Mercedes-Benz Cars Quality Standard for Vehicle ... · This quality standard was prepared by the central quality organization of the Mercedes-Benz Car Group by the purpose of validating

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Mercedes Benz Version 4.0 from 01.03.2020 Quality guideline and process standards

Mercedes-Benz Cars

Quality Standard for Vehicle Distribution

Center

Planning and Processes

Author: Markus Bopp

Sindelfingen, QM/KQR, +49 151 58609307

Date of approval: 01stth March 2020

Approved by : Petra Hönig and Marcel Voigt

------------------------------------- ---------------------------------------

P. Hönig M. Voigt

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Table of Contents

1. Introduction ............................................................................................................................. 5

2. Planning .................................................................................................................................... 6

2.1 Geographical Location .............................................................................................................................. 6

2.2 Logistics Infrastructure ............................................................................................................................. 7

2.3 Dimensioning of the Location .................................................................................................................. 7

2.4 Environment .............................................................................................................................................. 8

3. Requirements for the Logistics Center ................................................................................ 9

3.1 Outdoor Facility ....................................................................................................................................... 10

3.2 Supply Infrastructure .............................................................................................................................. 12

3.3 Main Plant Building (VPC) ....................................................................................................................... 12

3.3.1 Areas in the Logistics Center ............................................................................................................. 16

3.3.2 Dimensioning of the Workshop .......................................................................................................... 18

3.4 Workshop Equipment .............................................................................................................................. 19

3.5 Selection of the Service Provider ........................................................................................................... 21

4. Daimler AG Standard ............................................................................................................ 22

4.1 Assessment of Painted Vehicle Surfaces .............................................................................................. 22

4.3 Central Standards Catalog ..................................................................................................................... 28

4.4 Surface Defects ....................................................................................................................................... 29

4.5 Assessment of the Interior/Product Protection ................................................................................... 29

4.6 Problem Categories................................................................................................................................. 30

5. Processes ............................................................................................................................... 35

5.1 Car Wash ................................................................................................................................................. 36

5.1.1 Automatic Car Wash ........................................................................................................................... 37

5.1.2 Automatic Underbody Wash ............................................................................................................... 40

5.1.3 Manual Car Wash ................................................................................................................................ 41

5.1.4 Manual Underbody Wash (Only for < 25 Vehicles per Day).............................................................. 45

5.1.5 Acid Car Wash ..................................................................................................................................... 48

5.2 Vehicle Standard Check in the VPC ....................................................................................................... 50

5.2.1 Vehicle Preparation ............................................................................................................................. 50

5.2.2 Vehicle Inspection – "Vehicle Standard Check" (VSC) ..................................................................... 51

5.2.3 Vehicle Finish....................................................................................................................................... 58

5.3 Vehicle Repair ......................................................................................................................................... 59

5.3.1 Workshop ............................................................................................................................................. 60

5.3.2 Repair Process ..................................................................................................................................... 62

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5.3.3 Spare Parts Storage ............................................................................................................................ 66

5.3.4 Campaign Management ...................................................................................................................... 67

5.3.5 Equipment of Employees According to the OM................................................................................. 68

5.3.6 Vehicle Handling According to the OM .............................................................................................. 69

5.4 Quality Control ........................................................................................................................................ 70

5.5 Waxing Process ....................................................................................................................................... 75

5.6 Battery Care (Valid for Mercedes-Benz Passenger Cars and smart) ................................................... 79

5.6.1 Vehicles with Transport Mode ............................................................................................................ 80

5.6.2 General handling of 12 Volt Batteries ................................................................................................ 82

5.6.3 General Handling of High-Voltage Batteries ...................................................................................... 83

5.6.4 Battery Care for Vehicle Logistic Center (VLC) ................................................................................. 85

5.6.5 Battery Care Process at Seaports ...................................................................................................... 86

5.6.6 Battery Care Process at Vehicle Preparation Center (VPC) ............................................................. 86

5.7 Vehicle Maintenance Program during Storage in the VPC ................................................................... 87

5.8 QM System .............................................................................................................................................. 89

6. Process Audit ......................................................................................................................... 96

7. Contacts for Logistics Topics .............................................................................................. 97

8. List of Abbreviations ............................................................................................................. 98

9. Table of Figures ..................................................................................................................... 99

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Changes:

Date Content/topic Page

01.03.20 Selection of the service provider 21

01.03.20 Assessment of the Interior/Product Protection 29

01.03.20 Problem Categories 30

01.03.20 Vehicle Standard Check in the VPC 50

01.03.20 Vehicle Inspection – “Vehicle Standard Check” (VSC) 51

01.03.20 Vehicle Finish 58

01.03.20 Campaign Management 68

01.03.20 Battery Care 79

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1. Introduction The number of requirements in vehicle distribution is continuing to increase on a global scale and these requirements

are becoming more and more complex. Taking this fact as an incentive, Mercedes-Benz examined its logistics network

in order to ensure that it satisfies the future requirements, e.g. the increasing volume of vehicles or the complete

processing of vehicles, including those with alternative drive systems.

Nowadays, we need logistics partners whose service providers have modern distribution center. They need to be highly

efficient and dynamic in order to react to the constantly changing requirements of global vehicle logistics. This enables

smooth and standardized processing of the products.

Mercedes-Benz has created this Standard for Distribution Center to support its logistics partners and help them to

advance. The aim is to maintain the high quality of the vehicles throughout the entire transport. A standardized profile

of requirements serves as a planning basis for the distribution center and helps them to plan new logistics locations or

conversions. For specifications regarding logistics processes, (see page 9).

This quality standard was prepared by the central quality organization of the Mercedes-Benz Car Group by the purpose

of validating the delivery quality of Mercedes-Benz vehicles. Furthermore, it forms the basis for the commissioning of

services and for audits.

If you have any questions, please contact:

Daimler AG

Markus Bopp

Team Quality Management Product Audit QM/KQR, Sindelfingen plant

[email protected]

Tel.: +4915158609307

The principles of this standard are:

General requirements from the central specialist departments regarding logistics locations

Operations manual (quality manual for logistics)

Q maintenance standards for vehicles

Standard plans

GSP repair audit

Mercedes-Benz standard for surfaces

The core areas of this standard are:

Planning of distribution center

•Location

•Environment

Requirements for distribution center

•Buildings

•Open areas and storage areas

•Multi-level car park

•Loading zone

Process standards

•Vehicle inspection

•Vehicle repair

•Quality management

•Audits

mailto:[email protected]

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2. Planning Regardless of whether a new facility is built or an existing facility is converted, planning of vehicle logistics centers,

including buildings, multi-story car parks, parking areas, and loading areas, requires a project team that consists of the

departments listed below. The Market Performance Center (MPC), which is normally responsible for such a project,

informs the local and central units and arranges a first workshop meeting.

The required specialist departments are:

FP/DRE Corporate Real Estate Management

SC/WTP Weltweite Transportlogistik Fahrzeuge (Global Transport Vehicle logistics)

INS/CI Daimler Versicherungs Service (Daimler Insurance Service)

CS/SI Konzernsicherheit Standorte (Corporate Security for Locations)

IPS Einkauf Logistik Dienstleistungen (Procurement Logistics Services) (logistics centers incl. equipment and

processes)

QM/KQR Qualitätsbereich Produktaudit (Product Audit Quality Area)

The aim is to first determine the market requirements exactly, localize appropriate areas/buildings by means of

invitations to tender and find investors if necessary. The operator model shall also be determined; internal (MPC) or

external (service provider) contract award. The project business case shall be created based on these parameters; a

steering committee monitors the individual project steps up to final approval by the EXCOM. In general, all logistics-

relevant construction projects of Daimler AG and its logistics partners shall be handled in this way.

Key planning contents are:

Strategic planning of the volume of vehicles as part of the 10-year forecast, CBU/CKD volume

Real estate market analysis (search for real estate and location evaluation)

Market-specific guidelines and laws

Safety guidelines specified by the Accident Prevention and Insurance Association,

State building laws

Fire prevention regulations

Work safety

Tax law regarding repairs incl. parts supply

Requirements and guidelines of the responsible insurance company

Investigation of/check on the ownership structure

Leasing/purchase of a VPC building

In-house operation/subcontracted operation of the VPC

Holistic examination of the project by Corporate Security regarding property protection, theft, etc.

See document B82: http://erd3.e.corpintra.net/ERD/Home/Search#search=B+82&sort=0_0

References:

Consulting area: FP/DRE and QM/KQR

Aids, check lists: "User requirements", "Market research profile" and "General requirements"

2.1 Geographical Location The geographical location of a logistics location is normally based on the existing local conditions, e.g.

Location of the seaport

Existing distribution center

Traffic infrastructure

Market-specific regulatory specifications

Sales requirements of the target market

Availability of suitable areas.

Regardless of the geographical location, a risk analysis based on the geographical data of the location shall be

performed together with Daimler Insurance and focus on earthquakes, floods and hail, for example, and the general

requirements of the responsible insurance companies shall be obtained for the project.

A VPC location should not be located more than two kilometers from a Deep- Sea port. Should it not possible to stay

within this distance, the planning shall take into consideration the fact that all vehicles need to be transported from the

port to the VPC location by truck. It is prohibited to transport the vehicles on their own wheels.

References:

Additional document: General VPC Requirements "Location"

http://erd3.e.corpintra.net/ERD/Home/Search#search=B+82&sort=0_0

mailto:[email protected]?subject=Dokument%20VPC%20Requirements%20%22Location%22%20-%20Bitte%20um%20Zusendung

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Consulting area: INS/CI and SC/WTP

Figure 1: Risk analysis

2.2 Logistics Infrastructure Daimler AG operates a global logistics network for the transport of new vehicles. The locations shall fit into the network

in terms of their location and shall be checked with regard to their economic efficiency. Transfer depots with good

connections to highways or freeways, train connections with loading ramps for passenger cars, or compounds in the

direct vicinity of a seaport are preferred. Ports shall fulfill the requirements for RoRo shipping traffic (deep sea port).

The specialist department can provide more detailed information on this topic.

References:

Consulting area: SC/WTP u. QM/KQR

2.3 Dimensioning of the Location The strategic 10-year plan for the market in question forms the basis for specifying the dimensioning of the location.

The number of vehicles that will pass through the location every day can be derived from this. The overall area that is

needed, including all areas constructed for traffic, and the required building area can be calculated on this basis. The

preliminary test on the general usability of the target area or the existing facility can be performed in due consideration

of this data. The location shall be checked in terms of its expansion potential (option to add further areas, buildings,

etc.).

The area shall be dimensioned such that all necessary and location-specific logistics processes can be performed and

the vehicles can be stored safely.

References:

Additional document: Standard plans / Operations Manual

Consulting area: FP/DRE u. SC/WTP

Hail

Tornado

Storm

Storm flood

Flood

Tsunami

Earthquake

Volcanic

activity

Risk analysis summary

Further investigations required

Insignificant Noticeable Very high

Advisable Necessary

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2.4 Environment The influence of the immediate surroundings shall be examined when setting up a new logistics location or evaluating

existing locations. Should certain lines of industry be located in the immediate vicinity of a potential logistics location,

they shall always be assessed critically. Heavy industry in particular, e.g. iron and steel processing, refineries, paper

and cement factories, has an extremely negative effect on openly stored vehicles. Ore and iron dust lead to paintwork

damage caused by oxidation. Emissions from the food and primary industries can also cause severe surface damage.

For this reason, a safe distance of at least 2000 meters to such companies and their plants shall be kept, or it shall be

ensured that the entire volume of vehicles is under cover while in storage. The SC/WTP and QM/KQR specialist

departments can answer general questions regarding the location quality of VPCs. Detailed location analyses have to

be submitted to Daimler Insurance.

References:

Additional document: Operations Manual

Guideline on shipment and storage areas


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3. Requirements for the Logistics Center The logistics center shall be equipped and conditioned as is appropriate to its purpose and setup, so that the following

processes can be ensured:

Loading and unloading of the corresponding transportation vehicles

Storage and maintenance of vehicles

Automatic car wash

Vehicle inspection and necessary repair

Body repair and paintwork

The following shall be taken into account:

Gate area with a visitors' office

Office building for dispatching with sanitary facilities for the employees working in the storage area and the truck

drivers

(integrated in the gate area, depending on the conditions)

Storage area

Car wash

Workshop building with a storage area for spare parts and a paint shop

Cafeteria, break rooms, sanitary facilities

Offices, classrooms, meeting rooms, etc.

References

Additional document: Operations manual

General Requirements for VPC, "Facility" and "VPC Building"


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3.1 Outdoor Facility

Access road

The access road to the distribution center shall be marked with an information sign that is clearly visible and complies

with CI. Parking spaces for visitors and stopping zones for trucks shall be provided in front of the gate area.

The gate house in the access area shall be staffed 24 hours a day. This is where the transportation companies that

deliver and collect goods receive their instructions and shipping documents. The access and safety checks as well as

all necessary instructions for visitors (returning ID cards, code of conduct, etc.) are handed out there.

Safety and security

The entire area shall be surrounded by a security fence and equipped with an alarm system and video monitoring. The

minimum recording period for video monitoring is one month. Sturdy gates shall allow rail connection areas to be firmly

locked. Further security systems, e.g. drive-through protection or trenches around the facility, shall be installed

(SC/WTP specialist department). A maximum permissible speed of 40 km/h shall be ensured by means of traffic signs.

Employee parking spaces

These areas shall be located outside the premises near the gate (SC/WTP specialist department).

Roads and storage areas

Traffic and information signs as well as mirrors shall be installed in critical spots to ensure a safe traffic flow and safe

distribution haulage on the premises.

The entire floor area of the logistics center shall be equipped with drains such that reliable water runoff is ensured even

in heavy rain (see country-specific amounts). It is conceivable to design the parking areas on a slope so that the water

can drain off into surrounding trenches. The dimensioning, setup and equipment of the individual areas shall be carried

out according to the specifications in the specialist department's OM.

The entire vehicle storage area shall be set up appropriate to the volume of vehicles to the inspected every day.

The required vehicle storage area and the average number of parking spaces are calculated as follows:

Storage factor

𝑉𝑒ℎ𝑖𝑐𝑙𝑒 𝑠𝑡𝑜𝑟𝑎𝑔𝑒 a𝑟𝑒𝑎 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑣𝑒ℎ𝑖𝑐𝑙𝑒𝑠 𝑡𝑜 be 𝑐ℎ𝑒𝑐𝑘𝑒𝑑 𝑝𝑒𝑟

𝑑𝑎𝑦 𝑥 30 𝑥 𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑓𝑎𝑐𝑡𝑜𝑟

The individual storage factor of a logistics center shall be determined taking all relevant influencing factors of the

market into account. The storage factor for logistics centers lies between 0.90 and 1.27. It depends on the

following factors:

Performance of campaign management (short-term increase in unit figures)

Mixture of CBU and CKD vehicles (long-term storage of CKD vehicles – tax advantages)

Market characteristics, built to stock (BTS) or built to order (BTO) (BTS generally has higher storage volumes)

An open-air parking space shall have dimensions of 2.6 m x 5.5 m and allow each vehicle to be accessed

individually.

The ceilings of multi-level car parks require a payload of at least 0.5 tons per m².

If necessary, the width of the lanes in a multi-level car park/warehouse shall be specified as is appropriate for the

project.

The size of the parking spaces in a multi-level car park/warehouse shall correspond to the size of a parking space

in an open-air parking area.

It shall be specified in the project if necessary. (Multi-story car park standards)

Warehouses shall be 2.5 m high.

The lighting in the storage area shall have an illuminance of at least 200 lux.

The general aim shall be to provide covered storage for special vehicles, e.g. AMG GT, vehicles with high-voltage

technology or vehicles with special paint finishes such as “Magno / matt paint”.

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Figure 2: Example of an outdoor facility

Battery care area

A covered battery charging station shall be set up in the storage area, ideally in combination with covered storage

(multi-level car park/warehouse, etc.). Alternatively, batteries can be maintained in the workshop area. Two battery

quick chargers shall be provided per approx. 100 vehicles in long-term storage.

Depending on its product range of vehicles with high-voltage batteries, each location shall also provide at least two

high-voltage charging stations/wall boxes per approx. 100 electric/hybrid vehicles. The calculation is performed on the

basis of the average storage of the vehicles and the model mix of the market.

(See https://aftersales.daimler.com.)

Truck loading and unloading zones + first point of rest (FPOR)

This area is clearly separated from the storage area (ideally by a fence). The loading area shall be paved with asphalt, or

concrete in hot countries. A shipping area of approx. 7,500 m² should be provided for an annual volume of up to

approx. 25,000 units and a shipping area of approx. 15,000 m² should be provided for an annual volume of approx.

50,000 units. This area is clearly marked with color marking, road signs and signs. It shall be ensured that there is

sufficient light for carrying out the acceptance check after unloading.

Preliminary storage area

Before the vehicles are subjected to the actual inspection, they shall be provided in an area that is intended for this

purpose. Minor preparatory work can be performed here. This way, it is obvious that the vehicles belong to a special

allocation share and need not be marked specially. The preliminary storage area should be directly adjacent to the main

plant building. The required surface area is determined by the daily throughput volume of the check area (QM/KQR

department).

Markings

The traffic flow and storage of the vehicles shall be regulated clearly by means of floor markings on all surfaces and

lanes; these markings shall be implemented according to the specifications in the specialist department's OM.

References:

Additional document: Operations manual

Guideline on shipment and storage areas

Consulting area: SC/WTP and QM/KQR

https://aftersales.i.daimler.com/

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Figure 3: Truck loading and unloading area (example)

3.2 Supply Infrastructure

Electricity

A continuous and sufficient power supply that is appropriate for the equipment shall be ensured; an emergency power

supply shall be planned if necessary (market-dependent). Separate electricity meters shall be installed in the case that

external companies/service providers are commissioned.

Water

A continuous and reliable water supply shall be ensured, taking into account the water required by automatic systems

for extinguishing fires and by an automatic car wash. The parameters of such systems shall be obtained in advance. If a

service provider is involved, separate water meters shall be installed as required.

Communication

Telephone/data lines shall be available for trouble-free communication.

3.3 Main Plant Building (VPC)

Layout planning

For operating a VPC, it is recommended to plan a central main building where all the process steps and manufacturing

areas (car wash to final vehicle inspection) can be realized, see Layout PDI Center.

Plants with an annual volume of up to 25,000 units require a ground area of approx. 4,500 m², while plants with an

annual volume of up to 50,000 units require an area of approx. 9,000 m² (e.g. 75 m x 120 m).

This allows all relevant systems and stations to be accommodated, e.g. car wash, drying area, inspection area, electric

trolley and conveyor systems, workshop area, parts and paint storage areas, paint shop and quality control.

The building should be central and close to the vehicle storage area/multi-level car park. The workshop and the storage

areas for spare parts shall be planned according to the standard plans of Daimler AG.

The FP/DRE specialist department (Daimler Real Estate) creates and manages all the standard plans (construction

plans/layout plans) used for planning the workshops for all Mercedes-Benz divisions. The specifications given in the

standard plans are based on the experts' years of experience and specialized knowledge.

Assigning the planning of a workshop building to the FP/DRE specialist department offers the following advantages:

Global experience in planning, implementing and supervising workshop projects.

Standard plans for workshops help Mercedes-Benz partners/companies with the planning, setup and

implementation of conversions and new buildings.

False investments are avoided thanks to specified dimensions and suggestions for the setup.

Inexpensive planning by reducing the planning effort.

Optimized procedures in the workshop are taken into account during functional planning.

A workshop layout approved by the FP/DRE specialist department forms the basis for structured and safe working in

the workshop.

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Important aspects on planning the facilities

Depending on the location or the area, the plant buildings and plants shall be designed and built to withstand

earthquakes.

Fire protection measures, e.g. sprinkler systems and connections for firefighting water, shall be planned and

installed. The market-specific specifications and laws shall be considered and implemented with top priority.

An appropriate special permit for the market shall be obtained for operating a paintwork facility.

Oil separators shall be installed on all assembly, repair and water drains of the car wash.

The building shall be equipped with a heating/ventilation system. In tropical countries in particular, it is

recommended to install additional ventilators or possibly air conditioning.

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Layout of the inspection area

Depending on the market requirement, the available space and other factors, the area for the vehicle inspection within

the main building can be equipped with either a conveyor belt system or individual workstations.

The following figures show examples of alternative VPC layouts:

Figure 4: VPC Baltimore, individual workstations arranged in a fish-bone pattern (example)

Figure 5: VPC Shanghai, conveyor belt systems (example)

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Safety

Safety instructions, warning notices and emergency exit signs shall be in place in the buildings where they are easy

to see.

Fire extinguishers and fire protection equipment shall be provided in every area of the facility; they shall be easy to

access and operate.

Shop entrances and exits shall be equipped with an automatic express gate.

Suitable safety measures shall be in place, e.g. on pillars, corners and edges.

Lanes within the buildings, as well as gates and passages, shall be at least 7 meters wide.

Information signs and mirrors shall be installed to ensure a smooth and safe traffic flow.

Communication and IT infrastructure

The IT basics shall be established to ensure a smooth work procedure in the logistics center:

IT server room

WLAN and LAN networks (for online flash processes)

High-speed internet for secure and stable Xentry Diagnostics updates (SCN coding, etc.).

For detailed information on the national organization or the After-Sales platform of Daimler AG, please visit

https://aftersales.daimler.com

VPC system (e.g. IVIS, DMS, etc. incl. email inbox and outbox)

EVA/VEGA connection

Online access to Star diagnosis

Access to WIS/TIPS/EPC

GO/DISY connection

Connection to AM Plus/CIT/INTAKT (only for campaign management)

Connection to Q-DOME (recording of transport damage)

Internet access

Mobile amplifier (CDMA amplifier)

Environmental and Energy Management

The logistics location is to be planned with consideration of the Corporate Policy of Environmental and Energy

Management and operated. (http://erd3.e.corpintra.net/ERD/Home/Rule/1122)

Employee catering

The facility shall be equipped with a cafeteria, break and recreation rooms, as well as sanitary facilities that are

sufficient for the number of employees.


http://erd3.e.corpintra.net/ERD/Home/Rule/1122

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3.3.1 Areas in the Logistics Center

Car wash

The basic design of this part of the building is based on the manufacturer's specifications. The planning forms and the

requirements for an automatic car wash shall be taken into consideration. A conveyor-type car wash requires an area of

approx. 300 m².

A sufficient water supply, of at least 300 liters per minute per washing unit for the main wash, shall be ensured. The car

wash shall have a wastewater treatment system and a water recycling system.

In order to prevent the water from being carried over to the next process, the washed vehicle shall be stored

temporarily in a preliminary storage area with a drainage system that is covered with a grating.

Inspection and workshop areas including the final inspection (see also Daimler standard plans):

The room shall be at least 4.5 m high. The entire floor surface shall be made of antiskid material or be covered with an

appropriate coating. The floor surface shall be marked according to the standards specified by Daimler AG. The

standard dimensions of a workshop workstation are 5 x 8 m (40 m²). A tire station of roughly 30 m² (7.5 m x 4 m) for

mounting tires, an area for temporary tire storage, and mounting tools shall be set up.

Paint shop:

An area with bays, an area for storing parts, workstations with lifting platforms and paintwork and drying booths shall

be provided for body repairs and paintwork.

A spot repair workstation with a suction mechanism for minor paintwork shall be provided in addition.

A storage room for the paint and a separate color-mix booth are also required (observe legal provisions).

Quality assurance:

Two workstations for quality control shall be provided. One test station shall be equipped with a lighting system that

provides an illuminance of 1,000 lux. A second test station shall be equipped with a standard lifting platform.

Required surface area:

Surface Company processing

up to 25,000 units

Company processing

up to 50,000 units

Whole building approx. 4,500 m² approx. 9,000 m²

Sub-areas included:

Vehicle inspection area approx. 1,500 m² approx. 3,000 m²

Workshop approx. 750 m² approx. 1,500 m²

Tire station approx. 20 m² approx. 40 m²

Paint shop approx. 700 m² approx. 1,200 m²

Office rooms and meeting rooms approx. 300 m² approx. 400 m²

Sanitary facilities approx. 40 m² approx. 80 m²

Restrooms approx. 20 m² approx. 30 m²

Cafeteria and break room approx. 50 m² approx. 100 m²

Car wash with portal/conveyor, according to volume of

vehicles

approx. 100 m²/

300 m²

approx. 300 m²

Wash area with vehicle lift and high pressure water

blaster

approx. 40 m² Approx. 80 m²

Removed parts under warranty approx. 60 m² approx. 120 m²

Spare parts approx. 120 m² approx. 240 m²

Manuals, instructions and accessories approx. 40 m² approx. 80 m²

Removed parts approx. 40 m² approx. 80 m²

Large tools (vehicle jacks, filling unit for air

conditioning, etc.)

approx. 30 m² approx. 50 m²

Special tools, e.g. DAS systems approx. 10 m² approx. 20 m²

Building design (approx. 8% for walls, pillars, etc.) approx. 360 m² approx. 720 m²

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Lighting:

Workplace lighting Illuminance in lux

Lanes and parking spaces inside the building at least 300 lux

Workshop at least 500 lux

Inspection / Check area or Light tunnel (surface check) at least 1,000 lux (see Daimler AG standard, p. 22 )

Vehicle handover at least 500 lux

Vehicle warehouse at least 200 lux

Figure 6: Illuminance measurement (example)

Infrastructure

Climate control

Depending on the climate in the respective country, the workshop area and the paint shop shall be equipped with

HVAC systems to satisfy the required working conditions all year round (according to WIS/market-specific work safety

regulations, etc.).

Electricity

Each workstation in the workshop requires 240 V and 380 V power connections.

IT connection

Each workstation requires a LAN connection for processing flash procedures on vehicles in a reliable way. Furthermore,

WLAN should be installed in the entire building.

Compressed air

Each workstation requires a compressed air connection. Ideally, the individual workstations are supplied with power

from the shop ceiling. This optimizes the work processes and reduces the risk of accidents.

Exhaust extraction system

An air extraction system and an MB Cars-specific exhaust hose system shall be provided in the workshop area for

extracting vehicle exhaust.

Maintenance

All areas of the logistics facility shall be cleaned and maintained on a regular basis, at least once per month.

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Waste disposal and elimination of pollutants

General waste and all residues shall be collected separately in a recycling station. The recycling station provides waste

containers for the following types of waste:

Ferrous metals

Aluminum

Glass

Plastic

Paper

Residues containing oil

Emptied oil containers

General waste

It is mandatory to observe the separation of waste for the purpose of promoting an environmentally friendly economy

(refer to the environmental guideline of Daimler AG).

3.3.2 Dimensioning of the Workshop The dimensions of a VPC workshop with a paint shop depend on the location's daily throughput of vehicles.

The following workstations shall be taken into account for a company with an annual volume of up to 25,000 units

(single-shift operation/5-day week):

6 workstations in the workshop for mechanical and electrical repairs

10 workstations in the workshop for body and paint preparation (two of which for spot repairs)

2 Q gate workstations

Depending on the location, an additional approx. 50% of workshop workstations (mechanics/electrics) shall be

provided for carrying out plant campaigns.

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3.4 Workshop Equipment A workshop shall generally be equipped with high-quality tools in order to perform pending repairs of Mercedes-Benz

vehicles in an optimum way. Existing tools and workshop equipment that are OK from a technical perspective and that

fulfill the basic technical requirements (e.g. payload of a vehicle lift) can continue to be used temporarily. Before

replacing a tool or procuring a new one, the entrepreneur shall obtain information on the tools approved by Mercedes-

Benz. It makes sense to select manufacturers that are already represented on the market.

You can obtain access to by:


Contents are:

Workshop equipment database

Keyword search: A–Z search structure for repair topics

Product comparison of multiple approved alternatives

Search result with a precise application description, supplier, price, and order number

Possibility to order from the supplier

Additional information on the scope of delivery and accessory parts

Special tools database

Targeted search for individual special tools (name or part number)

Search for vehicle type, class and/or model

Search for test equipment

Detailed view of each special tool: Validity according to the Mercedes-Benz After-Sales standard

Paint technology database

Approved paint manufacturers/market-related

Guidelines on repair paintwork/spot repair

Mercedes-Benz-specific content/specifications

Repair methods for matt/special paint

Tool maintenance shall be performed in accordance with industrial policies or manufacturer's specifications.

A VPC requires the following pieces of equipment and tools

One tool cart with standard tools shall be provided for each mechanic/electrician/bodywork specialist.

Work bays Standard vehicle lift

3.5 t

Heavy duty-vehicle lift

5.0 t

Mechanical systems 4 3 1

Electrical systems 2 1 0

Paintwork and body 10 5 1

Q control 2 1 0

Campaigns (optional) 8 4 0

Total 18/26 10/14 2

Paintwork booth, paintwork and body tools

For a VPC of the size described above, at least one paint booth and two "spot repair" workstations shall be set up. It

makes sense to select a manufacturer that is represented on the market in question and can provide the required

service. Paint spray guns, paintwork equipment and equipment for removing dents and treating the surface are

required.

Star diagnosis

For a VPC of the size described above, 8 or 12 (optional) Star diagnosis devices shall be provided:

4 for the workshop

2 for the final inspection

1 for the Q gate

1 as back-up

4 for campaigns (optional).


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Battery charger

At least 6 mobile chargers and a charger for high-voltage batteries shall be available in the workshop. Ideally, the

location is also equipped with a "Wall box" for recharging the high-voltage batteries of electric vehicles quickly.

Figure 7: Mobile battery charger (example)

Figure 8: Wall box (example)

Special tools

A sufficient number of special tools and spare tools shall be provided for recurring tasks, e.g. torque checks:

Tire mounting and wheel balancing devices

Air conditioning evacuation and filling unit

Midtronics battery testing device

Jumpstarting equipment

Basic ESD kit

A basic ESD kit (electrostatic discharge kit) is mandatory for processing electronic vehicle components, e.g. COMAND.

Processing shall be carried out according to the operating instructions for the kit and the specifications given in WIS.

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3.5 Selection of the Service Provider If the operation of a logistics location will be outsourced rather than it being operated by Daimler AG, the service

portfolio offered is an important selection criterion when choosing the service provider to be commissioned with the

task.

A service provider shall be able to perform the full range of processes described in this standard (see page 31). This

includes the complete processing of the vehicle, from reception to vehicle inspection, repair and storage right up to the

delivery to the dealer.

This is why the local IPS shall enclose this document with the tender documents as a fixed part of the tender (RFQ).

Each participant thus has extensive information regarding the requirements they shall ultimately fulfill and can submit

their tender on this basis.

If service providers that have not yet been contracted by Daimler AG or service providers that have not been contracted

for a number of years submit an application in the context of a logistics tender, these applicants are audited in advance

(pre-audit). The aim of this measure is to check their logistics centers and processes to ensure that they can satisfy

Daimler AG's requirements and standards. One of the key requirements refers to the staff, which should have

appropriate knowledge of MB products/paint manufacturer training, etc. or shall acquire this knowledge by attending

training courses.

The audit focuses on:

The entire plant, open areas and buildings (compound audit, SC/WTP)

Logistics processes, e.g. battery care etc. (process audit, QM/KQR)

The results of the audit are made available to the MPC concerned and thus form the basis for the award decision.

The process flows of a newly contracted service provider are subjected to a process audit performed by QM/KQR

approx. 4–6 weeks after the start of operation to analyze the quality and efficiency of the operation. Depending on the

result of the audit, a follow-up audit is performed within 6, 12 or 24 months.

If two audits in a row have "RED" results, the service provider have to pay the costs for the Re-Audit (third audit) in full

(flight, hotel, etc.). In addition, the service provider shall be excluded from being awarded a contract in the next tender

due to quality-related reasons.

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4. Daimler AG Standard The strict observation of central standard specifications in the logistics centers ensures that every one of our

customers all over the world receives a vehicle that is in perfect condition and of the highest quality.

The inspection and processing of our vehicles as part of logistics processes requires that the personnel employed be

familiar with the complete specifications of the Daimler AG central standards catalog.

4.1 Assessment of Painted Vehicle Surfaces This section provides a detailed description of the procedure used for assessing painted surfaces and painted, coated

or chrome-plated detachable parts on the vehicle exterior according to the standard specified by Daimler AG. It shall be

ensured that only qualified and trained personnel that is capable of applying this standard reliably is employed for this

task. (The service provider shall present appropriate training certificates). This is the only way to ensure that any

identified deviations or damage are assessed and classified correctly and that the correct repair method is specified. All

rework shall be approved by authorized Mercedes-Benz specialists. Noticeable serial problems/standard deviations

shall also be checked using the "Production Deviation Request System" (PDRS); if a deviation permission was granted,

the defect shall remain on the vehicle.

Rework that goes beyond this standard cannot be invoiced to the account of Daimler AG. The arising expenses

shall be clarified within the market and borne by the market itself if necessary.

Procedure:

The vehicle is assessed in a test station with the corresponding technical equipment that was prepared specially for

this purpose. The overall vehicle is assessed from the customer's perspective; this means that the focus is not on the

expert's view and perception, but rather on noticeable problems on the vehicle that end customers would detect

themselves relatively quickly and easily.

Procedural instruction "Voice of Customer Audit (VoCA basis) for planning and executing start-up and series

production" forms the basis for this test step. Extracts from the PI are included in Chapter 4.2.

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4.2 Inspection Area, Assessment Position, Inspection Plan and Illumination The size of the audit station shall be dimensioned such that it is ensured that the vehicle can be assessed from a

distance of approx. 1.50 m around the entire vehicle; see inspection plan.

To do so, the vehicle shall be positioned in the center of the audit area. The following principles shall be observed to

ensure that a standardized procedure is used to appraise the surfaces of the vehicles:

The assessment position as depicted in figure 9 shall generally be observed when assessing the vehicles.

It is recommended to appraise the vehicle according to the inspection plan shown in Figure 10 10. Further

information see in sub item 4.3.

Observing both of these specifications ensures that the surface of the vehicle is inspected efficiently and correctly and

thus that all defects and damage are detected.

Figure 9: Assessment positions

1 = assessment position 1

2 = assessment position 2

3 = viewing angle

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Figure 10: Inspection plan (example)

A = Reflecting the paint surface

B = overall examination

1–21 = inspection position

The individual points in the inspection plan have the following meaning:

The points marked with an "A" are the ideal positions for reflecting the painted surfaces on the side of the vehicle. Less

pronounced dents and buckles become visible by slightly changing the viewing angle for looking at the vehicle surface

(inclining your head). Experienced inspectors detect even very small wave patterns caused by deep drawing. The

reflecting method is applied at the 4 marked points.

The points marked with a "B" are the ideal positions for examining the entire surface of the vehicle. The inspector takes

in the overall picture and looks for deviations in gap dimensions, fits and flows of lines, etc. Furthermore, the reflecting

method can be applied to the horizontal surfaces, e.g. the engine hood, the roof and the trunk lid.

Numbers 1–21 are inspection positions that are to be observed when walking around the vehicle to ensure that the

vehicle is examined from all angles.

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BAP description Item

Left front fender/left front wheel 1

Left A-pillar 2

Left outside front door/front left door sill, incl. from below 3

Left inner front door 4

Left outside rear door/rear left door sill, incl. from below 5

Left inner rear door 6

Left rear fender/left rear wheel 7

Trunk lid/tailgate 8

Trunk/load compartment/rear bumper, incl. from below 9

Right rear fender/rear right wheel 10

Right outside rear door/rear right door sill, incl. from below 11

Right inner rear door 12

Right outside front door/front right door sill 13

Right inner front door 14

Right A-pillar 15

Right front fender/right front wheel 16

Front hood/left and right headlamps/front bumper 17

Left front passenger compartment 18

Left rear passenger compartment 19

Right rear passenger compartment 20

Right front passenger compartment 21

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Lighting Equipment and Dimensions

From now on, the following lighting concept shall be taken into account for all redesigns.

The test station/audit station shall be set up in a closed/enclosed space. It shall be ensured that only approved

illuminants are used (see page 27). As part of performing maintenance on the lighting at the

audit station, it shall be ensured that the illuminants do not exceed the specified service life. A

standardized examination of luminosity is performed at defined test points.

Lighting arrangement:

The lighting equipment shall be arranged in a rectangle or parallelogram

The longitudinal light reflector shall be arranged with the "open side" facing the test station/audit station

Figure 11: Sketch of lighting arrangement

Lighting dimensions:

Overall length of the longitudinal lights (1): min. 6.0 m

Overall length of the transverse lights (2): min. 4.0 m

Distance between transverse lights (2): 2.0 m

Height of longitudinal and transverse lights from the floor: 2.70 m

Strip lighting

Triple appearance

Strip lighting

Quadruple appearance

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Transverse light = symmetrical reflector (2) Longitudinal light = asymmetrical reflector (1)

Figure 12: Sketch of lamp unit dimensions

Symmetrical strip lighting, triple

appearance

1 x 58 W; warm start electronic ballast;

special aluminum mirror reflector made of

MIRO-coated material with a strength of

0.7 mm; projects a 3-strip image of the lamp

onto the paint surface

Light Sources

Comparable to OSRAM Lumilux T8;

4,600 lumen, color rendition > 90; light color:

daylight white 6,500 K (965); service life

Asymmetrical strip lighting, quadruple

appearance

2 x 58 W; warm start electronic ballast;

special aluminum mirror reflector made of

MIRO-coated material with a strength of

0.7 mm; projects a 4-strip image of the lamp

onto the paint surface

Light Sources

Comparable to OSRAM Lumilux T8;

4,600 lumen, color rendition > 90; light color:

daylight white 6,500 K (965); service life

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4.3 Central Standards Catalog

The contents of the central standards catalog shall generally be applied for each vehicle test. This document describes

the classification and assessment of complaints in detail. It is valid for all Daimler plants, logistics centers and

dealerships. This ensures that our products are assessed, and reworked if necessary, on the basis of a uniform

standard worldwide. Only employees of Daimler AG can access the link below. (A print-out shall be created where

necessary; ensure release management)

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QBTQ-SDUX

Especially after a vehicle has been transported, attention shall be paid to the following:

Soiling caused during transport, such as flash rust, hydraulic fluid splash spots, lubricating grease, soot, etc.

Environmental influences (bird dropping, insects, chemical fallout, etc.)

Environmental damage/acid corrosion

Chip damage, scratches, dents, etc.

Excessive wear (chafe marks)

Corrosion

The vehicle surface shall be assessed with regard to all influencing factors

Stone chipping or other mechanical damage to all windows and windshield, headlamps and backup lights.

Damage to the front/rear and carrier areas, caused by bottoming in particular (front spoiler, rear apron, etc.).

Dirt in and damage to the vehicle interior, especially on the driver's side and in the area of the driver's door.

Mechanical damage to and deformation of tires and rims.

Notification of transport-related topics:

If multiple identical instances of transport damage are detected or if the cause of damage is unknown, this shall be

reported to the email distribution list indicated on the template, using the standardized form entitled "Worldwide

Vehicle Logistics Damage Form2. The person who reported the damage will receive some initial information from the

responsible department within 48 hours.

Reporting transport damage (Damage form Worldwide Vehicle Logistics)

Notification of production-related topics:

If during a vehicle inspection, faults / deviations are detected, the corresponding plant shall be informed immediately

via CAT (Case Analyzing Tool) or by means of a standardized notification form (Vehicle Condition Report-VCR) prior to

the repair to obtain appropriate instructions for the repair.

A CAT-Point / VCR must be created under the following conditions:

Individual errors with Prio1

Serial error (4 identical errors per month)

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https://docmaster.es.corpintra.net/DocMasterHTML/DirectLink.do?ACTION=VIEW_STANDARD&doknr=07.10.2009-QBTQ-SDUX

mailto:[email protected]?subject=Damage%20form%20Worldwide%20Vehicle%20Logistic%20-%20Bitte%20um%20Zusendung

mailto:[email protected]?subject=Vehicle%20Condition%20Report-VCR%20-%20Bitte%20um%20Zusendung

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4.4 Surface Defects

Figure 13: Surface damage (example)

Faults are assessed on the basis of how noticeable they are. The optical overall impression of the fault from the

customer's point of view is decisive for the assessment.

4.5 Assessment of the Interior/Product Protection

Figure 14: Interior protection (example)

The inspection of the interior covers the visible zones of the driver's seat and its surroundings as well as the steering

wheel, the center console, and the instrument panel. It shall also be check whether the transport protection

applications are OK and have been attached correctly, damaged transport protective measures that could result in

consequential damage shall be removed. The interior shall be free of foreign objects such as waste or tools. Floor mats

and other objects like the accessories bag must be stow in the trunk. The Transportmode must be active and the OBD-

cap must be close.

In general, all noticeable problems that are detected during the inspection shall be marked so that the individual points

can be identified immediately for the final inspection that determines what is to be repaired.

After the inspection and release for repair, defects, which pass on for rework, remain marked. All other markings are

complete removed.

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4.6 Problem Categories The problem categories are arranged according to a priority logic that is divided into four customer-relevant fields. The

priority logic represents a customer-oriented classification of defects. The customer benchmark influences the expert

benchmark.

The individual priorities are explained below:

Priority 1

Highest customer relevance/highest quality relevance/approval-relevant

Customer detects the fault and has to go to the workshop immediately.

Technical specifications are not fulfilled and are of very high relevance in terms of

quality.

Priority 2

High customer relevance/great displeasure

Customer detects the fault and goes to the workshop.

Fault is criticized and mentioned in a customer survey.

Technical specifications are not fulfilled and can lead to impairments regarding

product quality, long-term quality or construction feasibility.

Priority 3

Medium customer relevance/dissatisfaction

Fault may be mentioned in a survey.

Customer expectations are not completely fulfilled.

Technical specifications are not completely fulfilled. No direct influence on

product quality or long-term quality.

Priority 4

Low customer relevance

Fault is detected by a sensitive customer and a complaint is made.

Fault is detected only by a specialist.

Complaint, no influence on product quality or long-term quality.

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Priority 1 Highest customer relevance/highest quality relevance/approval-relevant:

Figure 15: Functional failure of SRS

Figure 16: Poly-V belt has come off/is loose

Figure 17: Oil loss in the transmission (clearly visible on the

floor)

Figure 18: Rubber grommet on firewall is leaky (water entry,

electrical systems/function affected)

Figure 19: Wrong version of information label for automatic

child seat recognition

Figure 20: Water entry in trunk/load compartment (electrical

systems/function affected)

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Priority 2 High customer relevance/great displeasure

Figure 21: Damage to a make-up mirror

Figure 22: Poor fit of bottom left paneling

Figure 23: Instrument panel damaged on the right

Figure 24: Valve cap missing

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Priority 3 Medium customer relevance/dissatisfaction

Figure 25: Poor fit of front left drip rail

Figure 26: Model designation not glued on properly

Figure 27: Luggage net in load compartment is the wrong color

(too light)

Figure 28: Adhesive on front fold of the trunk lid visible in the

center

Figure 29: Inner wheel arch not mounted correctly

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Priority 4 Low customer relevance

Cosmetic complaint (less pronounced)

Dents, bumps, damages, dirt inclusions, craters, soiling, polishing mark, structural defect, difference in color

Noise-related problem (less pronounced)

Driving noises: e.g. squeaky brakes, wind noises, seats

Operating noises: e.g. front door window

Mechanical/electrical function (faults that occur once during the inspection, self-repair)

Electrical: Screen of navigation system turns black (does not work)/engine restart, fault profile no longer available

Mechanical: Catch function of rear seat head restraint not OK/OK after second actuation, shift shock– weak

expressions, unstable roof, hose is partial loosely

Technical problem

Paint measuring technology: If color; coat thickness and flow not OK

Parts fit, gap pattern: Single tolerance violation (dimensioning on the basis of benchmark specifications or

specification)

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5. Processes All logistics service providers that are commissioned by Daimler AG or one of its national organizations to move,

inspect, repair and store Mercedes-Benz passenger cars shall adhere to the guidelines, specifications and standards of

Daimler AG without exception.

The following section deals with the processes required for the maintenance, inspection, repair, storage, and thus the

preservation of quality of the vehicles in logistics.

First, the most important features and special characteristics of a process are described. Depending on the topic,

pictures or diagrams are included for the purpose of clarification. The corresponding extract from the QM/KQR process

audit form is included at the end of the sub-section. The core requirements that shall be fulfilled in the context of an

audit are recorded here. In order to ascertain the company's own performance, it shall be check whether the company

fulfills all the requirements listed (see page 98).

All process steps based on standards or work instructions that shall be observe without restrictions. Deviations are

permitted only if they are verifiable and were required due to market-specific characteristics, e.g. laws or labor law-

related principles. The management of the logistics location shall report deviations from processes to the QM/KQR

specialist department immediately.

The table below clarifies which guidelines based on which processes.

OM Standard QM/KQR

5.1 Car Wash (see page 37)

5.1.1 Automatic Car Wash(see page 46)

5.1.2 Automatic Underbody Wash (see page 46)

5.1.3 Manual Car Wash (see page 46)

5.1.4 Manual Underbody Wash (see page 46)

5.1.5 Acid Car Wash (see page 49)

5.2 Vehicle Standard Check (VPC) (see page 51)

5.2.1 Vehicle Preparation (see page 51)

5.2.2 Vehicle Inspection (see page 52)

5.2.3 Vehicle Finish (see page 59)

5.2.4 Standard Rework "Quick Rework" (see page 59)

5.3.5 Equipment of Employees According

to the OM (see page 68)

5.3.6 Vehicle Handling According to

the OM (see page 70)

5.3 Vehicle Repair (see page 60)

5.3.1 Workshop (see page 60)

5.3.2 Repair Process (see page 63)

5.3.3 Spare Parts Storage (see page 67)

5.3.4 Campaign Management (see page 68)

5.3.5 Equipment of Employees according to the OM (see page

69)

5.3.6 Vehicle Handling according to the OM (see page 70) 5.4 Quality Control (see page 71)

5.5 Waxing Process (see page 76)

5.6 Battery Care (see page 30)

5.6.1 Vehicles with Transport Mode (see page 81)

5.6.2 General Handling of 12 V Batteries (see page 83)

5.6.3 General Handling of High-Voltage Batteries (see page 83)

5.6.4 Battery Care in Distribution Centers (FLC) (see page 86)

5.6.5 Battery Care in Seaports (see page 87)

5.6.6 Battery Care in Vehicle Preparation Centers

(VPC) (see page 87) 5.7 Vehicle Maintenance during Storage in the VPC (see page

89)

5.8 QM System (see page 91)

Compound Audit Process audit

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5.1 Car Wash The car wash is the first mandatory process step of the overall vehicle processing in a VPC. Only vehicles to which a full

body cover (FBC) or part protection applications have been applied shall not undergo a body wash. If necessary,

damaged applications shall be removed; then the vehicle shall be washed. For further information on handling FBC etc.,

please refer to the Operations Manual.

Thanks to the car wash, existing surface damage can be detected quickly and before the actual inspection process of

the vehicle begins. Surface damage caused by residues on the painted surface during the vehicle inspection is also

avoided.

Depending on the daily volume of vehicles (> 60 units/day), it is recommended to use an automatic car wash (conveyor

belt). The car wash shall be linked with a water treatment system in order to comply with the environmental guidelines

of Daimler AG. Such systems are designed to wash large volumes of vehicles quickly, efficiently, and in an

environmentally friendly way. It is also possible to integrate various special functions, e.g. a car wash that uses oxalic

acid to remove traces of flash rust.

Distribution centers with a smaller vehicle volume of 25–60 units/day can use a portal-type car wash. This type of

system is recommended mainly for maintaining the vehicles in the storage areas.

In exceptional cases or if the number of units processed per day is < 25, vehicles can also be washed by hand.

In the context of a modernization or the construction of a new automatic car wash, it shall be ensured during planning

that the following stated dimensions are taken into account. When new automatic car washes are commissioned and

when existing car washes are maintained, the settings shall be adjusted in accordance with the following information.

The only cleaning agents (e.g. car shampoo, wax) that may be used are those that have been approved by

Mercedes-Benz (see https://aftersales.daimler.com)

Systems:

Portal-type car wash Automatic car wash High pressure cleaner

Automatic Manual

Figure 30: Systems for washing vehicles (example)


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5.1.1 Automatic Car Wash

Process steps

Prewashing the vehicle

Washing the rims

Do not use brush. The rims shall be washed using nozzles, avoiding contact.

Main car wash

Rinsing the vehicle

Drying the vehicle

Figure 31: Car wash (example)

Figure 32: Car wash (example)

Specified dimensions for the automatic car wash:

Min. clearance:

2.200 mm (incl. roof rack etc.)

Min. width: 2.400 mm (with outside mirrors folded out)

Min. tire contact width:

Min. width of conveyor belt:

2.200 mm

360 mm

Important system parameters:

The new vehicle shall be washed with great care due to the hydrodynamic stress it is exposed to. The following settings

and requirements are therefore to be observed when maintaining or commissioning a new system:

Water quality: Water with a pH value of 7 ± 1 (reprocessed water) Water quantity: Permanent sprinkling with < 25 l/min and m²

Rinsing process with < 300 l/min Water pressure: For high pressure: < 80 bar (low volume)

For low pressure: < 30 bar (high volume)

Both with a spray nozzle or flat nozzle Nozzle settings: The spray angle of the rinsing water shall be > 30° to the side and shall point backward

and downward.

A spray angle of 90° is not permitted on the horizontal surfaces (roof, etc.).

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Figure 33: Spray angle of > 30° pointing backward and

downward (example)

Figure 34: Spray angle of < 90° for horizontal surfaces

(example)

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Cabriolet:

Automatic car wash facilities shall have a special washing program for cabriolets. In the special washing program, the

horizontal and lateral water pressure is reduced so as to prevent damage to the soft top and its seals.

Figure 35: Cabriolet roof (example)

Width of the wheel guide in the car wash (conveyor belt side):

Figure 36: Width of the wheel guide in the car wash is at least

360 mm (example)

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5.1.2 Automatic Underbody Wash The underbody wash of the vehicle is a prerequisite for the Mercedes-Benz winter wash program. The following shall be

ensured:

The entire underbody area of the vehicle shall be washed, from the front bumper to the rear bumper.

The wheel control at the front and rear axles shall be cleaned in order to remove traces of road salt from the

vehicle underbody and the wheel carriers completely.

The water pressure shall be set to 10–15 bar.

The washing process shall take 20 ± 5 seconds.

A perfect cleaning result is achieved when the underbody washer nozzles are set to a spray angle of 60° and the

nozzles are arranged both in the direction of transport and against it.

The water shall be fresh and have a pH value of 7 ± 1.

The spray nozzles shall be set according to the following illustrations:

Figure 37: Spray nozzle setting (example)

Figure 38: Setting of the sensor system for the underbody

wash (example)

Underbody wash using a portal-type car wash

It shall take 25 ± 5 seconds to wash the underbody. During this time, the entire surface of the underbody is blast-cleaned.

Underbody wash in the car wash:

The sensor system of the car wash shall be designed and adjusted such that the underbody washing process starts

automatically as soon as the sensors detect the front bumper. It does not end until the rear bumper has passed the

sensors completely. The spray nozzles shall be set according to the illustrations in Figure 37 and Figure 39 to ensure

that the wheel control areas of the front and rear axles are also cleaned.

A perfect cleaning result is achieved when the underbody washer nozzles are set to a spray angle of 60° and the

nozzles are arranged both in the direction of transport and against it.

Figure 39: Spray pattern (example)

Figure 40: Spray pattern (example)

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5.1.3 Manual Car Wash Only permissible for distribution center with a daily vehicle throughput volume of < 25 units.

Figure 41: Devices used for the manual car wash (example)

Work instruction:

The entire process of washing vehicles manually shall take place in a closed shop in order to be able to work

independently of the weather and ensure a continuous process flow.

It shall be ensured that the vehicle is not damaged during the washing process and that the washing process always

begins with the roof and ends with the wheels. A mobile set of steps is required for cleaning the roof (e.g. for cross-

country vehicles).

Specification:

High pressure lance with a fan nozzle

Water pressure: Between 10 bar and a maximum of 20 bar

Water temperature: Between 10°C and a maximum of 30°C

Water quality: Fresh water

Distance between lance and object: 50 cm (20 inches)

Steps:

Prewash

Main wash

Rinsing

Drying

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Prewash

Ensure that all windows, doors and the roof of the vehicle are closed.

Figure 42: Manual prewash (example)

The cleaning process begins with the roof and ends with the wheels. A safe distance of 50 cm shall be kept between

the high pressure lance and the vehicle. The jet of water shall not be directed at soft tops, seals, tires, etc. for a long

time. The entire vehicle (roof, all four sides, engine hood, trunk lid) shall be sprayed with the high pressure cleaner to

soften up dirt in advance. Major soiling is then removed completely with the high-pressure jet.

Main wash

Figure 43: Bucket for the main wash (example)

Three large buckets/barrels with a holding capacity of up to 200 l and a grating installed above the bottom as a grit

guard shall be provided. A mixture of hot water and special car shampoo, mixed according to the shampoo

manufacturer's specifications, shall be used to clean the vehicles. When the content of one of the buckets has been

used up, the bucket shall be rinsed out before it is filled again.

Container 1: Shall be used only for painted surfaces.

Container 2: Shall be used only for heavily soiled areas, e.g. the rocker panel or bumpers.

Container 3: Shall be used only for cleaning the rims.

Sponges, microfiber pads, and cloths can be used for cleaning the vehicle. They shall be cleaned and rinsed constantly

while in use and before each new vehicle.

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Soap down the prewashed vehicle starting with the roof and then continue on to the windows and windshield, the trunk

lid, and the engine hood.

Clean the sidewalls, including the doors and fenders. If the lower areas are heavily soiled, use the cleaning solution

in container 2.

Clean the rims using the equipment from container 3. A different sponge from the one used for the rest of the

vehicle shall be used for washing the rims.

At the end, the entire vehicle shall be in a lathered condition.

Figure 44: Manual main wash (example)

Rinsing

Figure 45: Manual rinsing (example)

After the manual main wash, the vehicle shall be rinsed. Starting with the roof, all four sides of the vehicle, the

engine hood, and the trunk lid shall be rinsed. This process removes all of the soap.

To prevent damage to the tires, seals, etc., a safe distance of 50 cm/20 inches shall be kept between the surface

of the vehicle and the high pressure lance of the high pressure cleaner.

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Drying

Figure 46: Manual drying (example)

After the vehicle has been rinsed, the entire vehicle shall be dried using a microfiber cloth, starting with the roof and

working downward step by step.

Dry the windows and windshield with a dry cloth.

Polish metal or chrome work separately to prevent water spotting.

Also use a separate cloth for drying the rims.

The microfiber cloth shall be rinsed and wrung out after each work process. It shall be ensured that all microfiber and

drying cloths are free of sand and dirt to prevent scratches and other surface damage to the vehicle. The wheels shall

not be washed with the microfiber cloth.

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5.1.4 Manual Underbody Wash (Only for < 25 Vehicles per Day)

Figure 47: High pressure cleaner for manual underbody wash

(example)

To clean the entire underbody, the vehicle shall be raised with a vehicle lift so that the worker can access the underside

of the vehicle. The operating instructions and the safety information for the vehicle lift shall be taken into account.

Underbody wash with a high pressure cleaner

Specification:

High pressure lance with a fan nozzle

Water pressure: Between 10 bar and a maximum of 20 bar

Water temperature: Between 10°C and a maximum of 30°C

Water quality: Fresh water

Distance between lance and object: Between 20 and 35 cm (between 8 and 14 inches)

Cleaning time: Approx. 1 minute

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Procedure:

Figure 48: Spraying pattern for cleaning the entire underbody

(example)

To remove the dirt, the underbody shall be sprayed according to the pattern above.

Figure 49: Information on the spare wheel well (example)

The water drain is located in the spare wheel well. The drain shall not be sprayed directly.

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Building, facilities and

surroundings

The building and the washing facility are not damaged. The floor is free of

heavy soiling and foreign matter (grease, rust, loose parts, etc.).

The entrances to and exits from the car wash shall be intact, there are no pot

holes, etc.

Wheel guide

The wheel guide/wheel guide rail is neither damaged nor soiled.

The wheel guide is at least 330 mm wide.

The wheel guide is coated with plastic (e.g. nylon) and does not have any sharp

edges or corners.

Vehicle prewash The vehicle prewash is carried out according to the Mercedes-Benz guidelines

(see above).

Main wash The vehicle main wash is carried out according to the Mercedes-Benz

guidelines (see above).

Condition of the brushes

The brushes are clean and free of foreign matter, e.g. grease, metal dust

remover, etc.

The brushes are in decent condition, possibly slightly worn (process-related

wear), but not defective. They are replaced according to the maintenance

schedule (verification).

Rinsing process The vehicle rinsing process is carried out according to the Mercedes-Benz

guidelines (see above).

Maintenance

The car wash is maintained according to the manufacturer's specifications on

a regular basis.

The maintenance record is complete.

Supervision of the car wash by a person who bears main responsibility is

ensured.

Washing result

Upon leaving the car wash, the vehicle is clean, undamaged (hairline scratches

at most) and to an overwhelming extent dry.

Subsequent manual cleaning is not required.

Figure 50: Perfect washing result (example)

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5.1.5 Acid Car Wash

An "acid car wash" may be performed as an option only if flash rust particles, e.g. rail dust, need to be removed from

large areas of the vehicle surface without causing damage.

When performing this task and thus handling oxalic acid-based rust remover, please observe the technical

information and notes on the safety data sheet that is provided with the product.

Figure 51: Pictogram of acids (example)

Only metal dust removers (oxalic acid) that have been approved by Daimler AG may be used. For further

information see at:

http://gms.aftersales.daimler.com

Read and observe the content of the safety data sheet.

Wear body protection equipment when handling the substance.

The maximum exposure time of the rust remover is 5 minutes.

Should the surface of the vehicle be warm due to sunlight, it shall be cooled down using water before

treating it with the acid.

Figure 52: Can containing acid cleaning agent (example)

Automatic car wash with oxalic acid

Spray the rust remover onto the vehicle using the spray arch integrated in the car wash so that the entire surface

of the vehicle is wetted.

The exposure time should be between 3 minutes and a maximum of 5 minutes.

Then rinse off the entire vehicle with clear water.

After the vehicle has been rinsed, it shall undergo a complete automatic washing process.

http://gms.aftersales.daimler.com/

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Manual car wash with oxalic acid

The vehicle shall be treated on a special surface (oxalic acid wash).

Apply the rust remover to the entire surface of the vehicle using an acid-resistant sprayer.

The exposure time should be between 3 minutes and a maximum of 5 minutes.

Then rinse the entire vehicle with clear water (hose/high pressure cleaner).

After the vehicle has been rinsed, it shall undergo a complete washing process (manual or automatic).

Cooling If necessary, the entire surface of the vehicle shall be cooled with water.

Applying the acid The flash rust remover shall be sprayed evenly onto the entire surface of the

vehicle.

The wheels, parts of the brake system and parts of the chassis shall not be

sprayed.

The flash rust remover shall not be applied while the vehicle is exposed to

sunlight.

Only approved chemicals are used (observe DAG instruction and safety data

sheet).

Exposure time The specific exposure time for the agent used shall be observed.

Rinsing The flash dust remover shall be rinsed off the vehicle surface completely and the

vehicle shall then undergo a complete washing process (manual or automatic).

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5.2 Vehicle Standard Check in the VPC The vehicle standard check involves checking the entire vehicle for shipping damage and environmental impacts. In

addition, standardized technical inspection items are worked through in order to detect any production-related defects.

This shall be carried out by personnel with sound knowledge of automotive engineering and very good knowledge of

Mercedes-Benz Cars products. The aim is to obtain a perfect vehicle that can be transferred to vehicle storage or straight

to the dealer at the end of the process without requiring any further measures.

Hint:

Within the acceptance check or the VSC, the completeness of the accessories bag is to be verified, the following is to be

noted: If content is missing in the unopened bag, the completion of the missing content must be billed via warranty. If it

is determined during the delivery control that the bag has been opened and contents are missing, it is a matter of

transport damage (theft). This damage may not be settled via warranty or goodwill. Missing contents in the package must

be noted on the shipping documents and to be claimed via freight insurance. Ideally, the accessory bag remains closed

until it is handed over to the retailer.

5.2.1 Vehicle Preparation The preferred way of preparing and marking the daily vehicle allocation share for the inspection process is to provide

the vehicles for the vehicle standard check in the VPC in special preliminary storage areas.

Depending on the conditions, initial tasks and checks, e.g. the product protection check, the removal of the tie-down

hooks, and the deactivation of "transport mode," can be performed in the preliminary storage area before the vehicle

enters the main process. Depending on the company, it is also checked whether the loose parts that are delivered in

the accessories kit are complete. In the event that parts are missing, proceed according to the specifications given in

the OM.

Vehicle handling and provision shall also be performed according to the OM. The employed personnel shall wear work

clothes and observe the work instructions.

Figure 53: Special tool for tie-down eyes

Supplier:

BOSCH Automotive Service Solutions GmbH

Am Dörrenhof 1, 85131 Pollenfeld-Preith

T: 08421 9731 720

F: 08421 9731 750

M: 0163 26 50 030

@: [email protected]

Part number: 990100

Handling the vehicle key The vehicle key shall be handled according to the OM.

Vehicle marking The vehicles shall be provided for the subsequent process (vehicle

standard check) in a special preliminary storage area.

Further markings, e.g. opened trunk or adhesive labels, are not permitted.

Tow hook The tie-down eyes used for transportation shall be removed professionally

and carefully, ideally using the special tool.

Cover of the towing eye The covers for the openings of the towing eyes located in the bumpers

shall be installed without damage.

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5.2.2 Vehicle Inspection – "Vehicle Standard Check" (VSC) The technical and optical inspection of the vehicles can be performed at individual workstations. Similar to a workshop,

a vehicle is fully processed and then approved by one employee. Alternatively, the vehicles roll from station to station

on a conveyor belt, like in Production, and are processed and inspected by multiple technicians according to their

subtask. The conveyor systems are similar to the conveyor-type car wash in that it shall be ensured that no gear is

engaged in the case of vehicles with manual transmission, and that the automatic transmission is in the "neutral N"

position. Since this requires the ignition to be on, the vehicle battery shall be recharged during or at the end of the

conveyor process. Absolute cleanliness and prudence shall be ensured when in direct contact with the vehicles.

The VSC inspection form in the Appendix forms the basis for the vehicle inspection. It shall be ensured that the version

used is always the current one. The individual inspection points shall be processed step by step and documented on

the form. This is done with the respective inspector's stamp or signature. All inspections shall be carried out according

to the specifications in the WIS (Workshop Information System). It is not necessary to perform a brake test or check

the wheel bolts (full check and documentation in the plant). Vehicles with a Full Body Cover (FBC), only the exposed

areas/parts are checked; the FBC shall remain applied until the vehicle arrives at the dealer. If the FBC is damaged, the

paint below shall be checked; if necessary, the FBC is released or removed completely. Detailed description see OM

chapter FBC:

https://docmaster.supplier.daimler.com/DMPublic/de/index.html

If a vehicle is equipped with “Speed limiters” (AMG GT/N253.99 F-Cell), they also have to remain in the vehicle until

arrival at the dealer. It is important to ensure, that appropriate safety instructions (label + work instructions) remain in

the vehicle.

In the event that there is a defect on a vehicle, the defect shall be described in detail on the inspection form. The defect

shall be documented in such a way that targeted rework can be performed. Reporting shall be established to ensure

that a detected defect is processed reliably and completely. Ideally, each case of damage is documented on the

inspection sheet and in a workshop system for vehicle control (DMS/IVIS). The vehicle documents, the vehicle

operator's manual, the service booklet, etc. shall be stored in a dry and clean place.

When placing the documents in the vehicle, it shall be ensured that they are placed either in the intended location in

the wallet provided, or in the accessories kit in the trunk. Depending on the market, the accessories kit can also be

placed in the vehicle.

Figure 54: Completed inspection sheet (example)

At the end of the vehicle inspection, the vehicle battery is assessed via the display in the instrument cluster. In the case

of vehicles with "transport mode," the condition of the battery is displayed in the instrument cluster immediately, e.g.

"Battery OK, remaining days: 28."

Time allowed for the "Vehicle Standard Check":

Processing time per vehicle, including body wash and final check: max.: 45 minutes

of which visual inspection of interior and exterior: max.: 15 minutes

mailto:[email protected]?subject=Prüfformular%20VSC%20-%20Bitte%20um%20Zusendung


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Vehicle Identification Number: Date:

Mileage: Technician:

Quantity of key received: Job card number:

Inspection step Code Inspection Item Task / Check Remarks OK NOK

P Drivers door opening/closing function

T / P 12 Volt Battery Voltage > 12,4 Volt is OK ____, __ Volt

T / P Battery / TransportmodeBattery State of Charge (SoC)

OK/ Charge/ Replace

T / P E-Cell / F-Cell VehicleSoC High voltage battery > 20% is OK

SoC HV _____

T / P Hybrid vehiclesSoC High voltage battery > 125 Volt is OK

SoC HV ______

P Parking brake Function, notch and alarm

P Audio System & Navigation System Function ・ Noise

P Combination switch Function

P Horn Function

T Towing hooks Remove both

T Towing eyelet cover Install both coversIf a full body cover is attached,

this task can be omitted

T Car washWash vehicle outside including

underbody washing

If a full body cover is attached,


P Engine Function ・ Vibration ・ Noise

P Automatic transmission Function ・ Vibration ・ Noise

P Brake function check Function ・ Vibration ・ Noise

P Steering Function ・ Vibration ・ Noise

P Noise check Noise

P Windscreen wiper Assembly ・ Noise

P Parktronic system FunctionIf a full body cover is attached,


Provide very detailed any problems / repairs required on items found to be "not OK". Indicate applicable job card number.

Keep Full Body Cover, selective product protection, protection foil and door pad. Note: If transport protective measures are damaged or partly

loose, such protection can be removed! Please refer to Full body cover chapter on latest version of Operations Manual for details!

Function test outside

( VPC-Vehicle Check)

Preparation before

VPC-Vehicle Check

Driving test outside,

parklot to workshop,

no special track!

( VPC-Vehicle Check)

VPC Vehicle Standard Check

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Inspection step Code Inspection Item Task / Check Remarks OKNot

OK

P Service Measures / Campaigns / RecallVerify all “Special Measures”, existing for

this vehicle has been performed

M

Owner's Manual

Service booklet/ Maintenance

Manual Radio/Comand

Manual Mercedes-Benz Dealer Network

Mercedes-Benz Roadside Assistance

Customer Guide

Place all necessary documents in the

appropriate compartments

M Navigation DVD

Upload current navigation DVD into

COMAND check map display

(if equipped)

T InteriorCheck the interior for damages

and cleanliness

T Exterior Check the painted surface for Scratches /

dents / rework

If protective measures(PM)

are attached the complete

check of the painted surface

isn't possible. Check visible

surfaces and the PM

regarding obvious damages

T Tires / rimsCheck for transportation

related damages, scratches, deficiencies

P/M Digital Owner Manual Upload the current DOM version

PSafety belt front left and right

(Only USA)

Check front belt system on stopping,

retrieving and clicking.

P Glovebox lock (Only roadster) Function check, mechanical key

T Undercarriage check

Walk around the vehicle and check the

undercarrige for transportation

related damages (e.g. use an mirror)

TSpeed limit label (AMG GT / N253.99 )

- except Japan -

The 6 mph speed limit label is at the

inside mirror,work instruction added.

T Transportmode check Transportmode activated

Detailed damage description:

To be delivered to the dealer

Rework ( Service measure / recall )

Repair ( e.g. transport damages etc.)

Retrofit

Others

VPC-Vehicle Check (Workshop)

Created by QM/QPR Plant Sindelfingen

Confirmed by QM of plants, GSP and MS

Date. 2020/02/28 Version 4

Code: T = Transportation relevant required by QM/QPR / GSP

P = Production relevant required by plants / GSP

M= Market relevant

Additional checks from plant/

Q-Organisation

(dynamic)

Vehicle requested for:

Technician / Date Supervisor / Date

Mark scratches with X

Mark dents with O

Defect need to be polished or reworked/ painted

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Inspection points

Test of vehicle functions, outside (VPC vehicle check)

Driver door:

Look out for irregularities when opening and closing the door (opening and closing behavior, noises, etc.).

12 Volt battery:

Check battery voltage (see page 30). If U > 12.2 V, battery is OK; recharge if necessary.

Vehicle in "transport mode:"

Read off battery condition from instrument cluster

E-CELL/F-CELL vehicles:

Read off SoC of the high-voltage battery from the instrument cluster. If the capacity is > 70%, battery is OK;

recharge if necessary (see page 30).

Hybrid vehicles:

Read off SoC of the high-voltage battery from the instrument cluster. If U >125 V, battery is OK; recharge if

necessary (see page 30).

Parking brake:

Check of the functionality, the detent and the warning tone.

Audio system & navigation system:

Check of the functionality and sound check.

Turn signal indicator:

Function check of the turn signal indicator.

Horn:

Function check of the horn/sound.

Preparation prior to the VPC vehicle check

Tie-down eye:

Remove both tie-down eyes using special tools.

Cover for the opening of the towing eyes:

Installation of both covers without causing damage.

Car wash:

Wash entire vehicle during winter months, including underbody wash.

Test drive, travel distance from parking space to workshop (no additional route):

Engine: 1) Check of functionality and possible irregularities

2) Check for unnatural vibrations

3) Check for unnatural noises

Automatic transmission: 1) Check of functionality and possible irregularities



Brakes: 1) Check of functionality and possible irregularities



Steering: 1) Check of functionality and possible irregularities



Driving noises: Check of the overall vehicle for unnatural/irregular noises

Windshield wipers: 1) Setting


Parktronic system: Function check during maneuvering, visual inspection of instrument cluster

(fault message)

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VPC vehicle check (workshop)

Service measure/campaign:

System check to assess whether there are service measures/campaigns for the vehicle; note on order regarding

transfer to workshop if necessary.

Vehicle documents Stowage space for all required documents and the hand-held scanner is provided in the compartments intended for this

purpose or in the trunk.

Wireless vehicle inspection project

Figure 55: Wireless vehicle inspection project (example)

Figure 56: Wireless vehicle inspection project (example)

Performing the "Vehicle Standard Check" with a wireless hand-held scanner allows the data to be transmitted in real

time; as a result, all vehicle-relevant data is available throughout the operation instantly. This leads to a considerable

increase in efficiency and higher data quality; in addition, processing market-specific and/or dynamic test points is

made significantly easier. (High flexibility)

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Storage location for the vehicle document wallet

Ideal way all vehicle documents inclusive bag, together with the accessories bag will be inserted into the luggage

compartment. If necessary, the documents can be market specifically or positioned immediately at the place

planned for it in the vehicle. (Depending upon vehicle model: Door stowage box/tray front passenger, parcel net

front passenger foot well, stowage compartment or parcel net behind driver seat)

Navigation DVD:

Function test/DVD or SD card in accessories kit.

Interior:

Check of the vehicle interior in terms of cleanliness and possible damage (see Chapter 4., Mercedes-Benz

Standard).

Exterior:

Check of the paint surface for scratches/dents/other damage (see Chapter 4., Mercedes-Benz Standard).

Tires/rims:

Check for damage caused during shipping, scratches, etc. (see Chapter 4., Mercedes-Benz Standard).

DiBA (Digital Owner's Manual):

Uploading of the current DiBA/DOM software (see WIS).

Front left and right seat belts:

Check of the stop function of the front seat belt systems (only in the USA). Retracting and engagement of the seat

belt buckle.

Glove compartment lock:

Function check of the mechanical emergency key (only Roadster).

Underbody:

Check of the underbody for transport damage (scratches, damage caused by bottoming, especially in the area of

the front and rear bumpers and both door sills). Alternatively, visual check of the critical areas in an inspection

pit/on a vehicle lift, using a mirror. Disassembly of underfloor paneling is not necessary.

Mirror tag indicating maximum permissible speed (only AMG GT):

The tag indicating the maximum permissible speed of 10 km/h shall be attached to the inside rearview mirror. The

work instruction is on the front passenger seat (except in Japan).

Transport mode:

Transport mode is activated; activate with Star Diagnosis/Xentry if necessary (see WIS).

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Figure 57: Underbody check (example)

Inspection form

The most up-to-date inspection form is used for the vehicle check.

The minimum inspection standard (QM/KQR) is fulfilled (see Appendix,

"Template").

Inspection steps,

inspection

confirmation

The individual inspection points are processed step by step and documented on

the form or in the system, if applicable.

All inspection points are confirmed with the inspectors' stamps or signatures.

Vehicle documents

(OM) The vehicle documents, e.g. the vehicle operator's manual, the service booklet,

etc., are stored carefully.

Documents are placed either in the intended location together with the

documents wallet (see attached GSP specification) or in the accessories kit in the

trunk.

Accessories kit The accessories kit, including all loose parts, remains in the trunk or is positioned

in the vehicle according to market specifications.

Battery check At the end of the inspection step, the battery is assessed via the display in the

instrument cluster.

In vehicles with "transport mode," the condition of the battery is displayed

immediately, e.g. "Battery OK, remaining days 28." Check for vehicles without

transport mode (see Section 5.6.)

Rework Should a vehicle exhibit a defect, this defect is described in detail and

documented such that the appropriate rework can be performed in a targeted

way.

Damage report Reporting has been established to ensure that detected defects are processed

consistently.

No vehicle leaves the process with damage (Q gate).

Each case of damage is documented on the inspection form and, ideally, also in a

vehicle/workshop control system (DMS/IVIS, etc.).

Vehicle tracking Vehicle movements and progress are logged in an IT system (see figure below).

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Figure 58: Autoline VPC Taiwan, information is exchanged 7 x per day

5.2.3 Vehicle Finish The finish area is located at the end of the overall process in the VPC. The main focus here is on the inspection of all

painted and coated vehicle surfaces and the rims. In order to create optimum conditions for checking the vehicle

surfaces, it shall be ensured that all the specifications from Chapter 4 (Standard) are met.

All noticeable problems and defects such as scratches, dents, paint inclusions, etc. shall be marked with water-soluble

pens or wax crayons. (Special colored pens for surface markings, e.g. Staedtler Lumocolor® non-permanent

omnichrom 768, refillable, water-soluble.)

The general rule is: Minimal surface defects such as very small paint inclusions, hairline scratches and other soiling

shall be removed immediately as part of the finishing process (max. working time 5–10 min. – standard rework).

This form of rework, also known as "quick rework", shall be included in the calculations for the service rate per vehicle.

A transfer of the vehicle to rework shall be avoided for reasons relating to time and quality.

Damage that cannot be rectified as part of the standard scope shall be recorded on the SVC test sheet. Repair approval

(repair type and scope) shall always be granted by an authorized Mercedes-Benz plant specialist. In addition, the fault

shall be documented clearly in the system (traceability).

If the defect in question is production-related, it shall always be assessed in due consideration of PRIO logic (Chapter

4.3).

The vehicle finish is concluded by a check of the interior in terms of cleanliness and order. Where possible, defective

transport protective measures shall be removed or replaced if necessary.

Hint: Tarnish/oxidized garnish molding have to clean with the mirror finish A 000 986 87 74 11.

5.2.4 Standard Rework "Quick Rework" The basic rule is to always choose the smallest possible repair type in order to keep the costs and quality impairments

to a minimum. "Quick rework" shall always be given preference over any other form of repair. Furthermore, this type of

rework is an adequate means of increasing operating efficiency. If minor damage cannot be rectified by means of a

touch-up or polishing, the next repair solution (spot repair or painting) shall be approved by the MB expert.

"Quick rework" working technique – surface rework on the line (station)

The workplace shall be equipped such that it is appropriate for the task. Ideally, energy (compressed air or

electricity) should be supplied from above in order to avoid trip hazards on the ground and on conveyor lines

in particular. The worker has a tool cart (padded or plastic) with equipment for polishing and carrying out

touch-ups (see figure below).

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Figure 59: "Quick rework" tool cart (example)

Figure 60: "Quick rework" on the line (example)

Trained specialists can process even difficult topics on the line or at the test station and thereby help to significantly

reduce the transfer of rejected vehicles to rework (higher first time capability rate), which improves the lead time.

Body and paint

All surface damage or defects are detected (marking with special colored pen).

The repair scope is specified on the basis of problem categories priority 1–4.

Priority 4 faults remain on the painted surface (rework by dealer) or remove

immediately as part of "quick rework" (standard process without extra cost).

Checking time including the interior: max. 15 minutes

Interior The vehicle interior is clean and tidy.

All transport protective measures have been applied, defective parts have been

removed or replaced if necessary

Luggage

compartment/load

compartment

The luggage compartment is clean and tidy.

Engine compartment The engine compartment is clean and exhibits only moderate water spotting.

Transport protective

measures (TSM) All transport protective measures have been applied, defective parts have been

removed or replaced if necessary

Quick rework Performed as part of the "vehicle standard check".

5.3 Vehicle Repair If there are repairs to be carried out on new Mercedes-Benz or smart vehicles, the highest quality requirements shall be

met. It shall be ensured that only highly qualified specialist personnel who can prove that they have undergone

appropriate training and technical training and possess theoretical knowledge on these vehicles perform all rework. If

transport damage or production defects cannot be rectified by means of "quick rework" are identified as part of the

vehicle check, the vehicles shall be transferred to the workshop along with a clear error description (test sheet and

order). Damaged vehicles shall always be repaired prior to storage or shipping. Damaged vehicles can be delivered to

dealerships only if the national dealer organization has received a written declaration of consent from the dealer.

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5.3.1 Workshop Daimler AG demands that the workshop area of a logistics center meets the highest standards; the layout and

workshop equipment allow an efficient and safe repair process to be performed on our vehicles.

The basic requirements are to use the best tools and to handle the vehicle and tools professionally and with care.

Modern workstations with an IT connection provide the basis for processing vehicles on the highest level.

In general, a workshop is to correspond to the standard plans of FP/DRE and the guidelines and requirements of GSP.

The standard plans and guidelines of GSP shall be fully implemented as part of conversions or new buildings at the

latest.

Figure 61: Workshop (example)

Figure 62: "Spot repair" workplace in the workshop (example)

The following applies to all workshop areas: The repair stations shall be clean, subject to constant maintenance, and

set up such that work can be performed safely and efficiently.

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Figure 63: Special tools (example)

Workshop layout The layout of the workshop corresponds to the GSP standard plans.

Minimum requirement: The workshop is designed and equipped in such a way that

work can be performed efficiently and safely according to the GPS repair

specifications.

Tools

All tools are in good condition and safe to use.

Test and measuring tools indicate that they were calibrated recently or are marked

as "not calibrated."

Handling of tools Tools are generally handled professionally and with care in the workshop.

Basic equipment

The tools and workshop equipment correspond to the specifications given in


Minimum requirement: The tools and workshop equipment enable work to be

performed efficiently and safely according to the GSP repair specifications.

Control of repairs There is a standard process for controlling the vehicles that require repair

(systemic recording and tracking recommended).

Surface treatment There is appropriate spot repair equipment for minor repairs

The tools are in perfect condition

The paintwork and finish areas are perfectly clean.

ESD workstation The workshop is equipped with a basic ESD kit


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5.3.2 Repair Process There is a standard process for controlling the repair process and all employees are familiar with it. Ideally, the vehicles

are recorded in a system in order to be able to follow the course of the repair and thus also the location at all times.

However, process-consistent vehicle control can also be done manually, using simple aids, e.g. mirror tags.

All mechanical and electronic repairs, body repairs and paintwork jobs shall always be performed in accordance with

the Mercedes-Benz repair specifications given in the Workshop Information System (WIS and TIPS). Prior to starting the

repair work, the employee shall check whether there are special instructions (TIPS) for the fault profile (repair scope).

Important note:

In contrast to the specifications given in the WIS, the "minimum principle" is applied for paint rework in the VPC (similar

to the work specifications and standards in the assembly, body, paintwork and stamping plants). This means that the

area to be reworked is kept as small as possible in order to keep the effect on surface quality to a minimum. Touch-ups,

polishing and spot repairs shall generally be preferred to large-area painting; the final decision on the repair is made on

a case-by-case basis and on the basis of technical circumstances and any specifications made by the local paint

manufacturers.

If the VPC has been tasked with installing/mounting accessories from Mercedes-Benz Accessories (MBA), it shall be

ensured that the assembly is performed in accordance with the associated installation instructions.

Figure 64: Mirror tag (example)

The VPC may need professional support due to a high volume of vehicles, complex troubleshooting or specific repair

knowledge. For this purpose, Mercedes-Benz keeps a team of experts available that can travel to the location in

question promptly to provide support. These colleagues can also provide support with plant campaigns. You can find all

details on this topic in the section "Contacts for Logistics Topics." You can find further information in the brochure

below: See GSP/BPS brochure

mailto:[email protected]?subject=Broschüre%20GSP/BPS%20-%20Bitte%20um%20Zusendung

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Vehicle repair guidelines

Star diagnosis software The most up-to-date software for processing the vehicles in a functionally

correct manner is available on the Star diagnosis devices (WIS/Xentry TIPS).

All diagnostic equipment is online once per day. Every diagnosis workstation

is equipped with a LAN connection for this purpose.

Detailed work instruction The rework orders shall be implemented in a clear, verifiable and direct way,

i.e. with a detailed description, so that inquiries are not necessary and work

can be commenced immediately.

Optical defects are marked clearly.

Rework

Rework (shipping damage and damage under warranty) is checked and

approved (signature) by a foreperson or, in the case of subcontracting, by a

Mercedes-Benz specialist.

Cost allocation

The cost allocation is correct, documented, and ensured.

The responsible personnel can explain the procedure used for allocating the

cost (damage profile/probable development of damage/occurrence).

Only production defects are settled via VEGA. Shipping damage is reported to

the responsible insurance company.

Repair processing

All repairs are carried out according to the specifications/work instructions

provided in WIS/Xentry TIPS/EPC.

MBA accessories are installed in accordance with the installation

specifications

Painting jobs/surface treatment is performed according to the "minimal

principle" (Daimler AG workshop standards) with the appropriate equipment

The procedure is logical, efficient, and resource-conserving.

Work safety regulations are fully observed.

Quick test After repair work, it is standard to perform a quick test, archive the fault

report, and delete the vehicle's fault memory.

Final inspection After each repair, the responsible mechanic subjects his work and the

adjoining areas to a final inspection.

All traces of the work performed have been removed completely (create as-

new condition).

Handling vehicle parts Parts that were temporarily removed from vehicles are stored in storage

racks/rooms provided specially for this purpose to prevent soiling and

damage. Small parts can be stored on a protective base in the trunk.

Allocation shares of parts are clearly allocated to a vehicle, e.g. a copy of the

order is attached.

Scrapping of warranty

parts Removed parts under warranty are marked properly and stored in a locked

location.

After they have been audited, they are scrapped according to the Mercedes-

Benz warranty manual (https://aftersales.daimler.com).

Parts to be scrapped are made unusable through drilled holes or hammer

blows, etc.

Fuels and lubricants Only fuels and lubricants as well as repair materials that have been approved

by Mercedes-Benz are used (http://gms.aftersales.daimler.com).



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Figure 65: Cleaning agents and polish from Mercedes-Benz

1. Gloss preserver

2. Polish

3. Paint cleaner

4. Plastics cleaner

5. Chrome care

6. Car shampoo

7. Nano polish

8. Wheel cleaner

9. Inside window cleaner

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Incorrect storage of removed parts

Figure 66: Incorrect storage of removed parts (example)

Figure 67: Incorrect storage of removed parts (example)

Correct storage of removed parts

Figure 68: Correct storage of removed parts (example)

Figure 69: Correct storage of removed parts (example)

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5.3.3 Spare Parts Storage All new spare parts, consumables, fuels and lubricants shall always be stored in a warehouse that can be locked and

that is comparable to that of a dealership operation. The parts are stored according to the requirements, in a way that

ensures that the spare parts are stored safely and in such a way that they do not suffer from damage or a reduction in

quality while they are in storage. The storage area is supervised and managed by trained personnel. Workshop

personnel cannot access the storage area.

Figure 70: Spare parts storage (example)

Organization of parts

storage The parts storage area can be locked.

Parts processing is managed and controlled by warehouse employees.

Handling new parts Vehicle parts are stored in a clean and safe place.

The parts are stored according to their requirements, e.g. windshields are stored in

an upright position.

Recycling/scrapping Removed parts and residues are disposed of separately at a residue collection

point (environmental guideline A25.1).

Hazardous substances Hazardous materials, e.g. solvents and paint, are stored separately (environmental

guideline A25.1 and market-specific regulations).

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5.3.4 Campaign Management Campaign management refers to the standardized follow-up of a manufacturing fault. It is normally performed at the

plants or, in special cases, in the VPC that are connected to the plants' campaign management. Because this form of

rework cannot be performed in every country, a check and assessment of the legal situation prior to the assignment in

the market is indispensable. (Local legal department)

If faulty vehicles have found their way into Logistics, and the plants no longer have access to them (e.g. if they are

already on the ship), the MPC in the target market receives a campaign message from the campaign manager

responsible at the plant, containing a list of affected vehicles and the required work instruction. The campaign manager

of the plant is the sole contact for the VPC. Close cooperation between the person responsible for campaigns in the

VPC and the campaign manager is important, especially in cases of supply bottlenecks for parts or software. In this

case, the required vehicles need to be prioritized together with the Sales department of the national organization. The

entire campaign shall be processed according to the procedural instruction "Aktionen im VPC durchführen" (Conducting

Campaigns in the VPC) see https://docmaster.es.corpintra.net).

Service providers that are also connected to the campaign management of the Mercedes-Benz plants will

receive the document from the QM/MQS-A department.

Tasks of the VPCs in the context of campaign management:

Record campaign information from the plants

Train staff at VPC

Carry out campaign at VPC

Reactivate transport mode if necessary, battery care

Document vehicles that were reworked in the VPC and can no longer be accessed by the VPC in CIT/INTAKT

Cost claiming according the requirements

Feedback on vehicle

distribution CIT/INTAKT immediately provides binding feedback on which of the affected

vehicles can be accessed by the VPC and how many are already in the field

(dealer access).

Data transfer from

CIT/MAIL to the

VPC system

Data transfer from the CIT/mail to the VPC system is verified on a daily basis or

takes place automatically.

Working instruction Work instructions are documented explicitly and with illustrations and are

available at the stations in the national language, if applicable.

Working method

The employed personnel has received appropriate instructions.

The necessary special tools are available.

The recall campaign is performed in accordance with the work instruction and the

procedural instruction "Aktionen im VPC durchführen" (Conducting Campaigns in

the VPC).

All technical specifications, e.g. torque specifications, are observed.

Final inspection and

documentation After it has been repaired, the vehicle is in as-new condition. Transportation

protection measures are applied and ok.

The work performed is subjected to a final check and documented.

Transport mode is reactivated and battery is charged.

Campaign confirmation After completion, information on the vehicles that were part of a campaign is fed

back via CIT/INTAKT on a daily basis.

Cost settlement Campaigns that were conducted are invoiced on the basis of the existing

guidelines and the country-specific agreement.

https://docmaster.es.corpintra.net/DocMasterHTML/DirectLink.do?ACTION=VIEW_STANDARD&doknr=29.11.2012-FB7I-DH6Y&ausg=2013-08-15

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5.3.5 Equipment of Employees According to the OM All employees who work at a logistics location and who come into direct contact with our new vehicles shall be dressed

according to the guidelines given in the operations manual and equipped with the appropriate personal protective

equipment for their task. Every employee is obligated to wear personal protective equipment and to replace it if it is

defective in order to prevent damage to the vehicles while handling them.


Personal body

protection Personal protective equipment is available.

Each employee has protective equipment appropriate to their task.

Use of stipulated

equipment The employees (drivers, inspectors, mechanics, painters, etc.) apply/wear

personal protective equipment according to their scope of tasks.

The protective equipment is clean and in good condition.

Cleanliness of

work clothes The work clothes are clean.

Dirty work clothes are changed as required.

Work clothes All employees have access to functional work clothes and wear them when

performing their tasks.

Sharp-edged objects/

work clothes Sharp-edged, pointed objects or tools, e.g. screwdrivers, pliers, etc., are not to be

carried in the pockets of work clothes.

Work clothes with sharp metal applications, e.g. zippers, large buttons, etc., are

not used.

Watches and jewelry Watches, jewelry and similar accessories shall be removed during the work.


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5.3.6 Vehicle Handling According to the OM In general, the vehicles shall be handled according to the regulations specified in the operations manual. The contents

shall be imparted in the context of internal training sessions and followed up during audits. In order to ensure a flawless

logistics process, Mercedes-Benz recommends its partners to provide the most important safety and handling

regulations for the vehicles to their employees in the form of a booklet or leaflet.


Figure 71: Source: BLG leaflet (example)

Figure 72: Vehicle in the process (example)

Figure 73: Mishandling (example)

Speed limit The maximum permissible speed of 40 km/h (transport mode) is observed.

Location-specific speed limits are observed.

Electronic devices Electronic vehicle components are switched on solely for inspection

purposes and are switched off again immediately afterward.

Vehicle abuse New vehicles shall not be used as towing, transport, or taxi vehicles.

Touching the

vehicle surface It is not permitted to lean against a new vehicle, support yourself on it or

touch it unnecessarily (no marks, brush marks and smears, etc. on the

vehicles).

Marking of vehicles

Under no circumstances may the vehicles be marked, e.g. for reasons of

selection. No adhesive seals shall be applied, the trunk lid shall not be left

open, the wiper arms shall not be put up, etc.

Closing doors The doors, windows, sliding roofs, and trunk lids, etc. of parked vehicles are

completely closed.


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5.4 Quality Control The performance of quality controls is a fundamental part of the overall process in a logistics center. Quality controls

serve as a sensor for internal process quality. Detailed evaluations enable operations to be controlled dynamically and

ensure a high level of quality when the vehicles are delivered to the dealership operations. In the case of complaints in

particular, quality controls can contribute to the prompt analysis and remedy of faults.

Quality control is the final step in the vehicle inspection process. The random samples should make up between 5% and

10% of the entire daily volume of the logistics center. Vehicles that were subjected to further processing, e.g. paintwork

or repair, after the standard process should preferably be delivered to the quality gate (quality control). This measure

ensures that all processes that take place in the logistics center are checked in terms of whether they fulfill quality

requirements.

The inspection scope should generally correspond to that of the VSC (vehicle standard check). Additional market-/VPC-

specific inspection scopes can be added in a variable way in order to react to special characteristics (product-specific

defects, internal deviations from the process, etc.), for example. It is also recommended to double-check that the

vehicle is complete to ensure that the employees did not forget to place all loose parts back into the vehicle after

performing the repairs.

The deviations from the specified vehicle quality that are detected as part of the vehicle controls are documented and

then consolidated in a report.

Example of inspection scope at a Q gate:

Short test drive on a specified route (see page 51)

Technical vehicle inspection (see page 51)

Check of the painted vehicle surface, including decorative parts and rims

Check of the vehicle interior in terms of cleanliness and the condition of the transport protective measures

Check of the repairs carried out according to the order, on the basis of the specifications from WIS

Completeness check, depending on the equipment (see list below)

Figure 74: Allocation of numbers on the vehicle

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Number Description Location on/in the

vehicle

Picture (example)

1 CCC label (only China) In the right-hand

corner of the

windshield.

2 Customs clearance label

3 VIN and SA code identification

plate

B-pillar on passenger

side

4 Fuel consumption label Rear side window,

market-specific

5 Accessories kit Luggage compartment

6 Refrigerator box Luggage compartment

7 Stowage box Luggage compartment

8 Luggage net Luggage compartment

9 Hazard warning triangle Luggage compartment

10 Bluetooth adapter Accessories kit in

luggage compartment

11 Vehicle literature

(maintenance/service booklet,

supplementary instructions for

the radio/COMAND, vehicle

operator's manual)

Accessories kit in

luggage compartment

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vehicle

Picture (example)

12 Navigation component (Becker

Map Pilot/SD card)

Accessories kit in

luggage compartment

13 Spare wheel Luggage compartment

14 Tool kit Luggage compartment

15 Screw set (5 pieces) for spare

wheel

Luggage compartment

16 Vehicle jack Luggage compartment

17 TIREFIT tire repair set Luggage compartment

18 Compressor Luggage compartment

19 Remote control and headphones

for the rear entertainment

system

Accessories kit in

luggage compartment

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vehicle

Picture (example)

20 First aid kit Luggage compartment,

vehicle-specific

21 Fire extinguisher Stowage compartment

under driver's seat

22 Cigarette lighters (2 pieces) Installed in the

front/rear ashtrays.

23 Keys (2 pieces)

Consisting of an electronic and a

mechanical part

Hung up in the front

section of the vehicle

on the combination

switch and in the

accessories kit in the

luggage compartment.

24 License plate molding Front and rear

bumpers, depending on

the model and version.

25 AUX connecting cable

Accessories kit in

luggage compartment

26 Start/stop cover for EIS Accessories kit in

luggage compartment

27 Cover for the opening for the

front and rear towing eyes

Accessories kit in

luggage compartment

28 Hub cap Luggage compartment

29 Ball head, detachable Luggage compartment

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vehicle

Picture (example)

30 Emergency key for soft top Accessories kit in

luggage compartment

31 Remote control for auxiliary

heating

Accessories kit in

luggage compartment

32 Basic carrier for roof systems Luggage compartment

Figure 75: Q control

Quality control

Quality controls for the purpose of ensuring process quality are performed

randomly (preferably with vehicles that have been repaired).

Inspection sheet

The current and, if applicable, market-specific inspection form or the previous

version are used.

Spot check

Depending of the daily volume of vehicles, spot checks are performed on between

5% and 10% of the daily VPC throughput.

Fault report

A fault report is generated on the basis of the results of the spot checks and

submitted to the management.

Collection of key

figures Key figures are collected and drawn on to ensure a continuous improvement

process.

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5.5 Waxing Process In this case, vehicle waxing serves as additional corrosion protection. In order to wax the vehicle, it is raised up on a

vehicle lift.

After the aerodynamic cladding on the vehicle underside has been removed, it shall be set down in a clean place that is

protected against damage. Specific areas of the vehicle whose surfaces are not to be waxed shall be covered up. A

specific waxing and covering up specification shall be used for each model series (provided by QM/KQR).

Before starting the waxing process, it shall be ensured that the components are clean and dry. If necessary, they shall

be cleaned and dried before waxing. Large areas shall be coated using a special waxing gun. Small areas are waxed

using a lance or a fine brush. Conventional waxing material shall not be used; instead, only wax that has been tested

and approved by Mercedes-Benz shall be used http://gms.aftersales.daimler.com. The expiration date of containers

that have already been opened and have been in the working area for a long time shall be checked. Material that is past

its best-before date shall not be used any longer. It shall be disposed of. To achieve a perfect waxing result, it shall be

ensured that the waxing material and the vehicle to be waxed are at a minimum temperature of 22°C.

It shall be ensured that the entire surface is covered with wax during waxing. The waxing results in a neat spray pattern

that covers the entire surface. Excess wax shall be removed and parts that were waxed by mistake shall be cleaned.

The tools and waxing utensils shall not show signs of wear, but shall be in perfect condition.

No strains or damage shall be caused while the underfloor paneling is being installed. The correct order shall be

observed. The screws shall be tightened with the specified torque (WIS). It shall be ensured that the interior and the

painted vehicle surface are completely free of traces of wax; if necessary, contaminated areas shall be cleaned

immediately, using approved cleaning agents.

Position the vehicle on the vehicle lift.

Remove the underfloor cover.

Areas that are not to be waxed shall be covered up (e.g. the exhaust system).

Wax the defined areas/parts.

Attach the underfloor cover.

Set down the car and put it into parking position.

Figure 76: Areas to be waxed


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Waxing process

Each model shall be waxed according to the valid specification by RD/KSO.

Ensure that the entire underbody is accessible. The vehicle lift shall be used.

Ensure that the underbody of the vehicle is clean (underbody cleaning in winter).

Waxing the underbody

Position the vehicle on the vehicle lift.

Figure 77: Vehicle on a vehicle lift (example)

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Process

Remove the underfloor cover.

Figure 78: Removal of the underfloor cover according to the

work instruction (example)

Component protection

Components that are not waxed shall be covered up with paper and cardboard.

Risk of injury!

Please remember that the exhaust system is hot.

Figure 79: Covered up areas that need not be waxed (example)

Figure 80: Covered up exhaust system (example)

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Waxing

Wax the defined areas/parts according to the waxing specification.

Figure 81: Waxing specification for the W166 (example)

Figure 82: Waxing process (example)

Figure 83: Waxed underbody (example)

Completion of waxing

Perform the final inspection and remove all paper/cardboard covers.

Figure 84: Completed waxing process (example)

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5.6 Battery Care (Valid for Mercedes-Benz Passenger Cars and smart and G-Class) The correct battery state of charge forms the basis for smooth and on-schedule logistics processes.

Breakdown cases in logistics caused by battery failures are time-consuming and cost intensive. For this reason,

targeted battery care shall be ensured in the global logistics hubs. The following section focuses on the care of the

different types of batteries and the different scopes of care at the respective logistics locations.

5.6.1 Vehicles with Transport Mode (see page 81)

5.6.2 General Handling of 12 Volt Batteries (see page 83)

5.6.3 General Handling of High-Voltage Batteries (see page 84)

5.6.4 Battery Care at Vehicle Logistic Center (VLC) (see page 86)

5.6.5 Battery Care at Sea Ports (see page 87)

5.6.6 Battery Care at Vehicle Preparation Center (VPC) (see page 87)

Only chargers that have been approved by Mercedes-Benz shall be used for maintaining the batteries of Mercedes-Benz

vehicles, especially for the care of high-voltage storage batteries. You can find the appropriate equipment on the

internet at: https://aftersales.daimler.com


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5.6.1 Vehicles with Transport Mode The following information shall be considered for vehicles with transport mode (can be seen on the display in the

instrument cluster). The display refers to the actually measured state of charge (SoC) of the 12 Volt battery.

The current battery charge status can only be validly assessed in the active transport mode. In the active transport

mode, the battery charge status is displayed as shown in Figure 85.

Figure 85: Display of transport mode in the instrument cluster

Recharging or replacing a battery does not affect the system parameters of "transport mode."

Battery care or a battery exchange will be detected automatically and the display in the instrument cluster is updated.

General instructions on handling vehicles upon their arrival at or departure from a warehouse at a port or

logistics center (see also Chapters 5.6 and 5.7)

Battery OK:

"Standby 40 days" vehicle is ready for storage/transport. No further measures

necessary

"Standby 25 days" vehicle is ready for transport

Charge battery:

The battery shall be recharged immediately. Afterwards the vehicle can be stored

or sent on.

Replace battery:

If the engine starts, the battery is only recharged and the vehicle is then put in

storage or transferred on.

In case of vehicles with high-voltage storage batteries (including 48 V batteries)

the 12 V on-board electrical system battery shall be replaced immediately!

See instructions under 5.6.2!

Vehicles without Transport mode will receive battery maintenance according the instructions of the

respective logistic center.

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Figure 86: Transport mode display in the instrument cluster

(example)

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5.6.2 General handling of 12 Volt Batteries

These charging instructions also apply to 12 V lithium-ion batteries; however, a maximum charging voltage of

14.4 V is permissible here.

Charging instructions:

The positive terminal of the battery charging cable shall be connected to the charging terminal point of the pre fuse box

in the engine compartment, and the ground terminal shall be connected to the ground terminal point.

Replacing on-board electrical system batteries:

Defective 12 V batteries in vehicles with alternative drive systems (hybrid/electric vehicles), but also vehicles with 48 V

technology, shall be replaced immediately in order to prevent damage to the HV battery. The following applies to

conventional vehicles: 12 V batteries that need to be replaced (vehicle cannot be transported) shall remain in the

vehicle until it is called up. When the vehicle is requested for shipment, the battery shall be replaced in one operation

step.

If a battery is replaced on warranty, the status message "Replace Battery" in the vehicle (SAM/body

controller in front/rear) must be read out and printed when the transport mode is active. For vehicles

without transport mode, a Midtronics battery test must be carried out and the test result must be printed.

The respective test results must be attached to the warranty application.

Figure 87: Battery charging stations (example)

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5.6.3 General Handling of High-Voltage Batteries

High-voltage on-board electrical system – risk of death!

All activities, without exception, shall be performed in accordance with the specifications given in WIS!

There are voltage values of >120 V in the entire high-voltage on-board electrical system. Touching components of the high-voltage on-board electrical system can cause burns, fibrillation of the heart, or

cardiac arrest through electric shock. It can take a few minutes before the consequences of an electric shock appear;

therefore, a physician shall be consulted in all cases.

In the event of a fire

In the event of a vehicle fire, you immediately leave the danger zone and secure the area. The leaking gas from the HV-

battery is highly flammable and pose a serious risk of injury.

Safety instructions/precautions

Persons with electronic implants, e.g. cardiac pacemakers, shall not work on high-voltage on-board electrical systems.

Under no circumstances may exposed lines and components of the high-voltage on-board electrical system be touched.

This applies in particular to accident vehicles before the high-voltage on-board electrical system is shut down. Work on

components of the high-voltage on-board electrical system may be performed only by persons who

Can prove that they have taken part in special quality measures

Have completed special electronic training

Are authorized.

The following vehicles are equipped with a high-voltage battery:

Hybrid (can be identified, e.g. by the nomenclature with "h" or "e")

Electric vehicles (can be identified, e.g. by the nomenclature with "e" or "electric drive")

F-CELL (can be identified, e.g. by the nomenclature with "f")

Important information on charging high-voltage batteries

It is prohibited to use the charging equipment provided in the vehicle.

The vehicle must not be moved during a charging operation or when the charging cable is connected.

Vehicles with high-voltage batteries should always be stored in a place where temperatures below 0°C and above

+40°C are not reached.

A battery charger >45 A/12 V is required for charging high-voltage batteries in hybrid vehicles (mild hybrid or

nomenclature "h") via the connection at the jumper cable connection.

A wall box or a charging station with alternating current/direct current shall be used for charging high-voltage

batteries in plug-in hybrids or EV vehicles.

The high-voltage battery can be charged at a voltage of up to 400 V.

The charging cable may only be connected to a power socket or “wall box”/charger, which has been professionally

installed, tested and approved by a qualified electrician.

No extension cables, cable drums, multiple sockets and damaged charging cables may be used

Variables for the discharge of the high-voltage battery:

Self-discharge rate per day: Approx. 0.1% SoC in the case of a SoC from about 30%

Per defrosting process: Approx. 2.65% SoC

Per Km driving operation: Approx. 0.3% SoC

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Recharging hybrid vehicles (only mild hybrid – nomenclature "h")

Option 1: Charge the 12 V battery via the jumper cable connection in the engine compartment until the vehicle is

ready to start, then continue with option 2 or 3, or continue normal charging

Option 2: Let the engine run at idle for at least 15 minutes

Option 3: Let the engine run at 2,000 rpm for at least 5 minutes

Recharging electric/F-CELL vehicles

High voltage batteries have to be charged until the state of charge (SoC, display in the instrument cluster) has reached

at least 50%.

Hint:

If the critical SoC is displayed in the instrument cluster, the HV battery must be recharged.

The self-discharge rate is about 0.1% SoC per day with a medium state of charge. As the SoC increases, the self-

discharge rate increases significantly. For this reason, electric vehicles in long-term storage should ideally have a SoC

of at least 20% to a maximum of 55%. This avoids an excessive self-discharge rate.

The all-electric vehicles that are charged with 220 V in the interim shall not be included in the battery

trickle charge, since the 12 V battery is charged automatically during the charging process. The charging

cable shall be disconnected immediately after the charging process is complete.

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5.6.4 Battery Care for Vehicle Logistic Center (VLC) Four weeks after vehicle arrival (28 days), all vehicles batteries generally have to be charged, according the instructions for 12

Volt and high voltage batteries. In connexion the batteries are to be recharged every six weeks (42 days).

Hint: The vehicle may only be forwarded to dealerships with the display message “Battery Ok” and a SoC in the high-voltage

battery of at least 10%.

Hint: In the case of vehicles that have been outsourced as part of a factory operation (Campaign center in the country of

production), a high-voltage battery SoC of at least 55% at the EQC and 26,5% for EVA2(analogous factory setting) shall be

ensured for dispatch.

Batteries that need to be recharged shall not be removed or disconnected for this purpose!

Charging instructions

The positive terminal of the charging cable shall be connected to the charging terminal point of the pre fuse box in the

engine compartment, and the ground terminal shall be connected to the ground terminal point.

Figure 88: Battery charging station (example)

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5.6.5 Battery Care Process at Seaports Six weeks after vehicle arrival, all vehicles batteries generally have to be charged, according the instructions for 12 Volt and

high voltage batteries. In connexion the batteries have to be recharged every six weeks (42 days).

Hint: The vehicle may only be forwarded with the display message “Battery Ok”.

Electric vehicles with the display message for the recharging of the high-voltage battery (HV-SoC ca.19 %) at

Port entrance or as part of the port handling, must be reloaded to at least 30 % up to a maximum of 55 %

SoC before shipment.

5.6.6 Battery Care Process at Vehicle Preparation Center (VPC) You can find information on the battery care process in VPCs in the section entitled "Vehicle Maintenance during

Storage in the VPC" (see page 89).

Hint: The vehicle may only be forwarded to the dealerships with the display message “Battery Ok” and a high-voltage SoC of at

least 10%.

Documentation of

battery maintenance Battery care is documented according to the standard.

Battery care process The battery care process is performed according to the time schedule (system-

controlled, DMS/IVIS).

The time schedule may be exceeded by a maximum of one week.

Battery handling Batteries are handled according to the standard.

Batteries always remain in the vehicle.

Battery charger Battery chargers correspond to the GSP standard requirements

Only approved battery chargers are used.

The charging voltage is limited to 14.4 V

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5.7 Vehicle Maintenance Program during Storage in the VPC Special care regulations apply for stock vehicles in the VPC. These results, among other things, out of special local

climatic conditions and possibly the environmental conditions. Since the VPCs all over the world have comprehensive

workshop equipment, including an automatic car wash, it is relatively easy to implement a care program.

Regular vehicle care ensures that the vehicles are available immediately and in perfect condition when they are

requested by the dealer, and that the number of complaints about the surface of the paint, the tires, the battery, etc. is

reduced considerably.

The contractual agreement and the payment of the arising expenses for the long-term storage care program are the

task of the responsible national organization in the market (MPC).

The following instructions apply to vehicles that are in storage in the VPC for 42 days and more (long-term storage). The

specifications also apply to the external storage areas of the VPC, e.g. in ports or external storage facilities.

The specifications of the OM (guideline on shipment and storage areas) and the specifications in Chapter 3 (see page 9)

apply to the storage areas and/or warehouses, multi-level car parks, etc.

The storage care program of a VPC covers the following inspection points:

Transport protection application

Car wash

Brakes

Tires

Battery

Work instruction for the storage care program

Transport protection measures

Transport protection applications, e.g. film or full body covers, shall be removed completely when they reach their

expiration date (see transport document) to prevent damage to the painted surface.

Car wash

Vehicles shall be washed according to the specifications in Section 5.1. The surface of the vehicle shall be checked.

Any remaining residues (residual adhesive, bird lime, etc.) shall be removed manually. In the case of flash rust on the

entire surface, it is recommended to wash the vehicle with oxalic acid (see page 49).

Brakes

Check the front and rear brake disks for signs of corrosion.

Please perform the following steps, if the components display clear signs of corrosion (flash rust).

Drive the vehicle for between 1 and 10 km on a safe route within the premises of the VPC.

Perform medium to hard brake applications at a maximum permissible speed of 40 km/h.

If signs of corrosion are still present when the vehicle is checked, repeat the driving cycle with further medium to

hard brake applications until the corrosion has disappeared to an overwhelming extent. The process shall be

interrupted after 14 brake applications in order to let the brake system cool down for approx. 60 seconds.

After the cleaning process, check whether you can feel a pulsation on the steering wheel/brake pedal. In this case,

all brake disks and brake linings shall be replaced. However, this work should not be performed until shortly before

the vehicle is delivered to the dealer.

Check if you can hear a grinding noise while braking or while driving slowly without applying the brakes.

The noise can be heard best when driving alongside a wall (noise reflection). If you hear such a grinding noise, the

brake disks and brake linings shall also be replaced.

Tires

Check the tire pressure of all four tires.

Ensure that the tire pressure is at least 50 psi/3.5 bar.

Perform a visual inspection to check the tires for external damage.

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Battery

Each battery has to be generally checked on arrival based on the displayed message in the instrument cluster

(Transport mode) before storage.

If a vehicle is stored immediately (without VPC Vehicle check), the announcement in the instrument cluster

have to be “Battery OK - 40 remaining days “ . With an announcement below 40 days, the battery has to be

recharged before storage. If the SoC of a high-voltage battery is less than 20% it must also be recharged. In

connexion the batteries have to be recharged every six weeks (42 days).

Vehicles those immediately receive the VPC Vehicle Standard Check(VSC or PDI), receive the battery charge

during the process. Vehicles leaving the VPC (transport mode actively) can only be released with the

announcement „Battery ok “.

The battery maintenance of all batteries has to take place according the instructions (S. page 84/85).

Additional scopes after 6 respectively 12 months:

For a storage period longer than 6 months, the brake fluid must be replaced.

(WIS Doc. Ref. AP00.20-P-1100B)

For a storage period longer than 12 months, the engine oil must be replaced.

(WIS Doc. Ref. AP00.20-P-1100B)

The inspections that are performed are entered on a form (maintenance sheet) and later entered in the system as well.

The purpose of this is to ensure that the maintenance performed can be traced without gaps and to control the

maintenance system in which the vehicles are managed and the care cycle is calculated.

An example of a form for care documentation can be found here: See Long Term Storage Record Sheet

EDP system The storage care program is managed with an EDP system (SAP/DMS, etc.)

that selects the vehicles that require care automatically every 42 days.

The program contains all the mandatory modules listed below.

Tires Tire pressure check and rotation of the wheels to prevent flat spots.

Brakes Brake check for eliminating corrosion.

The brakes should be firmly applied at the end of the care program in order

to dry wet brake disks by means of braking.

Battery care Battery care (charging).

Car wash The care program is repeated every 42 days. If the vehicle is in covered

storage, the wash can be omitted, depending on the condition of the vehicle.

In this case, the vehicle will be washed within the next maintenance.

Transport protection

measures Transport protection applications, e.g. paint protective film or full body

covers, are completely removed when they reach their expiration date.

Additional scopes The additional sizes are implemented according to the specifications.

mailto:[email protected]?subject=Long%20Term%20Storage%20Record%20Sheet%20-%20Bitte%20um%20Zusendung

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5.8 QM System Every logistics service provider shall have functioning quality management in order to fully satisfy the quality standards

of Mercedes-Benz. Quality management comprises the planning, control and monitoring of the quality of a process or

process result, thereby contributing to the improvement of quality and the validation of modern logistics processes.

The aim of quality management is to continuously optimize processes, to reinforce and further develop existing

structures, to increase the employees' motivation, and to maintain and increase customer satisfaction. Well-established

quality management offers the opportunity to detect deviations in the process at the earliest possible time, to analyze

the cause of the fault quickly, to remedy it for the long term, and prevent it in the future through coherent

documentation and communication to all employees. We are speaking of a quality structure that strengthens a

company and makes it a reliable partner according to the concept of quality of Mercedes-Benz.

The following section focuses on the individual modules and their requirements regarding the quality management

system and its content for distribution center. The quality characteristics that are relevant to transport can be found in

the operations manual. The QM/KQR standards are provided in the Appendix.

Operations Manual

The service provider shall obtain all information on vehicle transport, vehicle handling and vehicle storage from the

online operations manual to ensure that they are working with the latest information at all times. Strict adherence to

these specifications enables perfect vehicle handling and has a significant positive influence on the rate of shipping

damage. The contents shall also be applied and, if necessary, demanded for the daily interaction with transportation

companies and other transport service providers that deliver or collect the vehicles. The operations manual also serves

as a technical basis for invitations to tender. Adherence to all specifications is checked as part of compound audits

(SC/WTP), logistics process audits and audits of vehicles in stock (QM/KQR).


Description of the core process

A core process encompasses all activities whose purpose is to increase the added value of the company. It can be

derived from the core competence of an organization and it integrates all required sub-processes and defines all the

interfaces. The detailed description and holistic representation (figure 91) form the basis for comprehensible and

transparent internal company communication and process control.

The process shall be communicated to all employees in a comprehensible way in order to ensure a high degree of

transparency and process reliability.

The aim is for each employee:

To be familiar with the overall process,

To know which product it may expect from the supplier,

To know the product involved in the corresponding process step, including all detailed requirements for delivery to

the corresponding customer.

This allows deviations to be detected and remedied quickly.

The knowledge that each person involved in the process has on tasks, skills and responsibilities forms the basis for an

efficient and stable overall process and thus for a high level of product quality.


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Audit requirement

Each employee according to their activity can explain the core process description including diagrams; see the

following examples.

Figure 89: PDI process China (example)

Figure 90: Detailed description of the SOP in China (example)

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Figure 91: SVC process in Taiwan (example)

Work instruction

A work instruction shall be available in each working area to ensure that the operation steps and tasks are available to

every employee. Ideally, the work instruction should be posted on the notice board so that it is accessible to all

employees. It provides a detailed description, both written and illustrated (figure 94), of the sub-process that is

performed at this station. The employee concerned is also able to give a detailed explanation of the work instruction.

Figure 92: Work instruction on the notice board (example)

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Internal audits for the purpose of quality assurance

No organization and no measure works automatically after it is implemented. It is important for this issue to be

followed up and further developed. This is why it is necessary to carry out internal audits to ensure that the level of

process and product quality remains consistently high.

The audits should be performed by trained and highly qualified specialists. The aim of these systematic and continuous

audits is to ascertain whether the processes and the products involved

Correspond to the specifications

Are suitable for achieving the aims

Have potential for optimization.

The results are documented, evaluated, archived, and presented to the management on a regular basis (submission

during audits). Corrective action is initiated in the case of deviations and a re-audit is carried out if necessary.

Necessary audits are:

The purpose of compound audits is to ascertain the condition of the overall area in terms of safety and security,

the surfaces of roads and storage areas, lighting, etc. The audit is performed according to the contents of the OM

(SC/WTP).

The purpose of process audits is to check the vehicle-related processes in the distribution centers and to optimize

them if necessary. The audit is performed on the basis of the contents of this standard (QM/KQR) and extracts

from the operations manual.

The audit forms provided by the central SC/WTP and QM/KQR departments can be viewed in Chapter 6. Needless to

say, they can be drawn on for internal audits and self-checking.

Complaint management

Complaint management refers to the systematic handling of customer complaints. It covers the planning,

implementation and control of all measures that are necessary for processing a complaint.

Within complaint management, a distinction is made between aims relevant to customer relationships and aims

relevant to quality.

The most important aims relevant to customer relationships are to maintain customer satisfaction and promote a

customer-oriented corporate image.

The quality-relevant aims include using complaints to improve product quality and avoid (internal and external) costs

caused by mistakes.

Corporate management shall therefore draw up a complaint management process and firmly embed it in the company.

This means that the tasks, skills and responsibilities are fully clarified and communicated to all employees. Employees

were selected specifically for this task and obtained explicit qualifications.

Complaints shall always be processed in a standardized manner; this ensures reliability and a binding nature for both

sides involved in the process. A sample process for complaint management is provided below.

1. First: Select employees, clarify tasks/skills/responsibilities and qualify employees.

2. Make regular inquiries about satisfaction as a preventive measure to strengthen customer relationships.

3. Record and document incoming complaints.

Send a confirmation of receipt to the customer, e.g. within 48 hours.

Forward the complaint to the specialist department. Observe a specified time rule, e.g. 2 days for the fault analysis

(tracking).

4. Identify possible solutions in the specialist department; define and implement an immediate measure if necessary.

Prepare a long-term solution and implement measures for remedying faults.

5. Ensure that the measure is effective by performing random quality checks.

6. Inform the customer about the results of the solution.

7. Document the measures for the long term and communicate them (lessons learned).

A problem can be documented in the form of an 8D report. The advantage of such a report is that it provides fault

documentation, including the corresponding time schedule, fault remedy measure and sustainability check, that is

comprehensible to everyone, see document "8D Report Form".

mailto:[email protected]?subject=8D%20Berichtsformular%20-%20Bitte%20um%20Zusendung

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Quality feedback loop (QFL)

The QFL is an instrument for developing and validating quality. Establishing a QFL helps to ensure that the quality

targets required by Daimler AG are achieved. QFLs can be applied in a wide variety of areas in a company. They provide

methodical support with the determination of faults and their causes. The consistent application of QFLs helps to

remedy faults for the long term.

The feedback loop consists of the following steps:

Measuring the TARGET and ACTUAL statuses

Specifying measures, responsibilities and deadlines

Implementing the measures

Evaluating effectiveness

Figure 93: Quality feedback loop

During the control phase (measuring), the quality targets and specifications are checked on the basis of a

TARGET/ACTUAL measurement and the results are documented. This is usually done as part of a final inspection, also

known as a Q gate. The reports from the Q gate are integrated into the reporting that is presented to the management

in order to achieve a continuous improvement in quality.

Should deviations be detected during this inspection, an examination for the purpose of analyzing the causes shall be

initiated.

The first step involves defining immediate measures and appointing a fault remedy manager (FAV). This person initiates

the required measures and evaluates them in terms of effectiveness. A target deadline is specified in advance to ensure

that the fault is remedied promptly and in a binding manner.

The evaluation of effectiveness (spot checks or 100% checks, as appropriate) is kept up until the fault has been

remedied once and for all and the process is without faults again. The result and the cause shall be reported to the

affected areas and the management. All findings gained from fault remedy measures and the Q reports are integrated

into the revision and optimization of the internal specifications and quality targets. This regulating process is also

referred to as a continuous improvement process (CIP).

Measuring the TARGET and ACTUAL

statuses

Specifying measures, responsibilities and

deadlines

Implementation of the measures

Evaluation of effectiveness

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Escalation process

A description of and agreement on an escalation process, both internally and externally, is necessary for solving severe

problems/faults quickly and in a target-oriented manner. If two parties cannot agree on a topic due to a different

understanding or different task descriptions, this often leads to unnecessary and costly project delays.

It is recommended to agree on an escalation model with the business partner in order to solve such issues in a

professional way. This involves jointly specified regulations (time rule, etc.) that allow problems to be addressed to the

next decision-making level in a quick, factual and target-oriented way (see example below).

Figure 94: Escalation process (example)

Training on VPC processes

In order to ensure that work procedures run smoothly, workers shall receive basic and professional technical training.

Employees are thus required to participate in internal or external training courses regularly (at least once per year).

Training topics include:

Benchmark training on the assessment of painted surfaces etc. that corresponds to the Mercedes-Benz

specifications for personnel involved in the vehicle check

VPC processes from vehicle preparation and car wash to finish

Driver training

Fire fighting, first aid, etc.

The aim is for the employees to enhance both their professional and their social skills. Furthermore, it is important to

make sure that every employee is familiar with the individual process steps; this enables employees to be deployed at

all stations when necessary (illness etc.).

Training on rework

Employees who work in the technical area of a company shall participate in advanced technical training every year in

order to ensure a high level of rework quality. Due to the steady increase in requirements for the workshop personnel,

it is recommended to train specialists for the different manufacturing areas (electronics/body/paint, etc.) over the

years. The resulting requirements are identical to the requirements for repair workshop personnel. These specialists

can, in turn, be deployed internally as multipliers and trainers (training of new employees).

Technical product and repair training shall generally be booked through the national organization or directly via GSP.

Paint manufacturers also offer corresponding technical training.

Link to Global Training:

Intranet: http://gt.intra.corpintra.net/

Internet: http://gt.mercedes-benz.com/

GM

No solution after 48 h

Department management

No solution after 5 days

Person in charge/team

http://gt.intra.corpintra.net/

http://gt.mercedes-benz.com/

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Key Figures

Key figures represent a benchmark or quantitative information that provides information on certain developments in the

company. Key figures are used to compare ongoing developments, e.g. year-on-year profit development etc. They

provide support for decision making, the control and quality control of measures and processes. Logistics key figures

can provide information on physical, administrative and ordering performance quantities, the attainment of service

levels, and logistics costs. They are a fundamental part of modern corporate management and therefore one of the

requirements in the QM/KQR process audit. Below are the most important key figures of a logistics center:

"NOK rate"/first time capability, based on overall throughput/month (not including quick rework)

Faults per hundred vehicles (FPHV – production-related)

Warranty costs/unit (PNAK) based on overall throughput/month

Further key figures:

Damage rate entering the VPC: What percentage of the faults is caused externally/transport damage.

Internal damage rate in the VPC: What percentage of faults is caused internally.

Spare parts/material/software availability in %

Internal audits (number)

External audits (result in %)

Complaint rate for dealers (complaint management)

Audit requirements for quality management:

Daimler OM

The VPC has online access to the operations manual.

The responsible employees are familiar with the contents and make sure they

are distributed and applied.

Description of the core

process There is a description of the core process (verification).

Internal audits for the

purpose of quality

assurance

Regular internal audits are conducted (verification).

Complaint management

(CIP) Functioning complaint management has been established.

There is a process description (verification).

Quality feedback loop There is a process description for the quality feedback loop (verification).

The fault remedy process is performed, e.g. according to the 8D report method.

Escalation process An escalation process that has been agreed on with the partners involved in the

process has been described (verification).

Training on VPC

processes Training on VPC processes is provided every year. Documents and verification

are available.

Additional training on the topics of occupational health and safety, vehicle

handling, fire protection/firefighting, etc. is offered. Verification is available.

Training on rework VPC employees are trained according to their work profiles regularly, at least

once a year. Verification is available.

Collection of key figures Key figures are collected and used for the CIP process.

Work instructions There are work instructions for each workstation.

They are affixed to the stations such that they are easy to see.

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6. Process Audit In order to ensure the Mercedes-Benz process standards in vehicle logistics, the central quality management

organization performs regular audits on the basis of the following audit template. This ensures that the specifications

are implemented uniformly all over the world and that the quality of the vehicles that are transported to the dealers is

on a consistently high level.

See document "FL001_Audittemplate_Prozessaudit.xlsx"

See document "Compound Audit Logistic Provider"

mailto:[email protected]?subject=FL001_Audittemplate_Prozessaudit.xlsx%20-%20Bitte%20um%20Zusendung

mailto:[email protected]?subject=Dokument%20Compound%20Audit%20Logistic%20Provide%20-%20Bitte%20um%20Zusendung

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7. Contacts for Logistics Topics

Contact

Planning logistics center FP/DRE

Location risk analysis INS/CI

Logistics infrastructure SC/WTP

Logistics process and safety SC/WTP

Overall document and technical

processes

QM/KQR

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8. List of Abbreviations CCC label China Compulsory Certification

CI Corporate Identity

CIT Case Information Tool

DiBa Digitale Betriebsanleitung (Digital Owner's Manual)

DISY Distribution System

DOM Daimler Operations Manual

EPC Electronic Parts Catalog

ESD Electrostatic Discharge

FAV Fehlerabstellverantwortlicher (fault remedy manager)

FBC Full Body Cover

VLC Vehicle Logistic Center

FPOR First Point of Rest

GL Geschäftsleitung (general management)

GSP Global Service and Parts

IMO International Maritime Organization

MPC Market Performance Center

OM Operations Manual

PDI Pre-Delivery Inspection

QFL Quality Feedback Loop

RoRo shipping traffic Roll-on/roll-off shipping traffic

SA Sonderausstattung (special equipment)

SoC State of Charge

TIPS Technical Info Pool Service

VPC Vehicle Preparation Center

VSC Vehicle Standard Check

WIS Workshop Information System

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9. Table of Figures Figure 1: Risk analysis ......................................................................................................................................................... 7 Figure 2: Example of an outdoor facility ........................................................................................................................... 11 Figure 3: Truck loading and unloading area (example) ..................................................................................................... 12 Figure 4: VPC Baltimore, individual workstations arranged in a fish-bone pattern (example) .......................................... 14 Figure 5: VPC Shanghai, conveyor belt systems (example) .............................................................................................. 14 Figure 6: Illuminance measurement (example) ................................................................................................................ 17 Figure 7: Mobile battery charger (example) ..................................................................................................................... 20 Figure 8: Wall box (example) ............................................................................................................................................ 20 Figure 9: Assessment positions........................................................................................................................................ 23 Figure 10: Inspection plan (example) ............................................................................................................................... 24 Figure 11: Sketch of lighting arrangement ....................................................................................................................... 26 Figure 12: Sketch of lamp unit dimensions ...................................................................................................................... 27 Figure 13: Surface damage (example) .............................................................................................................................. 29 Figure 14: Interior protection (example)........................................................................................................................... 29 Figure 15: Functional failure of SRS ................................................................................................................................. 31 Figure 16: Poly-V belt has come off/is loose ................................................................................................................... 31 Figure 17: Oil loss in the transmission (clearly visible on the floor) ................................................................................. 31 Figure 18: Rubber grommet on firewall is leaky (water entry, electrical systems/function affected) ............................. 31 Figure 19: Wrong version of information label for automatic child seat recognition ........................................................ 31 Figure 20: Water entry in trunk/load compartment (electrical systems/function affected) ........................................... 31 Figure 21: Damage to a make-up mirror .......................................................................................................................... 32 Figure 22: Poor fit of bottom left paneling ....................................................................................................................... 32 Figure 23: Instrument panel damaged on the right .......................................................................................................... 32 Figure 24: Valve cap missing ............................................................................................................................................ 32 Figure 25: Poor fit of front left drip rail............................................................................................................................. 33 Figure 26: Model designation not glued on properly ........................................................................................................ 33 Figure 27: Luggage net in load compartment is the wrong color (too light)..................................................................... 33 Figure 28: Adhesive on front fold of the trunk lid visible in the center ............................................................................ 33 Figure 29: Inner wheel arch not mounted correctly ......................................................................................................... 33 Figure 30: Systems for washing vehicles (example) ......................................................................................................... 36 Figure 31: Car wash (example) ......................................................................................................................................... 37 Figure 32: Car wash (example) ......................................................................................................................................... 37 Figure 33: Spray angle of > 30° pointing backward and downward (example) ................................................................ 38 Figure 34: Spray angle of < 90° for horizontal surfaces (example) .................................................................................. 38 Figure 35: Cabriolet roof (example) .................................................................................................................................. 39 Figure 36: Width of the wheel guide in the car wash is at least 360 mm (example) ........................................................ 39 Figure 37: Spray nozzle setting (example) ........................................................................................................................ 40 Figure 38: Setting of the sensor system for the underbody wash (example) ................................................................... 40 Figure 39: Spray pattern (example) .................................................................................................................................. 40 Figure 40: Spray pattern (example) .................................................................................................................................. 40 Figure 41: Devices used for the manual car wash (example) ........................................................................................... 41 Figure 42: Manual prewash (example) ............................................................................................................................. 42 Figure 43: Bucket for the main wash (example) ............................................................................................................... 42 Figure 44: Manual main wash (example) .......................................................................................................................... 43 Figure 45: Manual rinsing (example) ................................................................................................................................ 43 Figure 46: Manual drying (example) ................................................................................................................................. 44 Figure 47: High pressure cleaner for manual underbody wash (example) ....................................................................... 45 Figure 48: Spraying pattern for cleaning the entire underbody (example) ....................................................................... 46 Figure 49: Information on the spare wheel well (example)............................................................................................... 46 Figure 50: Perfect washing result (example) .................................................................................................................... 47 Figure 51: Pictogram of acids (example) .......................................................................................................................... 48 Figure 52: Can containing acid cleaning agent (example) ................................................................................................ 48 Figure 53: Special tool for tie-down eyes ......................................................................................................................... 50 Figure 56: Completed inspection sheet (example) ........................................................................................................... 51 Figure 57: Wireless vehicle inspection project (example) ................................................................................................ 55 Figure 58: Wireless vehicle inspection project (example) ................................................................................................ 55 Figure 57: Underbody check (example) ............................................................................................................................ 57 Figure 58: Autoline VPC Taiwan, information is exchanged 7 x per day .......................................................................... 58 Figure 59: "Quick rework" tool cart (example) ................................................................................................................. 59

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Figure 60: "Quick rework" on the line (example) .............................................................................................................. 59 Figure 61: Workshop (example) ........................................................................................................................................ 60 Figure 62: "Spot repair" workplace in the workshop (example) ....................................................................................... 60 Figure 63: Special tools (example) ................................................................................................................................... 61 Figure 64: Mirror tag (example) ........................................................................................................................................ 62 Figure 65: Cleaning agents and polish from Mercedes-Benz ........................................................................................... 64 Figure 66: Incorrect storage of removed parts (example) ................................................................................................ 65 Figure 67: Incorrect storage of removed parts (example) ................................................................................................ 65 Figure 68: Correct storage of removed parts (example) .................................................................................................. 65 Figure 69: Correct storage of removed parts (example) .................................................................................................. 65 Figure 70: Spare parts storage (example) ........................................................................................................................ 66 Figure 71: Source: BLG leaflet (example) ......................................................................................................................... 69 Figure 72: Vehicle in the process (example) .................................................................................................................... 69 Figure 73: Mishandling (example) .................................................................................................................................... 69 Figure 74: Allocation of numbers on the vehicle .............................................................................................................. 70 Figure 75: Q control ......................................................................................................................................................... 74 Figure 76: Areas to be waxed ........................................................................................................................................... 75 Figure 77: Vehicle on a vehicle lift (example) ................................................................................................................... 76 Figure 78: Removal of the underfloor cover according to the work instruction (example) .............................................. 77 Figure 79: Covered up areas that need not be waxed (example) ..................................................................................... 77 Figure 80: Covered up exhaust system (example) ........................................................................................................... 77 Figure 81: Waxing specification for the W166 (example) ................................................................................................. 78 Figure 82: Waxing process (example)............................................................................................................................... 78 Figure 83: Waxed underbody (example) ........................................................................................................................... 78 Figure 84: Completed waxing process (example) ............................................................................................................. 78 Figure 85: Display of transport mode in the instrument cluster....................................................................................... 80 Figure 86: Transport mode display in the instrument cluster (example) .......................................................................... 81 Figure 87: Battery charging stations (example) ................................................................................................................ 82 Figure 88: Battery charging station (example) ................................................................................................................. 85 Figure 89: PDI process China (example) .......................................................................................................................... 90 Figure 90: Detailed description of the SOP in China (example) ....................................................................................... 90 Figure 91: SVC process in Taiwan (example) ................................................................................................................... 91 Figure 94: Work instruction on the notice board (example) ............................................................................................. 91 Figure 93: Quality feedback loop...................................................................................................................................... 93 Figure 94: Escalation process (example) .......................................................................................................................... 94