Cell: BIW spot / seal hybrid (anonymized)
Status claimed by integrator: “ready for production tryout”
Status per punch list: 37 open items (excerpt below)
Tone: ledger, not hero story
This brief is a living punch list—the commissioning format plants actually fight over—not a glossy FAT photo.
OPEN — Safety & safeguarding
| ID | Item | Age (days) | Blocker | | --- | --- | --- | --- | | S-04 | Scanner mute timing sheet unsigned | 11 | Safety eng travel | | S-09 | Temporary bypass zip-tie on light curtain OSSD “for teach” | 3 | Must remove before tryout | | S-12 | Fence door interlock chatter at south gate | 6 | Parts on order |
Rule: any temporary safety defeat = automatic RED. No tryout.
If the bypass is still zip-tied, the cell is not commissioned.
OPEN — Process & path
| ID | Item | Note | | --- | --- | --- | | P-02 | Seal bead path at takt +10% not proven | Only proven at teach speed | | P-07 | Tip dresser interval not in CMMS | Tribal card on the booth | | P-11 | Payload/inertia data for EOAT revision B missing | Program still on revision A mass |
P-11 alone explains yesterday’s “mystery” following error.
OPEN — Controls & data
| ID | Item | Note | | --- | --- | --- | | C-01 | Safety logic hash ≠ binder printout | Download happened Sunday | | C-05 | MES complete bit fires before clamp confirm | Will invent false throughput | | C-08 | No backup of robot image to plant escrow | Integrator laptop only |
CLOSED recently (do not celebrate yet)
| ID | Closed how | Residual risk | | --- | --- | --- | | M-03 | Cable carrier replaced | Flex-life counter still not enabled | | Q-01 | Torque tool calibrated | Certificate photo in chat, not QMS |
Closed without residual owners is how punch lists reincarnate after SOP sign-off.
Green stickies without hashes are interior design.
Tryout gate (non-negotiable)
Production tryout may start only when:
- Zero RED safety items
- Safety hash matches signed binder
- Payload/inertia matches installed EOAT
- MES bits match physical confirms
- Robot image in plant escrow
Integrator verbal “basically done” is not a gate.
Adjacent fences
Safety scanner muting protocols own mute proofs. Dress-pack guides own environment grease/cables. Tool-changer briefs own dock seals. Digital twin commissioning essays own simulation theater. None of them replace the brutal honesty of an open punch list with ages. Do not run a twin demo to hide S-09.
Close
Commissioning is not power-on. It is a ledger that reaches zero RED—and stays there under change control. Punch list 37 is every cell you called finished because the robot moved.