Procedure Manager

5 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D101[Dynamic] Gatebox with NON-Solenoid Locking Switches
	Open gate
	Anti-Tie-Down of Gate reset
	Anti-Tie Down of Auto Initiate PB
	Anti-Tie-Down of Gate reset - 2nd switch

8 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D102[Dynamic] Gatebox with Solenoid Locking Switches
	Solenoid LOCK Verification
	Ready System to Open Gate
	Solenoid UNLOCK Verification
	Ready system - Request to Enter PB
	Anti-Tie-Down of Gate reset
	Anti-Tie-Down of Gate reset - 2nd switch
	Anti-Tie Down of Auto Initiate PB

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D103[Dynamic] Gateless Gatebox
	Ready System to Open Door
	Ready system - Request to Enter PB
	Anti-Tie-Down of Gate reset
	Anti-Tie-Down of Gate reset - 2nd switch
	Anti-Tie Down of Auto Initiate PB

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D104[Dynamic] Gatebox: Remote Reset Verification for Externally Mounted Switches
	Remote Reset verification
	Remote Reset verification - 2nd switch

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D105[Dynamic] E-STOPS
	Anti-Tie Down of Reset PB

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D106[Dynamic] Intercell Guards (Press Exempt)
	Reset intercell from test cell
	Reset intercell from adjacent cell (this is N/A if crosswalk)

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D107[Dynamic] Perimeter Guards
	Obstruct PSD
	Anti-Tie-Down of Perimeter Guard reset

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D108[Dynamic] Muting PSDs
	Obstruct PSD
	Anti-Tie-Down of Perimeter Guard reset
	Reset PSD

7 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D109[Dynamic] Operator Guards
	Confirm Robots Speed @ 50% Or More
	Obstruct the point-of-operation guard ? robot
	Obstruct the point-of-operation guard ? Major Motion
	Obstruct the point-of-operation guard ? Tooling
	Anti-Tie-Down of point-of-entry Guard reset
	Obstruct PSD - OUTSIDE shared space with Robot

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D110[Dynamic] Station Disable Selector Switch
	Disable Switch Position
	Enable Switch Position

7 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D111[Dynamic] Crosswalks
	Obstruct Guard Side 1
	Anti-Tie-Down of Crosswalk Guard reset - Side 1
	Obstruct Guard Side 2
	Anti-Tie-Down of Crosswalk Guard reset - Side 2
	Crosswalk Prev. Inter-cell Guard obstructed
	Crosswalk Next Inter-cell Guard obstructed

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D112[Dynamic] Gate Switch with MPS-SCS Features
	Open gate
	Anti-Tie-Down of Gate reset at HMI

5 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D113[Dynamic] Intercell Guards AGC Tunnel 1
	Obstruct AGC tunnel Vertical Light Screen
	Reset intercell
	Obstruct AGC tunnel Vertical Light Screen
	Reset intercell

9 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D114[Dyanmic] Perimeter Guards AGC Tunnel 1
	Obstruct perimeter guard (Robot Clear of DCS zone)
	Resume Testing
	Obstruct perimeter guard (Robot In DCS zone)
	Attempt Reset
	Resume Testing
	Anti-Tie-Down of Perimeter Guard reset
	Reset PSD
	Resume Testing

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	D115[Dynamic] Station Disable Box for AGC tunnel
	Test Disable Switch Position
	Attempt Reset
	Test Enable Switch Position
	Resume Testing
	Test Disable Switch Position

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Estop

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Open booth door
	Anti-Tie-Down of perimeter reset on SCC

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Ready System to Open Gate
	Anti-Tie-Down of Gate reset

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Open gate
	Anti-Tie-Down of Gate reset

5 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Open gate & Obstruct Intercell
	Reset intercell from test cell
	Reset intercell from adjacent cell
	Repeat for Press Pos2
	Reset intercell from test cell

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Verify MPS Active Achieved - Adapter Plate Retracted
	Verify MPS Active Not Achieved - Adapter Plate Not Supported
	Verify MPS Active Achieved - Adapter Plate Supported By Rollers
	Verify MPS Active Achieved - Adapter Plate Extended

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS121[Dynamic] PAINTSHOP ONLY: E-STOPS

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS122[Dynamic] PAINTSHOP ONLY: Booth Doors

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS123[Dynamic] PRESS ONLY: Motorized Gate Entry

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS124[Dynamic] PRESS ONLY: Egress Gate

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS125[Dynamic] PRESS ONLY: Intercell Guards

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS126[Dynamic] PRESS ONLY: Automatic Die Change Perimeter Guards

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS127[Dynamic] PRESS ONLY: Request to Enter Within Automatic Die Change Perimeter Guard

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	DS128 [Dynamic] PRESS ONLY: Request to Enter Turnover Press

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F1000[SafetyMat_JBox] Verification of Jumpers
	Ready For Testing
	Check For Jumper on SM1

16 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Press Estop at Cell
	Switch to Bypass
	Press Estop On Generator
	Switch to Bypass
	Pull Maint. Gate Switch
	Reset Maint. Gate Switch
	Open Material Door
	Close Material Door
	Pull Maint. Gate Switch
	Reset Maint. Gate Switch
	Open Material Door
	Close Material Door
	Pull Maint. Gate Switch
	Reset Maint. Gate Switch
	Open Material Door
	Close Material Door

12 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F1200 [Autonomous Fork Truck] Station Interface
	Reset Operator PSD
	AFT obstructs Operator PSD
	Station E-stop
	Reset Station
	Reset AFT
	Automatic Reset of Operator PSD
	Automatic Reset of Operator PSD Disabled while obstructed
	Automatic Reset of Operator PSD Anti-Repeat
	Open gate w/ Rear Rack Guard Obstructed or There is no Rear Rack Guard
	Reset Gate
	Automatic Reset of Operator PSD Disabled with Re-Entry

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F201[Robot] High Speed Teach Disabled & Servo Disable SSW
	Open gate
	Set Cell into SingleRobotTeach mode
	Verify Robot Servo Disable SSW
	Return to Single Robot Teach
	Select robot high speed teach

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F202[Robot] Single Robot Teach
	Select teach for the 2nd robot in the cell
	Try to enable NEXT robot before resetting exposure @ gatebox
	Clear Gatebox Selection

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F203[Robot] GateBox: Multiple Gates Open
	Open TEST gate
	Try to Set Cell into Single Robot mode

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F204[Robot] GateBox: Enabling Pendant
	Pull the enable pendant shorting plug
	Reset enable pendant
	Release enable pendant

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F205[Robot] Intercell Guard
	Open gate & Obstruct Intercell
	Reset intercell from test cell

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F206[Robot] Perimeter Guard
	Perimeter Guard 1

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F208[Robot] Intercell Robot entering from an Adjacent Cell
	Open gate & Obstruct Intercell - Adjacent Cell
	Open gate - TEST Cell
	Test cell - Pos 2
	Select teach for a 2nd robot in the TEST cell
	Select teach for a 2nd robot, Test cell - Pos 3

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F209[Robot] Intercell Robot entering from an Adjacent Cell
	Open gate & Obstruct Intercell - Adjacent Cell
	Open gate - TEST Cell
	Test cell - Pos 2
	Select teach for a 2nd robot in the TEST cell
	Select teach for a 2nd robot, Test cell - Pos 3

5 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F210[Robot] Perimeter Guards for AGC Tunnel 1
	Obstruct Perimeter guard Robot In DCS zone
	Attempt Reset
	Clear Obstruction
	Obstruct Perimeter guard Robot Clear DCS zone

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F301[Conveyor] EOT Installation
	Verify Installation
	Verify Tethering
	Verify Trip Dog

11 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F302[Conveyor] EOT Functional Test
	Actuate EOT Both Switches
	Reset EOT
	Actuate EOT LS1
	Reset EOT LS1
	Reset EOT All
	Actuate EOT LS2
	Reset EOT LS2
	Reset EOTAll
	Actuate EOT with Tool
	Reset EOT

8 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F401[ToolMotion] GateBox: Enabling Pendant
	Open gate
	Place Cell in Unrestricted Mode
	Pull the enable pendant shorting plug
	Reset enable pendant
	Release enable pendant
	Reset enable pendant
	Open another gate in the cell

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F402[ToolMotion] Gatebox Pos 2 Exclusivity
	Tool Exclusivity
	Robot Exclusivity

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F403[ToolMotion] E-Stop
	E-Stop
	HMI Enable PB Anti-Tie down

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F404[ToolMotion] InterCell Guard
	Open gate & Obstruct Intercell
	Reset intercell from test cell

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F405[ToolMotion] Perimeter Guard
	Perimeter Guard 1

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F406[ToolMotion] Operator Guard
	Obstruct Operator Guard
	Clear Operator Guard

8 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F407[ToolMotion] All Tooling Power Verification
	Toggle Enable Pendant Tool Minor: List Qty & Manifold names Here
	For the Main Air Solenoid System : Toggle Enable Pendent Check Minor Motion Valves-
	Verify Operator Guard obstruction Tool Minor Motion: List Qty & Manifold names Here
	Verfiy Oper. Guard clear,(but not reset): List Qty & Manifold names here
	Test for connection to Tool Major: List Qty & Manifold names here
	For the Main Air Solenoid System :Toggle Enable Pendent Check Major Motion Valves
	Test For Manifolds Designed for System Reset Controlled Power: List Qty & Manifold names here

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F408[ToolMotion] Gate Switch with MPS-SCS Features
	Open Gate
	Motion Disabled
	Check "Motion Enable" PB After Gate is Opened
	"Enable Motion" Selected
	Open Another Gate (N/A if only 1 gate for cell)

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F409[Tool Motion] Perimeter Guard for AGC Tunnel 1
	Obstruct Perimeter guard
	Attempt Reset
	Reset Perimeter Guard

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Pull the Enable Pendant Shorting Plug
	Reset Enabling Pendant
	Release Enabling Pendant
	"Enable Motion" Selected
	Reset Enable Pendant
	Open Another Gate In Cell

9 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Installation of 2 Hand Control Device
	Construction of 2 Hand Control Device
	Motion Enabled with both hand control devices activated
	Motion Disabled with hand control device 1 released and device 2 activated
	Motion Disabled with hand control device 2 released and device 1 activated
	Motion Disabled with both hand control devices released
	Momentary Release of Hand Control device 1 with Hand Control Device 2 activated
	Momentary Release of Hand Control device 2 with Hand Control Device 1 activated
	Cycle AntiRepeat

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F500[E-STOPS] Setup Verification
	Press E-Stop @ the SCC or one HMI
	Reset

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F501[E-STOPS] All Cell Estops Verification
	E-stop
	Clear E-stop

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F502[E-STOPS] Adjacent Cell Verification
	E-stop On Adjacent Cell
	Clear E-stop

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F503[E-STOPS] PRESS ONLY: Die Blocks
	Die Block Switch At one column
	Reset

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F504[E-STOPS] PRESS ONLY: ALL Die Block Verification and Count
	Die Block Switch @ Col
	Reset

7 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Estop (When Not Bypassed)
	Clear Estop
	Intercell Safety Device (When Not Bypassed) N/A if no Intercell owned by Tool
	Select "Bypass" for Online Tool/Cell
	Tool/Cell Motion Disabled
	Estop (When Bypassed)
	Intercell Safety Device (When Bypassed) N/A if no Intercell owned by Tool

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F600 [Station Disable] Setup Verification
	Identify Devices to be controlled by Box
	Ensure Robot(s) are in shared workspace

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F601 [Station Disable] Individual Box Verification
	Station or Robot - Motion 1
	Station or Robot - Motion 1

7 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F602 [Station Disable] Disable with Gatebox Verification
	Release Gate Switch, Gatebox Position 1
	Teach Pendant Verification
	Release Gate Switch, Gatebox Position 2
	Teach Pendant Verification
	Release Gate Switch, Gatebox Position 3
	Teach Pendant Verification

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F603 [GateBox] Verify Reset Lost if Slide Lock Raised and any gate is opened (Applies only to G16 or > GateBoxes with Vertical Lock Slides, i.e. ECS-5011)
	Ready for Testing
	Open another gate in cell
	Reset other gate in cell

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F700[PSD] Initial Conditions
	Operator Guard Maintenance Switch - Configuration Verification

5 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F701[PSD] Cascading Configuration Check - Legacy
	Verify connections
	Verify cascaded connections
	Verify DIP switch settings - single pair
	Verify DIP switch settings - cascaded pair

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F702[PSD] Operator Station, No Turntable
	Obstruct PSD (Major Motion check)
	Attempt Reset

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F703[PSD] Operator Station Turntable
	Obstruct PSD (Major Motion check)
	Attempt Reset

7 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F704[PSD] Operator Guard Maintenance Switch
	Obstruct PSD
	Check Robot is disabled
	Check Operator Guard Switch
	Clear PSD
	Previous Steps Checked For Every Robot That Enters Shared Space
	Previous Steps Checked For Every TTBL Position and Not in Position

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F705[PSD] Intercell
	Test intercell PSD
	Reset Test Cell

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F706[PSD] Intercell Operator Deck
	Test intercell PSD 1
	Reset Test Cell

7 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F707[PSD] Crosswalk
	Obstruct PSD on Crosswalk (Open Gate for O/H geo pallet crosswalk)
	Attempt Reset
	UpstreamCellAdjHazard 1
	UpstreamCellAdjHazard 4
	DownstreamCellAdjHazard 1
	DownstreamCellAdjHazard 4

5 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F708[PSD] Intercell Chaining
	Test Intercell for 1st Cell
	Reset Cells
	Repeat testing from Last Cell
	Test Intercell for 1st Cell

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F709[PSD] Reach In Operator Station
	Obstruct Reach In PSD (Major Motion check)

8 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F801[MotorDriven] Gatebox
	Open gate
	Place Cell in Unrestricted Mode
	Connect Enabling Pendant
	Reset enable pendant
	Place Gatebox in POS2
	Place Gatebox in POS3
	Open another gate in the cell

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F802[MotorDriven] Intercell Guard
	Open gate & Obstruct Intercell
	Reset intercell from test cell

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F803[MotorDriven] Perimeter Guard
	Perimeter Guard 1

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F804[MotorDriven] Operator Guard
	Obstruct Operator Guard (N/A if this motion is not in this Operator Station)
	Clear Operator Guard (N/A if this motion is not in this Operator Station)

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F805[MotorDriven] Crosswalk
	Anti-TieDown of Crosswalk Guard reset - Side 1
	Anti-TieDown of Crosswalk Guard reset - Side 2

5 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Obstruct Operator Guard - Stop Lowered
	Reset Operator Guard
	Obstruct Operator Guard - Stop Raised
	Reset Operator Guard
	F806[MotorDriven] Retractable Safety Stop (cont'd)

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F807[MotorDriven] Conveyor Pull Cord
	Actuate Pull Cord - Conveyor Motor Stopped
	Reset Pull Cord - Start Conveyor Motor

6 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F808[Adjacent Cell MotorDriven] Gatebox
	Open gate
	Place Cell in Unrestricted Mode
	Connect Enabling Pendant (N/A if no enabling pendant connectivity box)
	Reset enable pendant (N/A if no enabling pendantconnectivity box)
	Place Gatebox in POS2 (N/A if testing SCS/MPS gate switch/not MPS gatebox)

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	F809[MotorDriven] Gate Switch (MPS add-on module)
	Open Gate
	"Enable Motion" Selected

1 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	Open gate & Obstruct Intercell [For CAMI only - horn should sound momentarily when Intercell reset is lost]

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	P000 [PreTest] Data Collection
	Obtain Prints
	Obtain Safety Device Layout Sheet ( ie. Sheet 6A, MEGA F02, etc) of System Layout
	Walk Around The Cell & Verify Hardware

7 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	P001[PreTest] Safety Task Configuration
	Verify all SCS I/O devices are present & correctly configured
	Verify Logix Configuration
	Compare Device Checklist
	Temporary Edits Removed
	Inhibit Unused motion output receptacles
	Check Robot Password Configuration

10 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	P002[PreTest] Guarding
	Guarding Effectiveness - Operator Guards
	Guarding Effectiveness - Awareness
	Guarding Safe Distance - penetration factor
	Guarding Safe Distance - Stopping Time Distance
	Guarding can't be easily defeated
	Guarding can't be easily removed
	PSD indicator for personnel
	Operator White Light PSD Checks
	POWERTRAIN ONLY - G-RISK Assessment

3 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	P003[Robot] DCS Zones - Checklist
	Identify All utilized DCS zones
	Review & Compare Documentation

4 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	P004[Robot] Rxx.I.ConfigMatch - Checklist
	Initial Conditions
	Make Robot DCS Change
	Undo DCS Change

2 procedures

Step #	Description	Perform Action	Verify / Results	Notes	Action
	P005[Robot] Collaborative Robot - Checklist
	Review & Compare Documentation

Procedure Database Manager