumatic) used to control 

the pneumatic system, no danger shall result from switching on or off 

the energy supply, from energy breakdown as well as resumption of 

energy (unexpected or intended). 

4.4.3.3 To avoid rapid, uncontrolled movements when switching on systems 

that employ 3 position valves, a filling circuit/valve shall be used. 

4.4.3.4 Construction: Air receivers and surge tanks shall be designed: 

• To conform to the ASME Unfired Pressure Vessel Code and to 

applicable governmental pressure vessel codes. 

• So that they cannot be dismantled while containing pressure. 

• With a separate port of adequate size for a safety relief valve. 

4.4.3.5 Receivers and Surge Tanks shall be permanently marked with 

outstanding words reading “CAUTION PRESSURE VESSEL”. 

4.4.3.6 Safe Working Range of Adjustable Controls: 

Pressure and flow control components shall be constructed in a 

manner that prevents adjustment outside their safe working range. The 

manufacturer’s information plate on pressure control components shall 

be marked to indicate their minimum and maximum pressure limits. 

4.4.3.7 Tamper-Resistant Protection: 

Where a hazard or damage may result if operating pressures are 

exceeded, tamper-resistant (e.g. internal positive stop, nonadjustable, 

etc.) overpressure protection must be provided. 

4.4.3.8 Cycle Restart: 

The equipment cycle may be manually restarted after an emergency 

operation, provided resumption does not create a hazard or cause 

damage to the equipment or to the work in process. Where continuing 

the cycle is not feasible, manual controls shall be provided for 

returning the actuators affected by the emergency control to their cycle 

start or other preset position. 

4.4.3.9 Emergency Controls: 

Emergency controls shall be provided at each operator’s work station. 



4.5 Lubrication 

4.6 Paint 

If technically possible, maintenance-free components shall be used. If not possible, lubrication 

points have to be easily accessible (without removing guards) and permanently tagged. 

Type of fluid and grease should be approved by Bosch. Attempts should be made to use 

lubricants stocked at Bosch sites. 

4.6.1 Paint being used must be resistant to oil and test fluid and also to synthetic coolants 

and any other consumable liquids with which the equipment may come in contact 

with during regular operation. 

4.6.2 Machine tool surfaces which come in contact with the workpiece, or surfaces which 

might be source of contamination shall not be painted. They might be constructed 

by using e.g. stainless steel, chromating, etc., in order to avoid rust or other 

degradation. 

4.6.3 All heat treat equipment surfaces exposed to high temperature shall be painted with 

heat resistant paint. Aluminum paint may be required. 

4.6.4 Colors: 

USE COLOR STANDARD 

Equipment 


Installations: Sprinkler Lines Red OSHA Red 

Gas Lines Yellow OSHA Yellow 

4.6.5 All paints shall be lead-free. 






* 

* 

* 

* 

* 

* 

* 

Page 

5.1 Standards ................................................................................................................5-2 

5.2 Control Systems Overview .....................................................................................5-2 

5.3 Documentation........................................................................................................5-2 

5.3.1...... Drawings....................................................................................................5-2 

5.3.2...... Software.....................................................................................................5-2 

5.4 Functional ...............................................................................................................5-2 

5.4.1...... Safety.........................................................................................................5-2 

5.4.2...... Manual Control ..........................................................................................5-2 

5.4.3...... Independent Control...................................................................................5-3 

5.4.4...... Diagnostics ................................................................................................5-3 

5.4.5...... Anti-Repeat................................................................................................5-3 

5.4.6...... Control Parameters/Values .........................................................................5-3 

5.4.7...... Bus Systems...............................................................................................5-3 

5.4.8...... Lamp Test..................................................................................................5-3 

5.4.9...... Cycle Counters...........................................................................................5-3 

5.5 Equipment...............................................................................................................5-3 

5.5.1...... Machine Voltage ........................................................................................5-3 

5.5.2...... Components ...............................................................................................5-3 

5.5.3...... Component Labeling ..................................................................................5-4 

5.5.4...... Controller Outputs......................................................................................5-4 

5.5.5...... Enclosures..................................................................................................5-4 

5.5.6...... Motors........................................................................................................5-5 

5.6 Wiring Methods ......................................................................................................5-5 

5.6.1...... Grounding..................................................................................................5-5 

5.6.2...... Test Points .................................................................................................5-5 

5.6.3...... Wire Termination, Labeling .......................................................................5-5 

5.6.4...... Splicing......................................................................................................5-6 

5.6.5...... Spare Wire .................................................................................................5-6 

5.6.6...... Wire Type ..................................................................................................5-6 

5.6.7...... Wire Colors................................................................................................5-6 

5.6.8...... Flexible Conduit.........................................................................................5-6 

5.7 Programmable Logic Controllers and Computers ...............................................5-6 

* 5.8 Data Management and Networking.......................................................................5-6 

5.8.1...... Infrastructure and Interfaces .......................................................................5-6 

5.8.2...... Virus Protection .........................................................................................5-7 

5.8.3...... Physical and Data Security.........................................................................5-7 

5.8.4...... Software.....................................................................................................5-7 

Electrical Design - 5 - 1



5.1 Standards 

All equipment shall conform to the latest NFPA 70 (National Electric Code) and NFPA 79 

(Electrical Standard for Industrial Machinery) unless otherwise stated in these specifications. 

5.2 Control Systems Overview 

A Control Systems Overview form shall be completed when the job is quoted. 

(See Appendix 5.1) 

5.3 Documentation 

* 

5.3.1 Drawings 

All drawings shall be drawn with CAD and drawing files shall be provided in plant 

specific format (See plant specific requirements, Section 10 - Attachments). In 

addition, drawings shall also be provided in Adobe Acrobat pdf format. 

Electrical Drawings shall be “A” or “B” size (DIN Size A4 or A3). 

* 

5.3.2 Software 

5.4 Functional 

All software needed to use or modify any component of the machine shall be licensed 

and provided. All software shall be in English. Source code of all software developed 

under this purchase order shall be provided and becomes the property of Bosch. 

A functional plan describing sequential operation shall be provided for all machines. 

5.4.1 Safety 

Control of all devices shall be designed such that loss of power in any form 

(electrical, pneumatic, hydraulic) shall not present a hazard to personnel or damage 

the equipment or work in process. No automatic restart shall occur when power is 

resumed. 

5.4.2 Manual Control 

Manual controls shall be provided for tool changing, setup and maintenance 

operation. The controls shall be interlocked to prevent machine or part damage. 



5.4.3 Independent Control 

Separate control systems shall be used for each individual machine. 

5.4.4 Diagnostics 

Diagnostic indication shall be provided for each possible state of the machine. 

5.4.5 Anti-Repeat 

On equipment where continuous consecutive cycling is not a normal condition, the 

controls shall be designed to prevent such operation. 

5.4.6 Control Parameters/Values 

Setup parameters which can affect the quality or the cycle time of the station shall be 

locked or password protected. Process values which can affect quality shall be 

monitored and should shut down the machine if not within tolerance. 

5.4.7 Field Bus Systems 

See plant specific requirements, Section 10 - Attachments. 

5.4.8 Lamp Test 

All lamps shall have a method of testing for defective bulbs. 

5.4.9 Cycle Counters 

5.5 Equipment 

Both a non-resettable and a resettable cycle counter shall be included. 

5.5.1 Machine Voltage 

The primary voltage for machines shall be 480 VAC, 3φ, 60 Hz. Control voltage 

shall be regulated 24 VDC. Receptacles for 115 VAC shall be standard US 

grounded 3 prong (Some plants have specific requirements for machine voltage 

tolerances, see Section 10 - Attachments). 

5.5.2 Components 

* 

a) Equipment shall be constructed utilizing Bosch “Preferred Electrical 

Components” (See plant specific requirements, Section 10 - Attachments). 

b) Transformers and power supplies shall have 30% excess capacity. 



5.5.3 Component Labeling 

All functional and electrical components shall be permanently labeled with their 

corresponding schematic designation. 

5.5.4 Controller Outputs 

Controller outputs shall have individual over current protection for each circuit. 

5.5.5 Enclosures 

a) Expansion: 

Enclosures shall be designed with 20% expansion capability. This shall include 

but not be limited to space for terminal blocks, relays, breakers, starters, 

wireways, and controller I/O. 

b) Lighting: 

Lighting controlled by a door switch shall be provided on enclosures over 0.425 

m 3 (15 cu. ft.). 

* 

c) Programmable Devices: 

All enclosures containing a programmable device shall have a 115 VAC GFCI, 

receptacle labeled “For programming device only”. 

A programming interface shall be readily accessible. 

d) Connectors: 

Wiring to enclosures not mounted on the machine shall have connectors. Plugs 

and sockets must be permanently labeled (See plant specific requirements, 

Section 10 - Attachments). 

e) Location: 

* f) Safety: 

Bottom of enclosures shall be a minimum of 100 mm above the floor. The 

control enclosure should be positioned so that the machine can be observed 

while working in the enclosure. 

Minimum working space in front of electrical enclosures shall be maintained. 

See Section 9 - Appendix 5.2 for more detail. 

Electrical cabinet doors shall be removable or able to open at least 90 degrees. 



5.5.6 Motors 

5.6 Wiring Methods 

AC motors shall be High Energy Efficient TEFC, 480 VAC, 3φ, 60 Hz. All motors 

25hp and above shall have continuous conductors from the control enclosure to the 

motor. No intermediate terminations are permitted. Such motors shall also have 

power factor corrected to above 90%. 

5.6.1 Grounding 

Transformers and power supplies shall have their neutral or common conductors 

grounded at the source. If special earth grounds are necessary, this shall be specified 

by the supplier during initial design review and detailed in the installation 

specifications. 

5.6.2 Test Points 

All control and power wiring shall have readily accessible test points in the control 

enclosures. 

5.6.3 Wire Termination, Labeling 

* For screw or screw clamp terminations, all wire ends shall be fitted with ferrules or 

crimp connectors. All wires shall be labeled, terminated and identified in the 

electrical prints. Multiple-device control panels shall be equipped with terminal 

blocks or attachment plugs and receptacles for all outgoing control conductors. 

Wiring directly to the terminal connection points on input or output modules of 

programmable electronic systems shall be permitted. 

Wire labeling method shall be specified by the customer. The machine builder is 

responsible for determining customer preference. Wires shall be labeled at each end 

either with wire numbers or termination labels. Wire numbers or termination 

labels shall be used exclusively. 

When wire numbers are used, each individual wire shall have the same 

number at all termination points. Terminal block labels shall match the wire 

numbers. Wires connecting to controller I/O shall be labeled with an I for 

Inputs and Q for Outputs followed by the I/O address, dropping any 

punctuation and adding leading zeros as appropriate. For example, the wire 

that connects to output Q2.4 should be labeled "Q024". 

When wire termination labels are used, the termination label shall identify the 

terminal name where the wire should terminate. Example: The wires connected 

to terminal A1 of –K911A shall be labeled –K911A:A1 



5.6.4 Splicing 

Splicing is prohibited. Wiring shall run uninterrupted from terminal to terminal. 

5.6.5 Spare Wire 

A minimum of 15% spare wire shall exist in each wireway that is external to an 

enclosure. 

* 

5.6.6 Wire Type 

Wire shall be stranded copper. Wire jacketing shall be type MTW for wires not 

leaving electrical enclosures. Elsewhere, wire jacketing shall be compatible with the 

associated fluids and working environment: 

- Type PUR: for areas with coolant, oil and diesel/gasoline calibration type fluids 

(e.g. VISCOR) 

- Type PVC: for brake fluid areas 

* 5.6.7 Wire Colors 


5.6.8 Flexible Conduit 

Each section of flexible conduit shall be kept to a maximum of 1 meter. 

5.7 Programmable Logic Controllers and Computers 


* 

5.8 Data Management and Networking 

The Bosch Corporate Network (BCN) is a private, global data network which interconnects 

all Robert Bosch GmbH sites throughout the world. The network has been designed to 

provide fast, secure, and reliable data transmission to all sites. To this end, it is requested 

that all vendors adhere to the BCN standards wherever possible. 

5.8.1 Infrastructure and Interfaces 

The physical connection to the BCN is generally provided via RJ-45 jacks installed 

as required near the equipment. These network drops will be terminated external to 

the equipment such that cable infrastructure troubleshooting or rewiring can be done 

without requiring access into the machine enclosures. 

Managed Cisco routers and switches comprise the backbone of the corporate 

network. To ensure network integrity and monitoring down to each networked 

device, manageable Cisco switches should be used rather than simple network hubs. 

Your Bosch representative should be able to obtain recommended equipment model 

numbers. 



TCP/IP over Ethernet is the standard protocol. Some sites may require specific 

subnetting or support for other management protocols for manufacturing devices, so 

be sure to check with your Bosch representative. Site-specific static IP addresses can 

be assigned by the local information technology group or equivalent responsible 

group. 

5.8.2 Virus Protection 

One of the greatest network security threats are viruses. The BCN has multi-layered 

anti-virus protection starting at company firewalls cascading down to each desktop 

computer. Anti-virus engines on desktop computers are updated daily with the latest 

virus definition files and anti-virus scans are scheduled to run automatically on these 

computers. Bosch requires that vendors evaluate the vulnerability of their equipment 

to computer viruses and worms. Reasonable safeguards and/or software updates 

should be part of the preventative maintenance recommendations for the equipment. 

Due to throughput and performance requirements of some manufacturing computing 

systems, real-time anti-virus scanning may not be possible. In this case, 

manufacturing computing systems may be isolated from the general-use BCN using 

Virtual Local Area Networks (VLANs). VLANs allow specific traffic flow from 

manufacturing lines’ data concentrators through to other systems located on the 

general-use BCN. In the event of a virus outbreak emanating from a manufacturing 

computer system, all traffic flow from that manufacturing system to the general-use 

BCN can be quickly stopped until the source of the virus is located and eradicated. 

5.8.3 Physical and Data Security 

Data confidentiality is extremely important to Bosch. Company policy states that 

unauthorized data transmission of any nature to external parties is strictly forbidden. 

To protect that policy, modems are not permitted on any computer connected to the 

BCN. If remote dial-up access is required, alternate techniques will be employed 

using existing Bosch standards and safeguards. 

Removable data storage devices (i.e., external hard drives, USB memory sticks, etc.) 

are not normally permitted on computers connected to the BCN because these 

devices can be used to transport sensitive data off the premises. Specific exceptions 

to the removable storage restrictions can be made when alternate procedures are 

instituted to ensure the security of Bosch corporate data. 

5.8.4 Software 

It is also the vendor’s responsibility to ensure that any third-party software, included 

as part of the finished equipment, is properly and legally licensed. Bosch may 

request physical proof of proper licensing or transferability. 

Any third-party software support agreements must be clearly documented so that all 

parties understand the terms. Where applicable, all software components and their 

interactions should be documented thoroughly and included as part of the operating 

and maintenance instructions for the equipment. 






6.1 General ...................................................................................................................6-2 

6.2 Guidelines for Statistical Evaluation.....................................................................6-2 

* 6.3 Gage, Process and Machine Capability ................................................................6-3 

6.4 Gage Scale and Signal Output...............................................................................6-3 

* 6.5 Equipment Effectiveness and Durability Demonstrations...................................6-4 

6.6 Run-off Conditions ................................................................................................6-4 

6.6.1 Process Data or Set-up Sheet .......................................................................6-4 

6.6.2 Adjustment Frequency Limitation................................................................6-4 

* 6.7 Software Validation ...............................................................................................6-5 

Page 

Quality Standards & Run-Off Conditions - 6 - 1




6.1.1 It is the policy of the Robert Bosch Corporation to conduct a pre-acceptance 

evaluation of new machines and test stands for proper quality of operation at the 

equipment supplier’s facility by a Bosch Project Engineer prior to authorizing 

shipment. The final acceptance evaluation will be conducted at the Bosch facility 

under plant operating conditions. The same or better quality level achieved during 

pre-acceptance trials must be achieved during final acceptance trials. 

6.1.2 All quality requirements outlined in the Purchase Order, its supplements and 

supporting documents (specifications, standards, drawings, etc.) must meet the 

evaluation criteria stated below or as indicated in Appendices 6. 

6.1.3 A pre-acceptance evaluation will be conducted only after the equipment supplier has 

presented data or sample parts indicating that the equipment meets the requirements 

of the Purchase Order. 

6.1.4 All pre- and final acceptance trials shall be witnessed or conducted by Bosch 

personnel using Bosch-supplied parts. Supporting equipment, gages, calculators, etc., 

and labor shall be provided by the supplier unless otherwise agreed upon. Acceptance 

plan, method of measurement and data record format must be approved by Bosch. 

6.1.5 For pre-acceptance trials, gage calibration may be certified by manufacturers’ data 

sheets and calibration data records. For final acceptance, calibration certification 

must be current. 

6.2 Guidelines for Statistical Evaluation 

6.2.1 As a general rule, quality of operation will be evaluated by statistical methods. 

Specific characteristics to be examined during pre- and final acceptance trials shall 

be provided to the equipment supplier as part of the equipment specification. 

6.2.2 Parts to be provided by Bosch for pre- and final acceptance trials will be production 

parts, pre-qualified for characteristics that could influence capability studies. 

6.2.3 See Appendix 6.1 for a Sample Size table which provides guidelines for determining 

numbers of parts to be used or manufactured during acceptance trials. Non-standard 

sampling plans for acceptance are to be specified in the Purchase Order. 

6.2.4 Where more than one part is produced simultaneously or for multi-spindle/station 

machines, the total production is to be divided equally among the work piece 

locations. Parts are to be identified with the location from which they came. 



6.3 Gage, Process and Machine Capability 

6.3.1 Gage, process and machine capability shall be demonstrated using appropriate 

procedures (See plant specific requirements, Section 10 - Attachments). 

* 6.3.2 The following capability requirements apply unless otherwise agreed upon in the 

Purchase Order: 

(a) Gage Capability: 

(i) If a standard gage Repeatability and Reproducibility (R&R) test is used, 

Study Variation / Tolerance shall be 12.5. 

(This calculation should be done using the Shainin Red X Tracker () 

software, not by hand.) 

The ISOPlot(sm) is valid only for cases where the operator does not 

influence the measurement result. If the operator can affect the 

measurement, e.g., use of a hand-held depth gage, consult the AIAG 

Measurement Systems Analysis manual and plant-specific requirements 

for standard R&R procedures. 

(b) Machine capability: Cmk shall be >1.67; and 

(c) Process capability: Cpk shall be > 1.33. 

Note: 

To be valid, Cmk and Cpk calculations must be based on measurements that 

are statistically stable and that are approximately normally distributed. 

Statistical stability must be verified before proceeding further. (See AIAG 

SPC Reference Manual.) If non-normality is confirmed, use an appropriate 

data transformation method to obtain an equivalent normal distribution from 

which reliable Cmk and Cpk values may be calculated. 

6.4 Gage Scale and Signal Output 

6.4.1 The least count of electrical gages or least division of mechanical gages shall be less 

than or equal to one-tenth OF THE SMALLEST PART TOLERANCE to be 

measured. Special consideration may be given to gaging used to measure 

characteristics with tolerances less than 0.010 mm. 

6.4.2 All gages shall display a variable data result unless otherwise specified. Electronic 

gages which measure pertinent product dimensions shall include an appropriate data 

output port (preferably RS232) with the capability for remote access for recording 

functional and quality data. Questions regarding what dimensions are pertinent shall 



be resolved prior to design approval. In general, all parameters useful in analyzing 

machine performance and quality of operation should be monitored. 

6.5 Equipment Effectiveness and Durability Demonstrations 

6.5.1 The minimum acceptable Technical Availability during production shall be 95% (e.g. 

downtime related to issues for which the manufacturer is responsible not to exceed 

5%) unless otherwise agreed upon and specified in the Purchase Order. Calculations 

shall be based on Appendix 6.2 guidelines (VDI 3423). 

* 6.5.2 All part-type changeovers (last good part to first good part) shall be performed in 

accordance with the Bosch Production System (BPS) guidelines (


b) The average number of unplanned machine cycle interruptions, including 

adjustments, shall not exceed once in 1.5 hours with the machine operating at 

100% capacity. 

c) If unplanned interruptions are required more often than allowed above, the 

cause(s) must be identified and resolved. Unless waived by the Project 

Engineer, the production run portion of a trial must be repeated after corrective 

action is completed. 

d) A minimum of one change per tool, following the established set up procedure, 

should occur during the run-off. 

6.7 Software Validation 

* 6.7.1 All modes and features of software operation, including output of printed reports, 

shall be demonstrated. Where applicable, operation on the plant network and remote 

access must be demonstrated during final acceptance trials. Arrangements for 

remote access shall comply with the requirements of Section 5.8, Data Management 

and Networking. Project engineers should contact their local RBNA/CIT group to 

investigate the feasibility of using the Bosch Remote Access System (RAS) to meet 

the project needs. 

6.7.2 Software that processes measurement system data or sets machine operating 

conditions which cannot be observed visually must be validated by an independent 

means. For such cases, equipment suppliers shall include appropriate test plan steps 

that independently demonstrate the proper operation of the software. This includes 

verification of calculation implementation. 




SECTION 7 – PRE / FINAL ACCEPTANCE CHECKLIST 


7.1 General....................................................................................................................7-2 

7.2 Checklist..................................................................................................................7-3 

Page 

CF06790006.doc Revision: 1, 4/1/05 Originator: ChW/BPS-LS W.Hasper Page 1 of 14


Bosch General Delivery Specifications for Machinery and Equipment 


7.1.1 All tests conducted at equipment supplier are preliminary acceptance tests. 

Final acceptance will always be conducted at Bosch. 

7.1.2 Bosch will provide qualified components for acceptance. Provision for 

gauges/measurement equipment and personnel to be coordinated with the 

project engineer. 

7.1.3 Evaluation of quality will be done with statistical method, when applicable, 

described in Section 6. 

7.1.4 Acceptance shall be based on the production result. Performance data and 

process time to be verified and documented. 

Instructions: 

Bosch Project Engineer/Leader is responsible for the completion of the Machinery & Equipment 

pre-acceptance checklist. 

The first “Yes” column P/A is for Pre-Acceptance; the second “Yes” column F/A is for Final 

Acceptance. 

Items that are Not Applicable shall be recorded as N/A in the comments section. All items that 

have checks in the “No” column require corrective action unless deviations have been 

authorized. 

CF06790006 .doc Revision: 1, 4/1/05 Originator: ChW/BPS-LS W.Hasper Page 2 of 14


Project: 

Project Leader: 

Date: 

GDS Section 1: 

General Procedure 

1.1 Has supplier agreed to 

conform to “Robert Bosch 

General Delivery 

Specification” dated: ? 

1.2 Are all documentation, 

(drawings, service manuals, 

etc.) available and in 

English? 

1.3 Are the quoted conditions 

Ref. 

GDS/ 

Other 

1.2.2.9 

1.2.2.d 

8.1.1 

1.2.1 

achieved 

1.3.1 ! Cycle Time? Quote 

1.3.2 ! Machine Utilization? 6.5.1 

1.3.3 ! Changeover Time Min.? 6.5.2 

1.3.4 ! Production Rate Quote 

Pieces/Hr.? 

1.3.5 ! Tool Life? Quote 

1.3.6 ! Gage Capability? 6.3.2 

1.3.7 ! Process Capability? 6.3.2 

1.3.8 ! Facility Utilities (i.e. 

power, steam, air, etc.)? 

2.2.3.e 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 

Comments/Test Results 

or N/A 

Date 

Needed 

Section 2: N/A 


Safety & Health Standards 

Emergency Stop 

3.1 Are Emergency Stop buttons 

for electrical, pneumatic and 

hydraulic systems accessible 

and properly labeled? 

3.2 Does Emergency Stop 

function and prevent 

additional movement? 

3.3 Does Emergency Stop 

require Manual Release and 

pushing the Start Button for 

the machine to restart? 

Ref. 

GDS/ 

Other 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 



GDS Section 3 


3.4 Is Emergency Stop located 

within close reach of 

operator and/or technician 

near point of operation? 

Machine Guarding 

3.5 Are all hazard areas guarded 

(push, stroke, capture, 

retract, clip and squeeze 

areas, sharp edges, hot/cold 

surfaces): 

3.5.1 ! Rotating shafts are 

enclosed? 

3.5.2 ! Belts, chains, etc., are 

enclosed? 

3.5.3 ! All pinch points 

guarded? 

3.6 Are guards clear where 

viewing is required? 

3.7 Are guards not easily 

removable by operator? 

3.8 Are guards for setup 

interlocked and not easy to 

defeat? 

3.9 Are protective barriers 

installed to protect other 

associates from flying 

objects (e.g. milling, 

grinding)? 

Controls 

3.10 Two hand control: Is check 

function, anti tie-down, anti 

repeat, distance acceptable? 

3.11 Are manual controls 

inoperative in automatic 

cycle? 

3.12 Are all instructions/labels in 

English? 

3.13 Are light barriers, light 

curtains, safety mats, etc., 

verified for proper 

operation? 

Ref. 

GDS/ 

Other 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910.217 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 



GDS Section 3 


3.14 Do all safety switches/ 

protective gates operate 

properly? 

3.15 Are all safety door interlocks 

verified to operate properly? 

3.16 Does the exhaust system 

operate properly (must stop/ 

must not stop) if emergency 

stop is activated? 

3.17 Are machine controls 

accessible and away from 

revolving spindle, moving 

tools or other hazards? 

3.18 Is control panel access 

adequate with no blockage? 

3.19 Are general operating 

controls configured for safe 

operation? 

3.20 Are there interlocks for point 

of operation guarding? 

Labeling 

3.21 Are the following labels 

posted (in English): 

3.21.1 ! Danger Signs? 

3.21.2 ! Caution Signs? 

3.21.3 ! Confined Space? 

3.21.4 ! Notice Signs? 

3.21.5 ! Safety Instructions? 

3.21.6 ! Hazardous Materials? 

3.21.7 ! Utilities? 

3.21.8 ! Fluids and Lubricants? 

Lockout/Tagout (LO/TO) 

3.22 Are lock-out devices 

provided for all utility 

shutoffs (Pneumatic, 

hydraulic and electrical 

systems)? 

Ref. 

GDS/ 

Other 

3.4.3 

OSHA 

1910.212 

OSHA 

1910.212 

OSHA 

1910. 

1200 

3.2.2 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 



GDS Section 3 


HAZCOM 

3.23 Are MSDS’s available and 

in English for all associated 

hazardous materials? 

3.24 Is safe storage provided for 

all hazardous materials? 

3.25 Are flammable liquids in 

metal (OSHA approved) 

safety containers? Is 

grounding provided? 

General 

3.26 Is potential oil & coolant 

leakage controlled? 

3.27 Have all operational hazards 

been identified (Job Safety 

Hazard Analysis)? 

3.28 Have special requirements 

for Division I Class I areas 

been addressed? 

3.29 Are sensors provided for 

Division I Class I areas? 

Sound 

3.30 Does sound level not exceed 

80 dB(A) under normal 

operating conditions? 

Lasers 

3.31 Does laser comply with all 

requirements of ANSI 

Z136.1 Safe Use of Lasers? 

3.32 Is laser labeled, classified 

and certified? 

Robotic Operations: 

3.33 Do robotic operations 

comply with ANSI/RIA 

R15.06 dated ? 

3.34 Are all power disconnects 

and interlocks installed as 

required? 

3.35 Have all mechanical stops 

and range of motion stops 

been verified? 

3.36 Is there full envelope 

guarding? 

Ref. 

GDS/ 

Other 

3.4.1 

OSHA 

1910.106 

3.4.1.f 

OSHA 

1910.119 

OSHA 

1910.307 

OSHA 

1910.307 

3.3 

3.2.6 

3.2.6 

3.2.4 

R15.06 

R15.06 

R15.06 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 



GDS Section 4 – 

Mechanical Design Ergonomics 

4.1 Are workplace dimensions 

according to the Bosch 

Workplace Measurement 

specifications? 

4.2 Is task lighting adequate, no 

glare? 

4.3 Are all secondary tasks at 

proper working heights 

(actuating or reading 

controls, handling parts bins, 

etc.)? 

4.4 Are all lifting tasks within 

NIOSH limits (changing of 

tools, fixtures, bins, etc.)? 

4.5 Are lifting aids provided for 

heavy items? 

4.6 Is maximum lifting weight 

30 lbs.? 

4.7 Is the following assessed: 

4.7.1 ! Improper/unnecessary 

lifting? 

4.7.2 ! Repetitive motions? 

4.7.3 ! Operator posture? 

4.8 Is accessibility for material 

handling, adjusting, 

maintenance, and cleaning 

adequate? 

Ref. 

GDS/ 

Other 

4.3.2 

4.3.3 

4.3.4 

4.3.5 

4.3.5 

4.3.5 

4.3.6.b 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 


Electrical Design 

5.1 Are electrical drawings 

created with CAD and 

provided in plant specific 

format and also in Adobe 

Acrobat pdf format? 

5.2 Are electrical drawings 

provided on paper in “A”, 

“B”, “DIN A4” or “DIN A3” 

size? 

Ref. 

GDS/ 

Other 

5.3.1 

5.3.1 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 



Ref. 


GDS/ 


Other 

5.3 Can Bosch make changes to 5.3.2 

all software? 

5.4 Is a functional plan 

5.4 

provided? 

5.5 Are controls designed so that 5.4.1 

loss of power (electrical, 

pneumatic, hydraulic) does 

not present a hazard to 

personnel or damage to 

equipment or damage to 

work in process? 

5.6 Are manual controls 

5.4.2 

provided and interlocked to 

prevent damage to machine 

or work in process? 

5.7 Are separate control systems 5.4.3 

used for each individual 

machine? 

5.8 Do machine controls include 5.4.4 

diagnostic indication for all 

machine states? 

5.9 Are abnormal continuous 5.4.5 

consecutive machine cycles 

prevented? 

5.10 Do passwords limit access to 5.4.6 

parameters? 

5.11 Do out of tolerance process 5.4.6 

values cause the machine to 

stop? 

5.12 Do field bus systems meet 5.4.7 

plant specific requirements? 

5.13 Can all lamps be tested? 5.4.8 

5.14 Are cycle counters present? 5.4.9 

5.15 Is input power 480 VAC, 3 5.5.1 

phase 60 Hz.? 

5.16 Is control voltage regulated 5.5.1 

24 VDC? 

5.17 Are receptacles for 115 VAC 5.5.1 

standard US grounded 3 

prong? 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 





5.18 Do machine voltages comply 

with plant specific 

tolerances? 

5.19 Is equipment built with plant 

specific "Preferred Electrical 

Components"? 

5.20 Are control transformers and 

power supplies sized 30% 

above maximum load? 

5.21 Are functional and electrical 

components permanently 

labeled with their 

corresponding schematic 

designation? 

5.22 Do controller output circuits 

have individual circuit 

protection? 

5.23 Do enclosures have room for 

20% expansion? 

5.24 Do enclosures larger than 

0.425 cu. m (15 cu. ft.) have 

lighting controlled by a door 

switch? 

5.25 Do enclosures with 

programmable devices have 

a 115 VAC GFCI receptacle 

labeled "For programming 

device only"? 

5.26 Do programmable devices 

have a readily accessible 

programming interface? 

5.27 Does wiring to enclosures 

that are not mounted on the 

machine have connectors? 

5.28 Are plugs and sockets 

permanently labeled per 

plant specific requirement? 

5.29 Are enclosures at least 100 

mm (3.75") off floor? 

5.30 Are the control enclosures 

positioned so the machine 

can be observed while 

working in the enclosures? 

Ref. 

GDS/ 

Other 

5.5.1 

5.5.2.a 

5.5.2.b 

5.5.3 

5.5.4 

5.5.5.a 

5.5.5.b 

5.5.5.c 

5.5.5.c 

5.5.5.d 

5.5.5.d 

5.5.5.e 

5.5.5.e 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 





5.31 Are control cabinet working 

space clearances 

maintained? Note! Depth – 

1m, Width – the greater of 

either 750 mm or cabinet 

width. 

5.32 Are control cabinet doors 

removable or able to open at 

least 90 degrees? 

5.33 Are AC motors High Energy 

Efficient TEFC, 480 VAC, 

3Φ, 60 Hz? 

5.34 Do motors 25hp and above 

have continuous conductors 

between control enclosure 

and motor? 

5.35 Do motors 25hp and above 

have power factor corrected 

to above 90%? 

5.36 Are all transformer neutral 

conductors and power 

supply common conductors 

grounded at the source? 

5.37 Does all control and power 

wiring have readily 

accessible test points in 

electrical enclosures? 

5.38 Where screw or screw clamp 

termination systems are 

used, are all wires fitted with 

either ferrules or crimp 

connectors? 

5.39 Are all wires labeled, 

terminated and identified in 

the electrical prints? 

5.40 Are all enclosure outgoing 

control conductors except 

conductors from controller 

I/O terminated at terminal 

blocks or attachment plugs 

with receptacles? 

Ref. 

GDS/ 

Other 

5.5.5.f, 

Sec 9 

Appen. 

5.2 

5.5.5.f 

5.5.6 

5.5.6 

5.5.6 

5.6.1 

5.6.2 

5.6.3 

5.6.3 

5.6.3 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 

CF4.02.619.doc Revision: 1, 4/1/05 Originator: ChW/BPS-LS W.Hasper Page 10 of 14




5.41 Are all wires labeled at each 

end? 

5.42 Are 'wire numbers' or 

'termination labels' used 

exclusively? 

5.43 Where 'wire numbers' are 

used, does each wire have 

the same number at all 

termination points? 

5.44 Where 'wire numbers' are 

used, are wires connecting to 

controller I/O labeled Ixxx 

for inputs or Qxxx for 

outputs? 

5.45 Where 'termination labels' 

are used, are wires labeled 

with the terminal name? 

5.46 Are all conductors installed 

without wire splices? 

5.47 Do wireways outside 

enclosures have 15% spare 

wire? 

5.48 Are only stranded copper 

conductors used? 

5.49 Is MTW wire jacketing used 

on wires not leaving control 

enclosures? 

5.50 Is PUR cable used in oil, 

coolant or VISCOR 

splash/mist areas, and PVC 

cable used in brake fluid 

splash/mist areas? 

5.51 Do wire colors meet plant 

specific requirements? 

5.52 Is maximum flexible conduit 

length one meter? 

5.53 Does computer hardware 

and operating system meet 

plant specific requirement? 

5.54 Does computer software 

meet plant specific 

requirement? 

Ref. 

GDS/ 

Other 

5.6.3 

5.6.3 

5.6.3 

5.6.3 

5.6.3 

5.6.4 

5.6.5 

5.6.6 

5.6.6 

5.6.6 

5.6.7 

5.6.8 

5.7 

5.7 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 



Ref. 


GDS/ 


Other 

5.55 Do program printouts and 5.7 

remarks meet plant specific 

requirement? 

5.56 Does use of software 

5.7 

modules meet plant specific 

requirement? 

Data Management and Networking 

5.57 Will the machinery be 5.8 

connected to the BCN? 5.8.1 

5.58 Is all 3 rd party software 5.8.4 

properly licensed? (Proof of 

ownership and original 

media are required.) 

5.59 Have virus protection 5.8.2 

measures be 

considered/implemented? 

(Please explain.) 

5.60 Is CAT5 UTP cabling used 5.8.1 

for all data network 

connections? 

5.61 Is TCP/IP protocol used? 5.8.1 

5.62 Have security measures been 5.8.3 

implemented to protect 

against loss or theft of data? 

(Please explain.) 

5.63 Will the machinery be 

integrated into an existing 

data collection system? 

5.64 Is there a contingency plan 

that will provide for 

“continuous production” in 

the event of hardware/ 

software failure or virus 

infection? (Please explain.) 

5.8.1 

5.8.3 

5.8.1 

5.8.2 

5.8.3 

5.8.4 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 


Quality Standards and Run-off 

Conditions 

6.1 Are sample sizes selected 

per Appendix 6.1? 

6.2 Are production samples 

divided equally among work 

piece locations? 

Ref. 

GDS/ 

Other 

6.2.3 

6.2.4 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 





Conditions 

6.3 Are Gage, Machine and 

Process capability studies 

conducted per paragraph 6.3 

and Plant Specific 

Requirements? 

6.4 Do results meet the 

following acceptance 

criteria: 

Ref. 

GDS/ 

Other 

6.3 

6.3 

P/ 

A 

Yes 

F/ 

A 

Yes 

! Gage Capability: Test Results: 

a) 12.5? 

6.4.1 ! Machine Capability: 

(C mk > 1.67)? 

6.4.2 ! Process Capability: 

(C pk > 1.33)? 

6.5 Is gage scale least count or 

least division < 10% of 

smallest part tolerance? 

6.6 Do gages display variable 

data unless otherwise 

specified? 

6.7 Is technical availability > 

95% as per Appendix 6.2? 

6.8 Does changeover time meet 

BPS guidelines (




Conditions 

6.12 Is at least one change per 

tool, using equipment 

supplier set up procedure, 

accomplished during run-off 

Ref. 

GDS/ 

Other 

6.6.2 

trial? 

6.13 Are all modes and features 

of software operation and 

data output demonstrated: 

6.13.1 ! Test plan available? 6.7 

6.13.2 ! Calculations verified? 6.7 

6.13.3 ! Remote access verified? 6.7 

6.13.4 ! Data transmission to 

Bosch network? 

6.7 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 



Documentation and Shipping 

Instructions 

8.1 Is machine documentation 

provided as per Section 8.1 

of the GDS? 

8.2 Does service manual format 

meet Appendix 8.1 

guidelines of the GDS? 

Ref. 

GDS/ 

Other 

8.1.2 

8.1.2.b 

P/ 

A 

Yes 

F/ 

A 

Yes 

No 


or N/A 

Date 

Needed 


Section 10: Plant Specific Additional Requirements 



SECTION 8 - DOCUMENTATION & SHIPPING INSTRUCTIONS 


Page 

8.1 Machine Documents ...............................................................................................8-2 

8.2 Shipping Instructions .............................................................................................8-3 

8.3 Ocean Freight Shipping..........................................................................................8-3 

8.4 Package Identification ............................................................................................8-4 

8.5 Shipping Documentation........................................................................................8-4 

8.6 Invoicing..................................................................................................................8-5 

Documentation and Shipping Instructions - 8 - 1


SECTION 8 - DOCUMENTATION AND SHIPPING INSTRUCTIONS 

8.1 Machine Documents 

8.1.1 The use of the English language is mandatory on all papers, documents and machine 

labeling. This includes support equipment located on machine (i.e. measuring 

devices, dressing attachments). 

8.1.2 Three (3) sets of hardcopy documents and, if available, CAD drawings in electronic 

format should be submitted to the Project Engineer along with the machine: 

The following documents are to be included, if applicable: 

a) Operation, Set-up, and Maintenance Instruction (See Appendix 8.1 for format 

guidelines) 

b) Service Manual (See Appendix 8.1 for format guidelines) 

c) Hydraulic Diagram, with parts list 

d) Pneumatic Diagram, with parts list 

e) Layout - Including location of switches, motors, solenoid valves, etc. 

f) Electrical Diagram - Including internal circuit diagrams, KVA ratings, fuse 

amperages, parts lists, general diagram on installation Position and panel 

layout diagram. 

g) PLC Program - program printout, symbol table and cross reference table in that 

order. 

h) Software diskettes, including source codes 

i) Function Plans 

j) Computer Program Listings 

k) Computer Program Flowcharts 

l) Preventative Maintenance Schedule 

m) Assembly and Detail Drawings 

n) Spare Parts List with manufacturer’s name & stock number 

o) Tooling List 

p) Certificates of Compliance (pressure vessel, calibration, high freq. etc.) 

q) Robotic Risk Assessment 

r) Laser Product Report and accession number from CDRH 

s) Safety Instructions 

t) Component Manuals 

8.1.3 The above documents have to be updated within thirty (30) days after final 

acceptance and sent to the Project Engineer. 



8.2 Shipping Instructions 

8.2.1 For direct shipment, all delicate equipment and parts are to be sufficiently secured or 

packed and labeled for the most extreme transportation conditions. 

8.2.2 During disassembly each joint must be labeled on both sides. 

8.2.3 Equipment supplier must comply with the following inbound routing instructions 

when delivery terms of our purchase order are “FOB Shipping Point”. 

8.2.4 Bosch/Affiliate will charge back to equipment supplier for all freight costs resulting 

from non-compliance with shipping instructions according to routing orders. 

8.2.5 If air freight is required due to late delivery it must be shipped prepaid at equipment 

supplier expense. 

8.2.6 Bosch/Affiliate is to be informed by the supplier in sufficient time about shipping 

date and transport means to handle insurance, etc. If this is neglected, supplier will be 

liable for transport damage exclusively. For damages not covered by insurance due 

to inappropriate lading and/or packing, the supplier is liable. 

8.2.7 Supplier will contact Project Engineer at least one (1) week prior to shipment with 

weight, dimensions, and an estimate of the number of trucks and types. 

8.2.8 All shipments and separate partials of tools, machines, and auxiliary equipment shall 

be stenciled (with black paint) in a conspicuous location with the Bosch /Affiliate’s 

Purchase Order number. 

8.2.9 Special transport instructions must be visible to handlers, i.e. lift points, labels such 

as “This End Up”, “Protect From Rain”, etc. 

8.3 Ocean Freight Shipping 

8.3.1 The Purchase Order Number, BOSCH Part Number and Release Number must 

appear on: 

• Packing List 

• Certification 

• Outside Container 

• Bill of Lading 

If applicable, Freight Authorization Number must appear on: 

• Consignee's copy of the Air Bill/Bill of Lading 

• and Invoice 



8.3.2 All freight should be shipped collect, unless it is: 

a) reshipment due to defective goods, 

b) shipment via Premium freight due to late delivery, 

c) shipment via non-designated carrier. 

THESE SHIPMENTS HAVE TO BE PREPAID AT EQUIPMENT SUPPLIER’S EXPENSE. 

8.4 Package Identification 

Mark each package or separate piece as below: 

Robert Bosch Corporation or Affiliate name 

City - U.S.A. 

Purchase Order No.:_____________ 

Made in:______________________ 

One copy of Packing List should be placed in each package or case. 

8.5 Shipping Documentation 

To be air mailed directly to Robert Bosch Corporation or it’s Affiliates. 

Five (5) copies of Commercial Invoice 

Three (3) copies of original Bill of Lading 

Three (3) copies of the Packing List stating contents of each package or case. 

8.5.1 Documentation for U.S. Customs Clearance 

To enable U.S. Customs to clear the shipment three (3) commercial invoices have to 

accompany the shipment: 

• 1 copy in package 

• 1 copy in envelope attached to the outside of the package 

• 1 copy attached to the Air Way Bill (AWB). 



8.6 Invoicing 

8.6.1 Equipment supplier to supply invoice according to purchase order terms. 

8.6.2 All invoices must show purchase order number and be sent directly to the Accounts 

Payable Department of Robert Bosch Corporation or it’s Affiliates as specified on 

the Purchase Order. 

8.6.3 Invoice should contain the following information in English, or in German with 

English translation: 

a) Individual price must be shown for each item, or set. If items are supplied in 

sets or groups this must be clearly stated on invoice and Packing List. 

b) Total gross, tare and net weight. 

c) Costs of packing. 

For International Orders only: 

d) Cost of freight from manufacturer to dock shipping agent. 

e) If shipment is made at “no charge”, such as a sample, the value must be stated 

on a Proforma invoice for Customs purposes. The shipment should be marked 

“SAMPLE”. The Proforma invoice should be marked “NO COMMERCIAL 

VALUE”. 

f) Kilowatt rating for electric motors (For Customs purpose only). 

g) Return shipment of repairs must show the value of the part and the cost of 

repair, including repair materials. 

h) Signature. 

8.6.4 Commercial invoice quantities and values must match exactly to shipping 

documents. Reference to specific page and line item from Purchase Order required. 






• Appendix 1.1 General Terms and Conditions for the Purchase of 

Capital Equipment 

* 

* 

* 

* 

• Appendix 2.1 Machine Data Sheet 

• Appendix 2.2 Design Review Checklist 

• Appendix 2.3 Investment Assessment 

• Appendix 4.1 US Contacts for Bosch Products 

• Appendix 4.2 Workplace Measurements 

• Appendix 5.1 Control Systems Overview form 

* 

• Appendix 5.2 Special Attention Points for Equipment Suppliers 

• Appendix 6.1 Parts to Produce for Total Test, Sample Size 

* 

• Appendix 6.2 Technical Availability 

• Appendix 8.1 Documentation 

Appendices - Section 9, Page 1

APPENDIX 1.1 

GENERAL TERMS AND CONDITIONS FOR THE 

PURCHASE OF CAPITAL EQUIPMENT 

1. Complete Agreement. These Terms and Conditions for the Purchase of Capital Equipment ("Terms 

and Conditions"), including the general delivery specifications (GDS), design and performance 

specifications, standards, and any other documents attached or referenced on Buyer's purchase order 

(collectively "the Contract Documents") issued hereunder constitute the Complete and Final 

Agreement (the "Agreement") of the Robert Bosch Corporation ("Buyer") and the Seller ("Seller"), and 

all prior negotiations, proposal and writings pertaining to the "Agreement" or the subject matter 

thereof, are superseded hereby. Any reference to Seller's quotation, bid or proposal contained on 

Buyer's purchase order does not imply acceptance of any terms, condition or instruction contained in 

such document unless expressly stated otherwise on Buyer's purchase order. In the event of any 

ambiguities, express conflicts or discrepancies in the documents referenced in Buyer's purchase order 

and these terms and conditions, Seller shall immediately submit the matter to Buyer for its 

determinations and shall comply with the determination of Buyer in such matter. All headings and 

numberings contained in these terms and conditions are for convenience of reference only. 

2. Scope of Work. Except as expressly stated otherwise in the Agreement, Seller is responsible for (i) all 

labor, materials, equipment, tools and supervision necessary to perform the Agreement; (ii) designing, 

assembling, constructing, and building the Equipment listed in the Agreement, and (iii) conducting 

testing and training procedures related to the operation and maintenance of the Equipment listed in the 

Agreement (hereinafter collectively "Scope of Work"). If the Agreement does not require Seller to 

install the Equipment at Buyer's facility, Seller agrees to provide Buyer installation supervision services 

at Buyer's facility. 

3. Taxes. Any tax imposed on Seller by any federal, state, local or other legal government taxing authority 

which arises out of or is based upon the sale of the Equipment (for greater certainty, excluding and 

excepting any taxes based on Seller’s income), whether characterized as present or future sales, use, 

excise, value added, or other similar tax applicable to the price, sale, or delivery of any products or 

services furnished hereunder or to their use by Seller or Buyer will be for Buyer’s account and will be 

quoted as separate itemized charges. In addition to the Contract Price specified herein, Buyer shall pay 

the gross amount of any such present or future sales, use, excise, value added, or other similar tax; or 

Buyer shall furnish Seller with evidence of an acceptable exemption to the taxing authorities. 

4. Contract Price. Buyer shall pay Seller the Contract Price identified on Buyer's purchase order as full 

consideration for Equipment and the Scope of Work covered thereby by this Agreement subject to 

changes only as provided in paragraph 22 of this Agreement. Unless expressly stated otherwise on 

Buyer's purchase order, the Contract Price shall be based upon FOB destination, and includes all costs 

related to testing at Buyer's and/or Seller's facility, installation (if any), start up, training, applicable 

taxes, excises, duties, quotations fees or any other governmental impositions on or related to the 

Equipment. The Contract Price referred to in Buyer's purchase order is stated in U.S. dollars unless 

expressly provided otherwise. 

5. Payment Terms. Buyer will make payments to Seller in accordance with the Payment Schedule set 

forth on Buyer's purchase order issued by Buyer, provided Buyer receives an invoice from Seller in 

accordance therewith. Payments shall be made net thirty (30) days of Buyer's receipt of a correct 

invoice. The Acceptance of any payments by the Seller shall constitute a release of Buyer from any other 

liability, except retainage, due to any reasons arising or incurred prior to the date of the invoice to 

Section 9, Appendix 1.1 - General Terms & Conditions for the Purchase of Capital Equipment 

Issued April 1, 2005, Page 1 of 10

APPENDIX 1.1 

which the payment relates. Acceptance of final payment by Seller constitutes a general release of Buyer. 

If Seller chooses not to release Buyer from any liabilities by not accepting payment, Seller agrees to 

return payment in entirety with a written affidavit of an officer of Seller listing every issue Seller is 

contesting. Buyer will not be obligated to make any payment to Seller if any one or more of the 

following conditions exist: (a) Seller is in material default of any of its obligations under this 

Agreement, (b) any part of such payment is attributable to work which is defective or not performed in 

accordance with this Agreement; provided however, such payment will be made as to the part 

attributable to work performed in accordance with this Agreement and which is not defective, (c) Seller 

has failed to make payments promptly to Seller’s subcontractors or for material or services related to the 

Equipment for which Buyer has made payment to Seller, (d) if Buyer reasonably determines that the 

portion of the amount remaining unpaid under this Agreement will not be sufficient to complete the 

work in accordance with this Agreement, no additional payments will be due Seller unless and until 

Seller, at its sole cost, performs a sufficient portion of the work so that such portion of the amount 

remaining unpaid is determined by Buyer to be sufficient to complete the work, or (e) Seller has failed 

to complete the work within the time period stated in this Agreement. In addition, Buyer may set off 

from payments otherwise due under this Agreement claims arising under other contracts or purchase 

orders with Seller. Upon receipt of payment from Buyer, Seller will promptly pay each subcontractor the 

amount to which said subcontractor is entitled, reflecting the percentage actually retained, if any, from 

payments to Seller on account of subcontractor's work. Seller will, by agreement, require each 

subcontractor to make payments to his sub-contractors in similar manner. Buyer has no obligation to 

pay or to see to the payment of any moneys to any subcontractor except as otherwise may be required by 

law. 

6. Delivery, Performance and Delivery Dates: TIME IS OF THE ESSENCE FOR THIS ORDER. 

Except as otherwise stated on the purchase order, delivery shall be F.O.B Buyer's facility or the 

destination designated by Buyer. Seller agrees to deliver the Equipment in compliance with this 

Agreement, including all scheduled performance and delivery dates set forth on Buyer's purchase order. 

Seller will ensure that the Equipment is packed and shipped in an appropriate and suitable manner. 

Buyer's count of the Equipment and components thereof, will be final for all shipments shipped 

without an accompanying packing list. Seller will notify Buyer immediately of any circumstance 

which may delay the delivery of the Equipment, along with any corrective action Seller has taken to 

minimize the effect. In the event delivery is not in compliance with this Agreement, including delivery 

of the Equipment in accordance with the scheduled delivery dates (unless caused by an excusable 

delays as defined in paragraph 15), at Buyer's sole discretion, Buyer shall have the right to (i) require 

Seller shall ship the Equipment, either completed or not completed at Buyer's option, at the earliest 

possible moment and by the fastest manner (air freight) at Seller's sole cost and expense; (ii) terminate 

this Agreement, by written notice to Seller, and shall, in addition to all other remedies available at law 

or in equity, be entitled to a refund of all monies paid by Buyer to Seller under this Agreement; or (iii) 

terminate part of the work to be performed under this Agreement or the applicable purchase order, and 

Seller shall, in addition to all other remedies available at law or in equity, be responsible for all costs 

incurred by Seller to complete the work in accordance with this Agreement. Any additional costs 

incurred by Buyer as a result of nonconformance with this Agreement will be paid by Seller, including 

additional production charges, labor charges, and transportation costs. 



APPENDIX 1.1 

7. Pre-acceptance and Acceptance. 

7.1 General. Seller will submit to Buyer all production, function and quality control test reports and 

other data as Buyer may request from time to time concerning the Goods. Seller grants to Buyer the 

right to enter Seller’s premises at any reasonable time to make an inspection and examination of the 

Goods, their component parts and the fabrications/assembly techniques proposed or used by Seller as 

Buyer may deem appropriate. Seller agrees to fully cooperate with Buyer in such inspections. 

7.2 Pre-acceptance. Upon completion of fabrication of the Equipment at Seller' facility, Seller shall 

provide Buyer notice that the Equipment is ready for shipment/pre-acceptance testing. Buyer shall have 

the right to inspect the Equipment prior to shipment at Seller's facility within thirty (30) days of the date 

Buyer receives such notice ("Pre-acceptance Inspection Period"). During the Pre-acceptance Inspection 

Period, Buyer shall confirm that the Equipment complies with all applicable specifications and 

requirements. Any defects or deficiencies discovered by Buyer shall be promptly repaired or replaced 

by Seller's at Seller's sole cost and expense, and the Equipment shall be subject to another preacceptance 

inspection or test by Buyer. 

7.3 Final Acceptance. All Equipment ordered under this Agreement shall be subject to final 

acceptance by Buyer ("Final Acceptance"). Buyer shall notify Seller at least ten (10) days prior to the 

date of the final acceptance testing, which shall be designed by Buyer to evaluate whether the 

Equipment is in compliance with all applicable specifications and operates as contemplated in the 

Agreement. In the event the Equipment fails to operate in compliance with this Agreement and/or does 

not meet all specifications and requirements contained in this Agreement (including the applicable 

purchase order), Seller shall at Seller's own expense, immediately make such repairs or adjustments so 

as to render the Equipment in compliance therewith and the Acceptance Test shall be repeated. 

Notwithstanding payment or any prior inspection, Final Acceptance will not occur until (i) Seller has 

corrected all deficiencies related to the Equipment identified by Buyer, (ii) Seller has provided all 

documentation pursuant to paragraph 12, (iii) Seller provides evidence to Buyer that all of Seller’s 

subcontractors have been paid, including lien waivers if appropriate, and (iv) Seller has satisfied all 

other requirements as are specified in the Agreement. In the event Final Acceptance by Buyer is not 

achieved within thirty (30) days of the date Buyer first began final acceptance testing, Seller shall be 

deemed in material breach of this Agreement, and Buyer may revoke the Agreement, terminate this 

Agreement for default, and/or reject the Equipment, in whole or part, in addition to any other remedies 

Buyer may have at law or in equity. 

7.4 Remedies. In the event that the Equipment or any portion of the Equipment is not in 

compliance with any laws, the specifications contained in the Agreement, or are otherwise defective, 

Buyer may return the defective Equipment or part thereof to Seller, who shall refund to Buyer its cost 

plus freight to Buyer’s facility and freight for return to Seller. If Buyer prefers to accept the defective or 

non-conforming Equipment instead of requiring correction or replacement, the Agreement will be 

adjusted to reflect a reduction in the total Contract Price as appropriate and equitable. Such adjustment 

will be effected whether or not final payment has been made. 

7.5 Testing Materials. For only the first pre-acceptance test and the first final acceptance test 

performed, Buyer shall be responsible for its own travel costs and the costs of providing any materials 

or supplies that Buyer deems necessary in order to verify the proper operation and performance of the 

Equipment. For all pre-acceptance and final acceptance tests performed after the first one, Seller shall 

be responsible, at its sole costs and expense, for any materials or supplies that Buyer supplies or that 

Seller requests Buyer to supply in order to verify the proper operation and performance of the 

Equipment. In addition, Seller shall be responsible for any and all travel expenses and other related 



APPENDIX 1.1 

costs incurred by Buyer as a result of the non-compliance of the initial pre-acceptance test or final 

acceptance tests performed or due to any subsequent pre-acceptance and/or final acceptance testing that 

are performed. The pre-acceptance testing and final acceptance testing parameters shall be established 

by Buyer and shall be based upon the specifications and requirements set forth in this Agreement. 

8. Seller’s Warranties. 

8.1 General. Seller warrants that the Equipment, including all material and work furnished 

pursuant to this Agreement, (i) will be of the highest grade and quality unless otherwise specified by 

Buyer in writing; (ii) will be free and clear of all liens, claims or encumbrances arising or resulting from 

the acts or omissions of Seller or anyone claiming by or through Seller; (iii) will not be less than 

merchantable and fit for the particular purpose(s) known by or disclosed to Seller as applicable thereto; 

and (iv) shall meet and conform to this Agreement, including but not limited to all design, manufacture 

and performance the specifications and requirements specified in the Agreement. If requested by 

Buyer, Seller will furnish satisfactory evidence as to the kind and quality of material and work furnished 

under this Agreement and/or incorporated in the Equipment. Seller further warrants that the Equipment 

will comply with all applicable federal, state, and local laws and regulations. Unless otherwise stated 

herein, Seller warrants that it is a seller in the ordinary course of goods of this kind. Seller warrants that 

the Software (as defined in paragraph 17) will conform to the Documentation in all material respects, 

and that if the Software is used in accordance with the Documentation, the Equipment will operate in 

accordance with the Specifications. These warranties are in addition to any “shrink-wrap”, “click-on” 

or other warranty regarding the Software that may be included with the Equipment. 

8.2 For a period of twelve (12) months after the date of Final Acceptance of the Equipment or 

eighteen (18) months following the date the Equipment is delivered to Buyer's facility, whichever 

occurs later, Seller agrees to promptly (not more than 24 hours from the date of Buyer's notice to Seller) 

perform any corrective work in connection with the Equipment which may be required without cost to 

Buyer. Seller shall also be responsible, at its sole cost and expense, for all labor and travel expenses 

incurred by Seller to perform any warranty service hereunder or to send its personnel to Buyer's facility). 

Seller further agrees that all materials, components, parts, and equipment incorporated into the 

Equipment will carry manufacture and/or vendor warranties involving terms and duration which are, at 

a minimum, not less favorable to Buyer than those typically offered and meeting industry standards of 

such materials and equipment. 

8.3 No Limitation. Nothing contained in paragraphs 8.1 or 8.2 of this Agreement will be construed 

to establish a period of limitation with respect to any other obligation which the Seller might have under 

this Agreement. The establishment of a time period of twelve (12) months after final acceptance of the 

Equipment or eighteen (18) months after the date the Equipment is delivered to Buyer, or a longer 

period of time as may be prescribed by law or by the terms of any warranty required by this Agreement 

relates only to specific obligation of Seller to correct the Equipment. 

8.4 In the event Seller fails to respond to any of its obligations under this warranty within the time 

frame established herein or to complete any warranty work within a timely manner as deemed by Buyer 

given the facts and circumstances, Buyer shall have the right to perform the necessary corrective action 

or repairs necessary by itself or by retaining a third party. In such cases, Seller will be charged any and 

all direct costs incurred by Buyer to perform the work covered under this warranty. Notwithstanding 

the foregoing, where the failure or any delay to correct such failure may result or threatens to create 

significant liability or damages or unreasonable costs to Buyer if not immediately 



APPENDIX 1.1 

repaired, Buyer shall have the right, without notice to Seller, to immediately perform the necessary 

repairs or corrective action by itself or through a third party, and Seller agrees to reimburse Buyer for 

any and all direct costs incurred by Buyer relating to the performance of such work. 

9. Insurance. Seller and its subcontractors shall maintain (i) Commercial General Liability Insurance, 

including coverage for products liability and completed operations arising out of or related to the 

Equipment or Seller’s performance under this Agreement, with a per occurrence limit of not less than 

$2,000,000, and a general aggregate of not less than $5,000,000; (ii) Automobile Liability Insurance 

with a combined single limit of $1,000,000 per occurrence for bodily injury and property damage 

covering use and operation of owned, non-owned and hired vehicles. Seller’s insurance shall be 

primary and non-contributing to any other insurance which may apply. Seller will furnish certificates of 

insurance to Buyer at the time the Agreement is issued by Buyer. The insurance policies will provide for 

cancellation only after thirty (30) days’ prior written notice to Buyer. Buyer’s failure to require or 

demand any evidence of insurance does not constitute a waiver of any requirement for Seller to obtain 

insurance, nor does it limit Seller’s other obligations. Seller agrees to insure all shipments of 

Equipment for full value unless expressly specified otherwise on Buyer's purchase order. Seller shall 

provide workers’ compensation insurance and unemployment compensation insurance as required by 

applicable law. In the event Seller is required to perform work to complete the Agreement on Buyer’s 

property, Seller will provide such additional insurance coverage as Buyer requests. Under no 

circumstance will employees of Seller be deemed to be the employees of, or under the direction or 

control of, Buyer for any reason. 

10. Work at Buyer's Facility. In the event this Agreement requires the performance of service work, 

removal, moving or installation of the Equipment by Seller upon any property, premise or project of 

Buyer, Seller shall examine the same to determine whether they are safe for such services and shall 

advise Buyer promptly of any situation Seller considers to be unsafe. Seller (its agents, employees, and 

sub-contractors) shall comply with the requirements of all applicable safety and health laws, 

regulations, rules, ordinances and orders. These include, but are not limited to the Occupational Safety 

and Health Act of 1970 ("OSHA"), the Toxic Substance Control Act ("TSCA"), the Construction Safety 

Act of 1969 ("CSA"), and all standards promulgated thereunder, and with Buyer's local/plant safety 

program. Seller shall comply with and is directly responsible for compliance therewith on the part of its 

respective agents, employees, material persons and subcontractors. Seller shall keep those portions of 

the Buyer's premises where Seller is performing work or services clean of debris, and upon completion 

of the work shall leave the premises clean an ready for use. If Seller fails to clean up to Buyer's 

satisfaction, Buyer may do so and the cost will be charged to Seller or deducted from the Contract Price. 

Seller shall directly receive and be responsible for all citations, assessments, fines or penalties which 

may be incurred by reason of its failure or failure on the part of their agents, employees, material 

persons or subcontractors, to so comply. Notwithstanding the provisions of any Workers Compensation 

statute, Seller agrees to and shall indemnify, protect, defend and save harmless Buyer from and against 

all costs (including reasonable attorney's fees), damages, and liability arising out of or allegedly arising 

out of any violations by Seller, its employees, agents, and subcontractors of any applicable safety and 

health laws, regulations, rules, ordinances, and orders, including but not limited to OSHA, TSCA, and 

CSA. Seller warrants that all certificates and licenses that may be required for the performance of any 

services or work under this Agreement will be obtained by Seller. Seller will coordinate all work and 

services to be performed at Buyer's premises with the Buyer in advance to ensure that suitable power, 

materials handling equipment and other items are available. 



APPENDIX 1.1 

11. Documentation. Seller will provide Buyer at no additional cost to Buyer, with (i) a complete listing of 

recommended spare parts for the Equipment, (ii) operation, maintenance, and training manuals, and (iii) 

copies of the technical and mechanical specifications relating to the Equipment, including layouts, 

drawings, diagrams, software and models of the Equipment (collectively hereinafter "Documentation"). 

In addition, no more than thirty (30) days after receipt of Buyer's purchase order, Seller will provide 

Buyer with any site/facility specifications relating to the requirements necessary for the proper set up of 

the Equipment, including necessary floor loads to hold the Equipment, height, depth and width 

requirements, electrical, power, water, and heating requirements, and all other requirements necessary 

to properly and safely install, set up, maintain and operate the Equipment. Any and all Documentation 

provided to Buyer shall be written in English. Seller further agrees, at its own cost and expense, to 

ensure that any Documentation provided to Buyer accurately reflects the description, design, 

specifications, etc. of the Equipment as of the date of Final Acceptance by Buyer. 

12. Subcontractors. Seller will furnish to Buyer in writing all names and addresses of the persons or 

entities (including those who are to furnish materials or equipment fabricated to a special design) 

proposed for the principal portion of the Equipment. Buyer will promptly reply to Seller in writing 

stating whether or not Buyer has objection to any such proposed person or entity. Neither party will 

make a substitution for any subcontractor, person or entity previously selected if the other party objects 

to such substitution. 

13. Confidentiality and Trade Secrets, and Know-How. Seller will at no time directly or indirectly 

reproduce, disclose, advertise, publish or otherwise make known (a) the fact that Seller and Buyer have 

entered into this Agreement, or that Seller has contracted to or has furnished Equipment to Buyer, or (b) 

any information, design, specification, idea, concept, plan, copy, formula, drawing, process, procedure, 

performance characteristics or other confidential information which has been or will be disclosed to 

Seller in connection with the Equipment or their evaluation, study, design, production, testing, 

installation or performance, or received in performing this Agreement (collectively, the “Information”). 

Seller will not use any of Buyer’s Information which is disclosed to or in possession or control of Seller 

except in performing this Agreement, unless in compliance with written instructions of Buyer. Upon 

Buyer's request, Seller shall execute a separate confidentiality/non-disclosure or development 

agreement, which shall be incorporated into this Agreement by this reference. 

14. Ownership of Improvements. Seller agrees to, and hereby does, assign its entire right, title and 

interest in all intellectual property, including, but not limited to, all writings, designs, mask works, 

software, inventions, improvements and discoveries, conceived or made by all employees and agents of 

Seller in connection with their provision of services or the Equipment to Buyer under this Agreement 

(collectively hereinafter "Improvements"), with the understanding that patent rights retained by Seller in 

the Equipment shall remain the intellectual property of Seller. Seller further agrees to do all lawful acts 

and sign all assignments and other papers Buyer deems necessary, appropriate or advisable relating to 

applications for patents, mask works, registrations, trademarks, and copyrights related to the 

Improvements, both United States and foreign, or relating to the conduct of any interference, litigation 

or other controversy in connection therewith, provided that all expenses incident to the filing of such 

applications, the prosecution thereof and the conduct of any interference, litigation or other controversy, 

including Seller’s employees’ time and travel expenses incurred in connection with such applications, 

shall be borne by the Buyer. Seller further agrees not to assert any intellectual property right against 

Buyer in relation to Buyer’s use of any Improvements in connection with Seller’s performance under 

this Agreement, and grants a royalty free, irrevocable, non-exclusive, worldwide license to any patent 

rights in the Equipment provided that Buyer use is limited to Buyer and its affiliates to use, operate and 

maintain the Equipment supplied under this Agreement. 



APPENDIX 1.1 

15. Excusable Delays. Either party may suspend performance during the occurrence of an excusable 

delay. An excusable delay may include any delay not the result of fault or negligence of the party whose 

performance is prevented by the delay and which results from the acts of God or public enemy, 

restrictions, prohibitions, priorities or allocations imposed by governmental authority, embargoes, 

floods, fires, earthquakes, epidemics, unusually severe weather, delays of similar nature or 

governmental causes, and strikes or labor disputes (of or involving the delayed party’s employees only). 

Notwithstanding the foregoing, Seller shall not be excused from performance hereunder where the 

reason for the delay was reasonably foreseeable and/or avoidable, or where alternate sources of 

materials, goods or services are reasonably available even if at a higher cost to Seller. If the Seller 

anticipates any event that could constitute a delay in delivery or in its ability to comply with any of its 

performance obligations under this Agreement, Seller shall promptly notify Buyer in writing of the 

same. In the event of excusable delay, performance of this Agreement will be extended for a reasonable 

period of time to be determined by Buyer and not to exceed a period equal to the length of the delay 

itself. Buyer reserves the right to visit Seller’s facility during normal business hours and, after due 

notice, to inspect Seller’s operations to evaluate the progress of the Work and determine adherence to 

the Contract Schedule. Seller shall promptly take all commercially reasonable steps to avoid or end 

delay without additional cost to Buyer. Notwithstanding anything to the contrary set forth in this 

Agreement, in the event an excusable delay affecting Seller's performance exceeds thirty (30) days, 

Buyer may terminate this Agreement without liability notwithstanding anything to the contrary stated in 

this Agreement. 

16. Spare Parts. Unless otherwise specified by Buyer on Buyer's purchase order, Seller agrees, for a period 

of ten (10) years after the delivery of the Equipment, to maintain an adequate inventory of all unique or 

specially manufactured parts to properly support and maintain the Equipment purchased under this 

Agreement. For parts that are commercially available at a comparable price, Seller will identify for 

Buyer the manufacturers, vendors, or other sources of Seller’s supply of such parts, as well as parts 

numbers and prices, and agrees to maintain for a period of seven (7) years after delivery of the 

Equipment an adequate inventory of such purchased parts to properly support and maintain the 

Equipment purchased. The prices of all parts shall be adjusted in accordance with Seller’s price list. 

17. Software. In the event that software is required for the installation, testing, calibration, operation or 

maintenance of the Equipment (“Software”), Seller hereby grants to Buyer an irrevocable, perpetual, 

paid-up, worldwide, nonexclusive license to use the Software for such purposes. Any Software that is 

custom developed by Seller for Buyer under this Agreement ("Custom Software") shall be delivered to 

Buyer with the applicable source code. All rights, title, ownership and interest in such Custom 

Software shall best in Buyer upon payment by Buyer to Seller for the work performed. At the time of 

delivery of the Equipment, Seller shall deliver written documentation to Buyer that adequately describes 

the functionality and operation of the Software (“Documentation”). 

18. Federal Contractor. Seller acknowledges that the Buyer serves from time to time as a subcontractor 

for the United States government. In those cases Seller shall comply with the federal laws regulations 

and rules applicable to subcontractors of government contractors including but not limited to those 

relating to equal employment opportunity and affirmative action in the employment of minorities 

(Executive Agreement 11246), women (Executive Agreement 11375) the handicapped (29 USC 793), 

and certain veterans (36 USC 2012), and contracting with women-owned or small and disadvantaged 

business concerns. Where applicable, Seller certifies that it maintains no segregated employee facilities 

as provided in 41 CFR 60-I8 and that it is not debarred from being awarded federal or federally assisted 

contracts. 



APPENDIX 1.1 

19. Termination for Default. In the event Seller shall be adjudged bankrupt, make a general assignment 

for the benefit of its creditors, or if a receiver shall be appointed on account of Seller's insolvency, or in 

the event Seller is in default of any material provision or requirement of this Agreement that breach is 

not remedied within ten (10) days of notice given by Buyer to Seller, Buyer may terminate this 

Agreement in whole or part, in addition to any other rights or remedies which Buyer may have, cancel 

further performance by Seller under this Agreement. In the event of such termination, Buyer may 

complete the performance of this Agreement by such means as Buyer selects, and Seller shall be 

responsible for any additional costs incurred by Buyer in so doing. Seller shall deliver or assign to 

Buyer any completed work or work in progress as Buyer may request. Any amounts due Seller for goods 

and services completed by Seller in full compliance with the terms of this Agreement prior to such 

termination shall be subject to offset Buyer's additional costs of completing the Agreement and other 

damages actually incurred by Buyer as a result of Seller's default. Waiver by Buyer of any default of 

Seller shall not be considered to be a waiver of Buyer of any provision of this Agreement, or the waiver 

of any other defaults. Any failure of Buyer to insist on the performance of any term or condition of this 

Agreement shall not be deemed a waiver of Buyer's rights thereunder. 

20. Termination for Convenience. Buyer shall have the right to cancel for its convenience further 

performance of all or any separable part of this Agreement at any time by written notice to Seller. On 

the date of such cancellation stated in the notice, Seller shall discontinue all work pertaining to this 

Agreement, shall place no additional orders, and shall preserve and protect materials on hand purchased 

for or committed to this Agreement, work in progress and completed work both in Seller's and in its 

suppliers’ plants pending Buyer's instruction, and shall dispose of same in accordance with Buyer's 

instructions. Buyer shall give such instruction within 5 days of its written notice to cancel, failing which 

Seller may make reasonable disposition which shall be deemed to have been done in accordance with 

Buyer’s instructions. In the event of cancellation by Buyer for convenience, Buyer shall compensate 

Seller, upon demand for all costs and expenses already incurred or commitments made by Seller in 

connection with the processing, handling and fabrication of said equipment including reasonable and 

necessary expenses resulting from the cancellation, as substantiated by documentation reasonably 

satisfactory to Buyer, plus reasonable amounts for overhead and profit on such costs and expenses, 

though not for anticipated profit or anticipated overhead charges. Cancellation payment to Seller or 

refund to Buyer, if any, shall be made promptly. Seller shall not be entitled to any loss of profits, 

contribution to overhead or incidental, consequential or other damages because of such cancellation. 

Seller shall deliver or assign all goods with all-applicable warranties or dispose of goods as instructed 

by, or as deemed to have been instructed by, Buyer prior to final payment. 

21. Right to Offset. Buyer, without waiver or limitation of any rights or remedies of Buyer, shall be entitled 

from time to time, to deduct from any amounts due or owing by Buyer to Seller in connection with this 

Agreement, or any other agreement with Seller, any and all amounts owed by Seller to Buyer. Buyer, 

without waiver or limitation of any rights or remedies of Buyer, shall be entitled from time to time, to 

deduct from any amounts due or owing by Buyer to Seller in connection with this Agreement, or any 

other agreement with Seller, any and all amounts owed by Seller to Buyer. 



APPENDIX 1.1 

22. Arbitration. The parties agree to submit all disputes between them arising out of or related to this 

Agreement or the breach, alleged breach or interpretation thereof to binding arbitration. Within thirty 

(30) days after either party has notified the other in writing that it is submitting a dispute to arbitration, 

one arbitrator shall be selected under the then current rules of the American Arbitration Association 

(“AAA”) pertaining to commercial disputes. The arbitration shall be held in Chicago, Illinois (unless 

the parties otherwise agree in writing) and shall be conducted in accordance with the Commercial 

Arbitration rules of the AAA except the AAA shall not have authority to make any award for damages 

excluded herein. The arbitration award shall be by a written decision and shall be final and binding, and 

enforceable by any court of competent jurisdiction. 

23. Changes. Buyer shall have the right to make changes in the specifications and drawings for goods or 

services covered by this Agreement. Buyer shall initiate such change by written direction to Seller. If 

Seller believes that any such change affects the price or delivery date for the goods or services, Seller 

shall so notify Buyer in writing, with adequate supporting documentation, within five (5) business days 

after acknowledged receipt of said written direction, or a maximum of ten (10) business days total. 

Seller shall suspend performance of the change unless thereafter released, in writing, by Buyer to 

perform said change, and Buyer and Seller shall mutually agree in writing upon an equitable adjustment 

in the Contract Price and/or applicable performance or delivery schedule(s) to reflect the effect of such 

change. Seller's request for any adjustments shall be deemed waived unless submitted in writing within 

ten (10) business days after Seller receives initial written direction to make such changes. To the extent 

possible, Seller shall not suspend performance of the unaffected portion of the Work while Buyer and 

Seller are in the process of making such changes and any related adjustments, or at any time thereafter 

unless so instructed in writing by Buyer. If released in writing by Buyer, Seller shall comply with and 

perform such change in accordance with the terms of this Agreement during the time Seller and Buyer 

require to mutually agree upon an equitable adjustment. No substitutions shall be made in this 

Agreement without the prior written authority of Buyer. 

24. Patent Indemnity. Seller shall, at its sole expense, indemnify, hold harmless and defend Buyer, its 

officers, employees, successors and customers from and against any suit or proceeding brought against 

Buyer based on a claim that the manufacture, use or sale of the Equipment or services or any part 

thereof, supplied under this Agreement, constitutes infringement of any patent, copyright, trademark or 

proprietary information right of others, and Seller shall pay all damages and costs awarded therein 

against Buyer. Seller shall be promptly notified, in writing, of the suit or proceeding and shall be given 

adequate authority, information and assistance, at Seller's expense, for the defense of same, subject to 

the right of Buyer to participate at its expense and to be fully advised by Seller in advance of all actions 

taken. In case said goods or any part thereof are, in such suit, held to constitute infringement or the sale 

or use of said goods or parts thereof are enjoined, regardless of whether such determination constitutes 

a final judgment, Seller shall, at its expense, either procure for Buyer the right to sell and use said 

Equipment or part thereof; replace the same with substantially equal but non-infringing Equipment or 

parts thereof; or, if approved by Buyer, remove said Equipment or parts thereof, and refund the 

purchase price and the transportation and installation costs thereof. The preceding shall not apply to 

any claim to the extent it arises from designs furnished and required by Buyer, nor shall it apply to 

claims that arise from the use of the Equipment in combination of with equipment or parts not supplied 

by Seller hereunder with other goods infringes any patents, if such process or other goods were not 

supplied by Seller and Seller's supplying the Equipment hereunder does not constitute contributory 

patent infringement. 



APPENDIX 1.1 

25. General Indemnity. For and in consideration of the covenants of Buyer under this Agreement, 

including the agreement of Buyer to pay to Seller the amounts which may become due and payable 

under the terms of this Agreement, Seller hereby agrees to assume the risk of and to release, defend, 

indemnify and save harmless Buyers and the related entities, directors, officers, employees, agents and 

assigns of Buyer ("Indemnitees") from and against all loss, damage, liability, cost and expense 

(including reasonable attorney's fees) arising out of any injury or death to any person or damage to any 

property, including damage to or failure of the goods furnished hereunder or damage to other 

components caused by such failure, resulting from or in any way connected with the performance of this 

Agreement or Seller's breach of this Agreement or the Equipment furnished hereunder, regardless of 

whether or not such loss, damage, liability, cost or expense is caused in part by an Indemnitee. Neither 

this Article nor any other provision of this Agreement shall be construed in any circumstances to 

constitute an indemnification against any loss, damage, liability, cost or expense caused solely by the 

negligence of such Indemnitee. The indemnity obligations in this Agreement shall be deemed to be 

modified as required to exclude indemnification which is expressly prohibited by applicable law. Seller 

acknowledges receipt of specific payment of Ten Dollars ($10.00), incorporated into the purchase price, 

as legal consideration of Seller's indemnity under this Article and all other indemnities as may be 

provided in this Purchase Order. 

26. Miscellaneous. All agreements contained in this Agreement shall bind and inure to the benefit of the 

respective successors and assigns whether so expressed or not, except that Seller shall have no right to 

assign its rights or any interest herein without the prior written consent of Buyer. No amendment, 

modifications, termination or waiver of any provision of this Agreement will be effective unless in 

writing and signed by both parties, and then such waiver or consent will be effective only in the specific 

instance and for the specific purpose for which given. In performing its obligations, Seller is and will be 

deemed to be an independent contractor and not an agent or employee of Buyer. This Agreement shall 

be governed under the laws of the State of Illinois. If any provision provided in this Agreement is or 

becomes invalid or unenforceable under any law of mandatory application, the Parties agree that such 

provision will be deemed severed and omitted from the Agreement and the remainder of this Agreement 

will remain in full force and effect. 

RBUS/LEG\Legal Library\Drafting...Appen11.DOC 

Final Version LEG05012000 



APPENDIX 2.1 

MACHINE DATA SHEET 

BOSCH DATA 

SC No: Investment No: PO No: 

Description: 

For Component: Production Rate: Qty./Day 

Requested by: 

Name Dept. Date 

SUPPLIER DATA 

Supplier: Model No: Serial No: 

Supplier Proj. Engr: Dim. : L W H Weight: 

Utility Usage 

Elect. Main Breaker: Amps Volts 

Elect. Full Load Current 

Elect. Panel attached Yes No 

Chilled Water GPM BTU/H 

DI Water 

GPM 

Potable Water 

GPM 

Gas SCFM 

Pressure 

Steam lb/hr. 

Pressure 

Air SCFM 

Pressure 

Coolant System 

Motors 

Function Qty KW RPM Volt Amp 

Environmental 

PH 

System Capacity: gals. Pump Cap.: Exhaust SCFM Vol. Temp. 

Sys. Type: Solid Waste Type Vol. 

External Tank Cap: Size: Contaminants: Smoke Dust 

Type of Filter Media: Mist VOC Drip Pan Req.: Yes No 

Treatment 

Chip System 

Waste Water Discharge GPM: Chip Material: Volume: 

Waste Oil Discharge GPD: System Type: 

Other Systems 

Special Foundation Requirements 

Cranes: 

Special Hazards: 

OSHA Req. 

Max. Weight: 

Communication Requirements 

Number of Network Jacks Required: 

CF06790005 .xls Originator: ChW/BPS-LS W.Hasper 

Revision: 1, 4/1/05 

Section 9, Appendix 2.1 - Machine Data Sheet 


APPENDIX 2.2 

DESIGN REVIEW CHECKLIST 

Project: 

Project Engineer: 

Date: 

Vendor Representative: 

1.0 First Design Review 

1.1 Review of BPS Assessment 

1.2 Concept Drawings 

1.2.1 Main/Final Assembly Drawing 

1.2.2 Machine Operation and Process Drawings 

1.2.3 Control System Overview 

1.3 PFMEA Review 

1.4 Material Handling, Ergonomics 

1.5 Hazard Assessment 

1.6 Special Attention Points, Machine Guarding 

1.7 Machine Data Sheet 

1.8 Component Specifications & Literature 

1.9 Approval Prints 

1.10 Other special design concerns: 

Reviewed? 

Yes No N/A 

2.0 Final Design Review 

2.1 Mechanical Assembly and Subassembly Drawings 

2.2 Detail Drawings and Parts Lists 

2.3 Pneumatic & Hydraulic Schematics and Parts Lists 

2.4 Control System Functional (Sequence) Plan 

2.5 Electrical Control System Diagrams, Drawings, & Parts Lists 

2.6 Critical and Proprietary Parts 

2.7 PFMEA Review 

2.8 Updated Machine Data Sheet 

2.9 Hazardous Material List 

2.10 Foundation Drawing 

2.11 Approval Prints 

2.12 Anticipated PM Requirements (Labor, Material, & Frequency) 

2.13 Other: 

Acceptable? 

Yes No N/A 

CF06790004 .xls Originator: ChW/BPS-LS W.Hasper Rev. 1, 4/1/05 

Section 9, Appendix 2.2 - Design Review Checklist 


APPENDIX 2.3 

Investment Assessment 

Attachment 2 to the supplementary manual for the ZI Central Directive Investment Assessments 

BPS-Assessment with qualitative criteria 

BPS-Principle Criteria Value 

Comment 

0 1 2 3 4 

Process Orientation 

The equipment layout is according to the sequence of operations (routing). There are no 

1 

batch processes. 

The move batch size between processes is defined, small and constant throughout the 

2 

value stream (SNP- Standard Number of Parts) 

The transportation distances in the value stream are reduced to a minimum with a material 

3 

flow oriented layout 

Pull System 

1 Workpiece carriers are limited to 3 per station in the production lines when a fault occurs 

The finished goods of a process are stored at the supplying process (in Supermarkets if 

2 

needed), the transportation to the following process is based on consumption 

3 The replenishment lead time for the internal transportation is defined and minimal ( 25% of the area evaluated 

1 Characteristic is present in isolated cases 

0 Characteristic is not present 

For update and further information see http://www.intranet.bosch.com/ZI11/Investment_assessments/ 

Section 9, Appendix 2.3 - Investment Assessment 


APPENDIX 4.1 

US Contacts for Bosch Products 

Bosch Rexroth Corporation 

Contact: 

Kim Huff 

Bosch Rexroth Corporation 

2810 Premiere Parkway – Suite 500 

Duluth, GA 30097 

Industrial Hydraulics\ 

▪ Valves and controls\ 

▪ Compact hydraulics\ 

▪ Pumps\ 

▪ Power units / accessories 

▪ Hydraulic cylinders 

Electric Drives and Controls 

▪ Motion controllers and PLCs 

▪ Servo drives and motors 

▪ Frequency converters 

▪ Fastening and press-fit technology 

▪ Resistance welding 

Pneumatics 

▪ Valves and actuators 

▪ Cylinders 

▪ Fieldbus valve manifolds 

▪ Electro-pneumatic valves and positioners 

Phone: (678) 957-4055 

Mobile: (770) 310-1398 

Fax: (678) 417-6637 

E-mail: kim.huff@boschrexroth-us.com 

Web site: www.boschrexroth-us.com 

Linear Motion and Assembly 

▪ Linear Motion Technology 

• Linear Motion Guides (standard and 

miniature series, roller and ball elements) 

• Ball Screws 

• Linear Ball Bushings and precision 

ground round shafting 

• Linear Actuators (belt, ball screw, lead 

screw, pneumatic drives) 

• Ball Transfers 

▪ Assembly and Material Flow Technology 

• FMS Aluminum extrusion – full line of 

sizes, shapes and accessories. 

• Workstations (adjustable, powered, air 

supply, lighting) 

• Lean Manufacturing technology 

• Transfer Systems and non-synchronous 

conveyors (TS palletized systems) 

• Single strand material handling and 

product flow conveyors, (VarioFlow) 

Robert Bosch Tool Corporation (EW) 

Power Tools Contact: John A. Onik 

Robert Bosch Tool Corporation 

1800 West Central Road 

Mount Prospect, Illinois 60056 

Phone: (224) 232-2000 

Section 9, Appendix 4.1 - US Contacts for Bosch Products 


Issued April 1, 2005 

Workplace Measurements 

for Manual and Machine Work Stations (Dimensions in mm) 

Section 9, APPENDIX 4.2 Page 1 of 2 

BOSCH 

s 

Controls and Displays 

Operating Mounting 

frequency Height 

per Shift 

100 max. 1500 

Max. Positioning 

Height d: 1500 

e 

s 

c 

Max. 1400 

“Unobstructed” 

View 

s 

e 

c 

d 

s 

s 

k 

b 

i 

max. 

300 

BOSCH FMS-Worktable 

α 

H 1 

A 

k 

b 

i 

max. 

300 

BOSCH FMS-Worktable 

α 

A 

H 2 

H 2 

A 

600 

i 

e 

Fig. 1 

t 1 

t 2 

Fig. 2 

t 1 

2 t 2 

Fig. 3 

t 1 

t 2 

Description Seating Workplace (Fig. 1) Seating/Standing Workplace (Fig. 2) Standing Workplace (Fig. 3) 

Distance to work area 

Working height 

Working Surface Height 

From tabletop to work 

area 

Leg room depth 

Foot room depth 

t 2 

Leg room width 

t 3 

Footrest: 

Free room for knees k 

Inclination 

α 

Room for foot movement: 

Clearance height i 

Seating Height 

b 

Visual distance 1) s 

e 

H 1 

H 2 

A 

c 

t 1 

0 to 325 

Aim a minimum distance from the front edge 

Pay attention to dimension c 

min. 900 

Above a = 90, k = 520 to 750 

is possible 

of the fingers is decisive) 

900 - 1080 

Dependent on: Body height 

Fixture height 

Work piece height 

Make as small as possible, large distances cause unfavorable arm positions 

(holding posture). Compromise between visual distance and arm position. 

(Compare Fig. 5 and Table 1.) 

min. 350 

min. 550 (for free movement) 

min. 800, Getting up from chair must be possible by swiveling the chair 

Installed at workplace (platform continues to rear) 

520-750 (adjustable height), at A = 900 only k = 520 to 700 possible 

5º - 10º 

Also for chair legs 

min. 120 

Adjustment range min. 250, preferably 300, adapted to height of work area 

s is almost independent from body height when 

seated and can be adjusted via seating height 

Influence on: 

Influence on: 

min. 80 

min. 150 

min. 600 

Arm position 

Visual distance s 

Head inclination 

Reference values for working height see Fig. 5 & Table I. (the work area 

Arm position 

Visual distance s 

Head inclination 

s is heavily dependent on body height when standing 

and can be influenced via working height (see Fig. 5) 

1) Visual distance is dependent on 

several parameters. 

Reference values can be 

determined by comparing similar 

workplaces or by experimenting. 

The following parameters must be 

comparable: 

Size and shape of recognizable 

details 

Type of activity 

Contrasts (object/surroundings) 

Illumination intensity 

Individual power of vision 

min. 

1000 

Area of free movement per workplace 

min. 1.5 m 

2 

recommended. 

Fig. 4 

Top view of knee room, clearance in the 

back, distance of persons and area of free 

movement. 

Deviations from the given values must be tested in individual cases (e.g. with the aid of a “Template 

for the Human Figure”, software ERGOMAS). 

t 3 

min. 1000 

min.1000 

1870 

720 

530 

1760 

640 

440 

1660 

370 

1540 

240 

1200 

1100 

1000 

950 

900 

Fig. 5 

Visual distances and underarm positions illustrated depending on body height and work height 

570 

460 

© 1999 Robert Bosch GmbH 

Responsible FV/PLP1

Issued April 1, 2005 

Section 9, APPENDIX 4.2 Page 2 of 2 

Table 1 

Reference values for working heights H 1 and H 2 depend on work requirements 

and body height (5th and 95th percentile) for Female (F) and Male (M). 

Work Requirements Examples Working Height 

H 1 (Sitting) 

H 2 (Standing) 

5th 

Percentile 

95th 5th 

Percentile 

95th 

F M F M F M F M 

High requirements for 

Visual control 

Fine biomechanical 

coordination 

Adjustments 

Visual Inspections 

Assembly of very small parts 

400 450 500 550 1100 1200 1250 1350 

Medium requirements for 


Fine biomechanical 

coordination 

Minor requirements for 


High requirements for 

Movement of arms 

Wiring work, 

Assembly of small parts with 

minimal use of muscular force 

Sorting 

Packaging 

Assembly of heavier work 

pieces with increased use 

of muscular force 

300 350 400 450 1000 1100 1150 1250 

250 350 900 1000 1050 1150

APPENDIX 5.1 

Control Systems Overview 

Controller Type 

Manufacturer 

Model 

Programming 

Language 

Programming 

Device 

Comments 

CF06790003 .xls Page 1 of 2 

Originator: 

ChW/BPS-LS W. Hasper 

(German translation, next page) 

Revision: Original, 03/11/05 

Section 9, Appendix 5.1 - Control Systems Overview 


Control Systems Overview Form 

Instructions 

Each programmable device for a project shall have an entry in the Control Systems Overview form. Programmable in the previous 

sentence includes any device which requires the purchaser of the equipment to configure the equipment prior to its use in the 

intended application. This however shall not include any equipment that is configured entirely by jumpers, dip switches or potentiometers. 

This shall include but not be limited to computers, PLC's, CNC's message displays, robots, motor controllers, networks, data collection 

equipment, intelligent modules or interfaces, etc. 

Controller Type 

This field should contain the type of equipment used, such as PLC, motor controller, etc. 

Manufacturer 

The manufacturer of the equipment. 

Model 

The model number of the equipment including enough information to completely order the item, such as 

revision level, ROM version, etc. 

Programming Language 

The programming language or languages used to configure or program the described equipment including 

version or revision level. 

Comments 

Provide more descriptive information, clarifications, or comments regarding the described equipment. 

CF06790003 .xls Page 2 of 2 Originator: 

ChW/BPS-LS W. Hasper 

Revision: Original, 03/11/05 

Section 9, Appendix 5.1 - Control Systems Overview 


APPENDIX 5.2 

Special Attention Points for Equipment Suppliers 

Spaces around Control Cabinets and Compartments: 

1. Working Space Depth and Width 

Electrical 

Cabinet 

As per: 

NFPA 79 

12.5.1 

12.5.1.1 (Minimum depth requirement 

for Bosch to be 1 meter.) 

Depth 

of working space 

min. 1 meter 

12.5.1.2 The width of the working space in 

front of control cabinets and 

compartments shall be the width of 

the control cabinet or compartment, 

or 750 mm (2-1/2 ft.), whichever is 

greater. 

Width 

of working space 

per 12.5.1.2 

Fig. 1 

2. Recessed Control Cabinets and Compartments 

As per: 

NFPA 79 

12.5.1.3 

Recess cannot be 

more than 6 inches 

Electrical 

Cabinet 

Fig. 2 

Fig.1 and Fig.2 are examples of many possibilities. For more details, see the entire NFPA 79 12.5. 

Section 9, Appendix 5.2 - Special Attention Points for Equipment Suppliers 


APPENDIX 6.1 

Parts to Produce for Total Test 

Acceptance tests for production machines shall be designed to produce parts for at least 8 hours running 

at maximum rate. The run duration shall be extended, as necessary, to complete a minimum of 300 

parts. For test stand acceptance, the component type and nature of the test(s) will determine the 

number of parts required. 

Sample Size 

For those characteristics that can be studied using X-bar and R-charts, a short-term study should be 

conducted using measurements from at least 125 parts*, sample size 5, to produce at least 25 

subgroups. To the extent feasible, tests should be designed to capture machine performance over time, 

including effects of tool change, temperature and humidity variation and start-up/shut-down that would 

be associated with a shift change. Circumstances may warrant a reduction in the number of 

measurements required. Any departure from these requirements must be approved by the Project 

Engineer. 

*Where more than one part is produced simultaneously at a single station, a total of at least 125 

measurements is required. For multi-spindle/multi station machines, the requirement is for at 

least 125 measurements per spindle/station. 

Calculation example: 

Cycle time: 

To be evaluated: 

15 seconds (one part produced at a time) 

Dimensions 

A) Number of parts to be produced = 8 x rated hourly output 

= 8 x 3600/15 = 1,920 Pcs. 

(Excludes any preliminary production for system tuning or warmup) 

B) Number of sample batches to be taken = Total sample size/n 

= 125/5 = 25 

C) Frequency of sampling (piece-based) = A/(B-1)** = 1,920/(25-1) 

= approx. every 80 Pcs. 

** First sample should be taken just after start of test. 

References: 

AQC/AIAG Production Part Approval (PPAP) manual 

AQC/AIAG Statistical Process Control Reference Manual 

Section 9, Appendix 6.1 - Parts to Produce for Total Test, Sample Size 


APPENDIX 6.2 

Technical Availability 

VDI 3423 Draft Aug.1998 (excerpts, translated by Robert Bosch Corp. Charleston SC, USA. Jan. 2000) 

For updated and complete information see latest German/English issue. It can be purchased via 

http://www.beuth.de/index_en.php 

Technical availability V T 

The technical availability provides the percentage of operating time for machines / systems available to 

production without technical defects. 

V T 

= N T 

= 100% - T 

T 

100% = 1 T 

T 

T 

B 

T 

B 

100% 

Technical downtime T T 

Technical downtime is the total of all downtimes, caused by design or construction defects of a machine / 

system. These are the manufacturer's responsibility. 

Defects, for example are: 

• material defects 

• design or construction defects 

• defects in documentation 

which consequently results in downtimes for 

• repair ( troubleshooting) 

• waiting on spare parts 

• waiting on service technicians 

• trial run to find defect 

• trial run after troubleshooting 

These downtimes are basis for negotiation between user and manufacturer about technical degree of 

utilization and/or the availability of machines. 

Observation period 

(e.g. all year, month, shift, warranty period) 

Loading time T B 

(planned loading time of machine, e.g. according to production plan 

Utilization time T N 

Scheduled 

downtime T O 

Technical 

downtime T T 

Non-loaded time (e.g. 

insufficient orders) 

Maintenance 

time T W 

(can possibly run into 

idle time) 

unplanned time 

(e.g. Sundays and 

Holidays) 

Testing time T C 

Loading time T B 

Loading time is the portion of time within the observation period, in which the machine / system is planned 

to be used (see graph above). 

Section 9, Appendix 6.2 - Technical Availability 


APPENDIX 8.1 

DOCUMENTATION 

1. Preferred format for Operation Instructions and Service Manual 

When a vendor does not have a manual format which is agreed upon with the Project Engineer, the 

following guidelines should be followed for manual organization and layout. 

1.1 Order of contents: 

1. Title Page 

2. Table of Contents 

3. List of Tables 

4. List of Illustrations 

5. Safety Considerations 

6. 1.0 Introduction 

7. 2.0 General Description 

8. 3.0 Detailed Description 

9. 4.0 Theory of Operation 

10. 5.0 Operations 

11. 6.0 Calibration Procedures 

12. 7.0 Troubleshooting 

13. 8.0 Service and Maintenance 

14. 9.0 Recommended Spare Parts List 

15. Appendices (optional, as required) 

1.2 Paragraph numbering system. Each topic and sub-topic should be numbered in a 

coordinated fashion. Example: 

5.0 OPERATIONS 

5.1 CONTROLS AND INDICATORS 

5.1.1 Normal Indicators 

5.1.2 Abnormal Indicators 

5.2 STARTUP PROCEDURE 

5.2.1 Ventilation 

5.2.2 Air Supply 

5.2.3 Fuel Supply 

5.3 SHUTDOWN PROCEDURE 

5.3.1 Normal Shutdown 

5.3.2 Abnormal Shutdown 

Section 9, Appendix 8.1 - Documentation 


APPENDIX 8.1 

1.3 Pages numbering shall include section identification. Example: 

• SECTION 2 pages would be numbered 2-1, 2-2...2-12, etc. 

• The Table of Contents, List of Tables, List of Illustrations and Safety Considerations 

shall be numbered using lower case Roman numerals (i.e. i, ii, iii, iv...xii). 

1.4 Section Content. 

1. Section 1.0 Introduction - Provides background or special information that may help 

familiarize the readers with the equipment. References other manuals that may be 

included with the machine. Identifies manufacturer and provides point of contact 

information (i.e. address, telephone numbers). 

2. Section 2.0 General Description - Prepares the reader for the detailed description by 

providing information regarding the components and nomenclature and define 

terms. 

3. Section 3.0 Detailed Description - States the function and location of major components 

in order for the reader to follow the Operations section of the manual. Includes a 

functional block diagram. (Note: for small, non-complex machines, sections 2.0 and 

3.0 may be combined, but the intent of section 2.0 should be preserved.) 

4. Section 4.0 Theory of Operation - Explains why the machine and components operates 

as it does. Defines principles that play an important role in the components 

operations. Describes sequence of machine operations. This theory becomes 

important when the maintenance person cannot solve the problem using the 

Troubleshooting section. 

5. Section 5.0 Operation - Consists of directions that command the readers to perform 

specific operations. The directions are written in the imperative mood (i.e. Place the 

Purge Bypass switch to the “ON” position). Contains Startup and Shutdown 

Procedures. 

6. Section 6.0 Calibration Procedures - Provides clear direction for the calibration of 

components. Reference other manuals that contain the calibration procedures for 

third-party components. 

7. Section 7.0 Troubleshooting - Provides fault isolation steps that correspond to the steps 

outlined in the Operation section. 



APPENDIX 8.1 

8. Section 8.0 Service and Maintenance - Provides recommended preventive maintenance 

checks, procedures and schedule. Refers to third-party manuals as required. 

9. Section 9.0 Recommend Spare Parts list (see paragraph 1.4) 

1.5 Modifications to this format shall be agreed upon in writing by the Project Engineer and the 

vendor. 

1.6 The language of the manual must fit the intended user. Sections 1.0 through 3.0 and 5.0 

should be written for the machine operator and setup person; section 4.0, 7.0 and 8.0 should 

be written for the maintenance technician and section 6.0 should be written for the 

calibration technician.

General Delivery Specifications for Machinery and Equipment - Bosch

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