Request_for_Proposal_2031ZA17R00001_DRAFT.pdf

SOLICITATION, OFFER AND AWARD 1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

RATING PAGE OF PAGES

2. CONTRACT NUMBER 3. SOLICITATION NUMBER 4. TYPE OF SOLICITATION 5. DATE ISSUED 6. REQUISITION/PURCHASE NUMBER

CODE7. ISSUED BY 8. ADDRESS OFFER TO (If other than item 7)

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

SOLICITATION

9. copies for furnishings the supplies or services in the Schedule will be received at the place specified in item 8, or ifSealed offers in original and hand carried, in the depository located in until local time

CAUTION - LATE Submissions, Modifications, and Withdrawals: See Section L, Provision No. 52.214-7 or 52.215-1. All offers are subject to all terms and conditions contained in this solicitation.

10. FOR

INFORMATION

CALL:

A. NAME B. TELEPHONE (NO COLLECT CALLS)

AREA CODE NUMBER EXTENSION

C. E-MAIL ADDRESS

11. TABLE OF CONTENTS

(X) SEC. DESCRIPTION PAGE(S) (X) SEC. PAGE(S)DESCRIPTION

A B C D E F G H

I

J

K

L

92 -111 M EVALUATION FACTORS FOR AWARD

INSTRUCTIONS, CONDITIONS, AND NOTICES TO OFFERORS

REPRESENTATIONS, CERTIFICATIONS AND OTHER

STATEMENTS OF OFFERORS

PART IV - REPRESENTATIONS AND INSTRUCTIONS

LIST OF ATTACHMENTS

PART III - LIST OF DOCUMENTS, EXHIBITS AND OTHER ATTACH.

CONTRACT CLAUSESSOLICITATION/CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/COSTS

DESCRIPTION/SPECS./WORK STATEMENT

PACKAGING AND MARKING

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

CONTRACT ADMINISTRATION DATA

SPECIAL CONTRACT REQUIREMENTS

NOTE: Item 12 does not apply if the solicitation includes the provisions at 52.214-16, Minimum Bid Acceptance Period.

OFFER (Must be fully completed by offeror)

12. In compliance with the above, the undersigned agrees, if this offer is accepted within calendar days (60 calendar days unless a different period is inserted by the offeror) from the date for receipt of offers specified above, to furnish any or all items upon which prices are offered at the set opposite each item, delivered at the designated point(s), within the time specified in the schedule.

13. DISCOUNT FOR PROMPT PAYMENT

(See Section I, Clause No. 52.232-8)

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments to the SOLICITATION for offerors and related documents numbered and dated):

10 CALENDAR DAYS (%) 20 CALENDAR DAYS (%) 30 CALENDAR DAYS (%) CALENDAR DAYS(%)

DATEAMENDMENT NO.AMENDMENT NO. DATE

15A. NAME AND

ADDRESS

OF OFFER-

OR

CODE FACILITY 16. NAME AND THE TITLE OF PERSON AUTHORIZED TO SIGN OFFER

(Type or print)

15B. TELEPHONE NUMBER

AREA CODE NUMBER EXTENSION

15C. CHECK IF REMITTANCE ADDRESS IS

DIFFERENT FROM ABOVE - ENTER SUCH

ADDRESS IN SCHEDULE.

17. SIGNATURE 18. OFFER DATE

AWARD (To be completed by Government)

19. ACCEPTED AS TO ITEMS NUMBERED 20. AMOUNT 21. ACCOUNTING AND APPROPRIATION

22. AUTHORITY FOR USING OTHER THAN FULL OPEN COMPETITION:

10 U.S.C. 2304 (c) ( )41 U.S.C. 3304(a)

24. ADMINISTERED BY (If other than Item 7)

26. NAME OF CONTRACTING OFFICER (Type or print)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other authorized official written notice.

AUTHORIZED FOR LOCAL REPRODUCTION

Previous edition is unusable

23. SUBMIT INVOICES TO ADDRESS SHOWN IN

(4 copies unless otherwise specified)

25. PAYMENT WILL BE MADE BY

27. UNITED STATES OF AMERICA

(Signature of Contracting Officer)

28. AWARD DATE

CODE

ITEM

STANDARD FORM 33 (REV. 6/2014)

Prescribed by GSA - FAR (48 CFR) 53.214 (c)

SEALED BID (IFB)

NEGOTIATED (RFP)

(Hour) (Date)

PART I - THE SCHEDULE PART II - CONTRACT CLAUSES

EP001

BEP-ACQUISITION

Bureau of Engraving and Printing, Washington, DC 20228-0001

2031ZA17R00001

1:00PM

Gladys Wilks gladys.wilks@bep.gov

2 - 5 6 -79

81 - 86 87 - 90

142-146 133-141

112-119

06/27/2017

202 874-2636

05/24/2017

122-132

(See RFP for Submission Instructions)

DRAFT

2 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

SECTION B – SUPPLIES OR SERVICES AND PRICES/COSTS

The Contractor shall provide facilities, labor, materials, fabrication, assembly, delivery, and all other efforts necessary for a turn-key installation and operation of non-sequential Large Examining and Printing Equipment (ns-LEPE) machines in accordance with Section C of this document, for the Bureau of Engraving and Printing (BEP).

This requirement will result in a firm fixed price contract for new equipment. Contractor shall provide pricing for one (1) ns-LEPE that will be installed at the Bureau of Engraving and Printing’s (BEP) Western Currency Facility (WCF) located in Fort Worth, Texas. Contractor shall also provide pricing for up to five (5) optional ns-LEPE machines, spare parts, UV curing systems and demonstration materials, which will be installed at BEP’s WCF and/or Washington, DC Facility (DCF).

Offeror is required to submit, at a minimum, an offer that conforms to the solicitation specifications with pricing for all Contract Line Item Numbers (CLINs). Contractor shall price each individual CLIN on a firm fixed price basis. Failure to submit an offer which conforms to the solicitation specification may render the proposal unacceptable. The Government will negotiate payments based on the deliverable schedule submitted by the Contractor and agreed to by the Government.

ns-LEPE #1

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

0001 ns-LEPE 1 (WCF) 1 EA $__________ $___________

0002 Factory Inspection Test 1 EA $__________ $___________

0003 Bureau Acceptance Testing 1 EA $__________ $___________

0004 Training (including travel costs)

1 EA $__________ $___________

OPTIONAL FOR ns-LEPE #1

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

0005 UV Curing System 1 EA $__________ $___________

0006 Demonstrations Materials C.7.3

1 EA $__________ $___________

0007 Spare Parts 1 EA $__________ $___________

0008 Vertical Numbering Blocks 1 SET $__________ $___________

0009 Finalization of Reports (C.5.1.35)

1 EA $__________ $___________

3 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

OPTIONAL ns-LEPE #2

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

1001 ns-LEPE 2 (DCF) 1 EA $__________ $___________

1002 Factory Inspection Test 1 EA $__________ $___________

1003 Bureau Acceptance Testing 1 EA $__________ $___________

1004 Training (including travel costs)

1 EA $__________ $___________

1005 UV Curing System 1 EA $__________ $___________

1006 Demonstrations Materials C.7.3

1 EA $__________ $___________

1007 Spare Parts 1 EA $__________ $___________

1008 Vertical Numbering Blocks 1 SETS $__________ $___________

1009 Finalization of Reports (C.5.1.35)

1 EA $__________ $___________

OPTIONAL ns-LEPE #3

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

2001 ns-LEPE 3 (WCF) 1 EA $__________ $___________

2002 Factory Inspection Test 1 EA $__________ $___________

2003 Bureau Acceptance Testing 1 EA $__________ $___________

2005 Training (including travel costs)

1 EA $__________ $___________

2006 UV Curing System 1 EA $__________ $___________

2007 Demonstrations Materials C.7.3

1 EA $__________ $___________

2008 Spare Parts 1 EA $__________ $___________

2009 Vertical Numbering Blocks 1 SET $__________ $___________

2010 Finalization of Reports (C.5.1.35)

4 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

OPTIONAL ns-LEPE #4

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

3001 ns-LEPE 4 (WCF) 1 EA $___________ $___________

3002 Factory Inspection Test 1 EA $___________ $___________

3003 Bureau Acceptance Testing 1 EA $__________ $___________

3005 Training (including travel costs)

1 EA $__________ $___________

3006 UV Curing System 1 EA $__________ $___________

3007 Demonstrations Materials C.7.3

1 EA $__________ $___________

3008 Spare Parts 1 EA $__________ $___________

3009 Vertical Numbering Blocks 1 SET $__________ $___________

3010 Finalization of Reports (C.5.1.35)

1 EA $__________ $___________

OPTIONAL ns-LEPE #5

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

4001 ns-LEPE 5 (DCF) 1 EA $__________

4002 Factory Inspection Test 1 EA $__________

4003 Bureau Acceptance Testing 1 EA $__________ $___________

4005 Training (including travel costs)

1 EA $__________ $___________

4006 UV Curing System 1 EA $__________ $___________

4007 Demonstrations Materials C.7.3

1 EA $__________ $___________

4008 Spare Parts 1 EA $__________ $___________

4009 Vertical Numbering Blocks 1 SET $__________ $___________

4010 Finalization of Reports (C.5.1.35)

5 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

OPTIONAL ns-LEPE #6

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

5001 ns-LEPE 6 (DCF) 1 EA $___________ $___________

5002 Factory Inspection Test 1 EA $___________ $___________

5003 Bureau Acceptance Testing 1 EA $__________ $___________

5005 Training (including travel costs)

1 EA $__________ $___________

5006 UV Curing System 1 EA $__________ $___________

5007 Demonstrations Materials C.7.3

1 EA $__________ $___________

5008 Spare Parts 1 EA $__________ $___________

5009 Vertical Numbering Blocks 1 SET $__________ $___________

6 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

SECTION C – DESCRIPTION/SPECIFICATIONS/STATEMENT OF NEED

C.1 STATEMENT OF NEED

This Statement of Need (SON) is for the design, fabrication, assembly, integration, delivery, installation, set-up, testing and training of a Non-Sequential Large Examining and Printing Equipment (ns-LEPE) machine that will convert previously printed sheets into finished currency.

The equipment to be supplied under this contract shall match the design and processing capabilities of the existing LEPE machinery in operation at both the DCF and WCF with the exception that the notes in the packages will not be in numeric sequence and the insertion of stars to replace removed product will not occur. Currency produced with the machinery to be supplied under this contract shall appear physically identical to that presently produced by the BEP with the exception of the numeric sequence of the notes within the packages and the paper band on straps width and printing.

C.2 DOCUMENTS

C.2.1 REFERENCED DOCUMENTS

Equipment to be delivered under this contract shall meet all current U.S. commercial codes and industrial standards, or equally stringent international standards, for manufacturing of high quality industrial equipment, commercial printing presses and finishing equipment to be utilized within an industry environment. At a minimum, all equipment shall conform to National Electric Code (NEC) standards.

The following is a listing of specific standards that the ns-LEPE shall meet:

All applicable sections of American Conference of Government Industrial Hygienists (ACGIH) (www.acgih.org)

All applicable documents related to Energy Policy Act of 1992 with specific reference to Executive Order 13123 (www.omb.gov)

All applicable Occupational Safety and Health Administration (OSHA) standards with specific references to OSHA standards 29 CFR 1910 (www.osha.gov)

All applicable codes and standards and environmental permitting of U.S.

Environmental Protection Agency (EPA) (www.epa.gov) and District of Columbia (DC) government (www.doee.dc.gov) and State of Texas (TX) government (www.tceq.texas.gov).

C.2.2 ATTACHED DOCUMENTS

The following lists the documents attached to this SON.

NOTE – Attachments identified with an asterisk (*) require a Non-Disclosure Agreement (NDA). All NDA documents provided under this contract shall be considered proprietary and sensitive to the government. NDA documents shall not be copied, scanned or reproduced without written approval by the contracting officer. All NDA documents shall be returned to the BEP when no longer required.

7 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

NOTE – Some documents will only be made available in redacted versions (abridged). Request to have copies of the original versions must be made to the Contracting Officer with information on why the information is required.

Identifier Title/Description 001 Paper Specifications* P: CDT5-1C Type V Currency Paper – 12Aug2015_abridged

P: CDT4-1B Type IV Currency Paper – 12Aug2015_abridged P: CDT1-B Type I Currency Paper – 12Aug2015_abridged P: NDBT5A NBP Type V – 12Aug2015_abridged P: NDBT4A NBP Type IV – 12Aug2015_abridged P: NDBT1A NBP Type I – 12Aug2015_abridged

002 Paper Skid Drawing 003 Drawings of Seals and Numeral Plates* Drawing 300608: Treasury Seal Drawing US-001: Universal Federal Reserve Seal Drawing DBNS-002: Federal Reserve Seal and Numeral Plate Drawing 3000609: Federal Reserve Numeral Plate 004 Letterpress Ink Specifications* Cope Spec. TCGB-1F Sept.1 2010 005 BEP-FRB Currency Skid 006 Paper Band Specification 007 Shrink-wrap Films Specification 008 BEP Label Specifications PSC-5 July27 2015 - Label Specification Drawing 30084 r1 - Cash-Pak Shipping Label Drawing 30085 - Cash-Pak Eagle Label Drawing of Bundle Label 009 Letterpress Packing and Blanket Materials 010 Drawing 30100 Strap of 100 Notes* 011 Drawing 30101 Bundle of 1000 Notes* 012 Drawing 30102 Brick of 4000 Notes* 013 Drawing 30083 Cash-Pak of 16000 Notes* 014 Cash-Pak Drop Test 015 Skid of 640000 Notes* 016 Brick Tank 017 Printing Location Drawings* Drawing PL123A1 Currency Sheet Layout* Drawing 30076 Currency Sheet Layout* 018 ns-LEPE Process Diagrams 092415* 019 Load Tag Sample 020A ns-LEPE Load Report 020B ns-LEPE Partial Load Report 020C ns-LEPE Consolidated Load Report 021 ns-LEPE Process Report

8 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

022 Site Drawing PE-100 023 IT Computer Attachments DOJ Ref Mapping PIVCard Certificates to a Privileged Account Open

Version

FIPS-PUB-200

NIST.SP.800-53r4 USGCB-Windows-Settings Combined Treasury TD P 85-01 and BEP Minimum Standard Parameters for Unclassified Systems 024 75.00-ENV-005-FW: EHS Boilerplate Requirements for Construction Services

Contractors 025 ns-LEPE Draft Test Plan

C.3 GOVERNMENT FURNISHED MATERIALS

The items listed in this section will be supplied by the government for utilization with the ns- LEPE. Any other materials required for the operation of the system shall be provided by the vendor as per section C.6.15 - Vendor Furnished Materials.

C.3.1 CURRENCY SHEETS

The ns-LEPE shall accept previously printed currency sheets that may include Offset and Intaglio printing. Federal Reserve currency sheets are presently processed in multiple sheet sizes and formats.

32-subject $1s and $2s – 561 +/- 1 mm long by 631 +/- 1 mm wide (22.09 inches +/- 0.04” by

24.84 inches +/- 0.04”). The sheets are printed with thirty-two (32) images; four notes across the sheets by eight down the sheet. The sheets are face and back Intaglio printed.

32-subject $5s, $10s, $20s, $50s and $100s – 582 +/- 1 mm long by 657 +/- 1 mm wide (22.91 inches +/- 0.04” by 25.87 inches +/- 0.04”). The sheets are printed with thirty-two (32) images;

four notes across the sheet by eight notes down the sheet, and have color bars and other non-note printing within trim margins. The sheets are face and back Offset and Intaglio printed.

50-subject $1s – 700 +/- 1 mm long by 818 +/- 1 mm wide (27.56 inches +/- 0.04” by 32.20 inches +/- 0.04”). The sheets are printed with fifty (50) images; five notes across the sheets by ten down the sheet. The sheets are face and back Intaglio printed.

Specifications for the papers are provided as Attachment 001. The drawings of the skids are Attachment 002.

During the term of this contract, the size and format of currency sheets and the printing previously applied for a denomination may change. Sheets shall not be considered square due to the intaglio printing process. All sheet dimensions are for blank paper prior to printing.

9 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

Sheets will be supplied in loads of up to a total of 20,000 sheets on two (2) skids with each skid holding up to 10,000 sheets. The two (2) skids constitute one load. Due to previous processing and removal of unacceptable sheets from the load the total number of sheets supplied may be less than 20,000 for a load. The sheets will be divided into sheets verified to be of acceptable print quality and sheets identified to contain defective notes.

C.3.2 TYPOGRAPHIC PRINTING ELEMENTS

The ns-LEPE shall utilize the BEP’s typographic printing elements for the production of the finished currency. The following will be furnished by the BEP:

Treasury Seals (LEPE orientation) Federal Reserve Universal Seals Federal Reserve Bank Designation Numerals (LEPE orientation) Federal Reserve Bank Seal with Designation Numerals

Drawings of the seals and numerals are provided as Attachment 003.

Mounting holes for the typographic printing elements are shown on the drawings. Typographic printing elements are to be shimmed to the correct printing heights by means of placement of paper shims between the printing element and the contractor provided mounting blocks.

The ns-LEPE shall allow the BEP to apply any graphical design for future seals while maintaining the thickness of the printing elements and mounting locations.

C.3.3 PAPER SHIMS

The ns-LEPE shall utilize BEP supplied paper shims to compensate for the height of individual Seals and Plates to provide a uniform embossing of the currency. BEP paper shims are available in the following thicknesses: 0.030 mm, 0.020 mm, 0.015 mm and 0.010 mm. Paper shims have holes pre-punched to align with the mounting locations on the seals and plates.

C.3.4 TYPOGRAPHIC INKS

The ns-LEPE shall utilize the BEP’s typographic printing inks. The BEP utilizes unique inks for the printing of the Serial Numbers, Treasury Seal, Federal Reserve Seal and Federal Reserve Designation Numeral or Letter/Numeral. The specifications for the typographic inks are provided as Attachment 004.

The following are the inks utilized by the BEP. The system supplied shall utilize these inks:

BEP 1401 – $1 Black Typographic Ink BEP 687 – $2 Black Typographic Ink BEP 1391 – $5 Black Typographic Ink BEP 895 – $10 - $100 Black Typographic Ink BEP 347 – $1 & $2 Green Typographic Ink BEP 1201 – $5 - $100 Green Typographic Ink

10 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

Time to clean and cleaning frequency of the typographic printing elements for individual inks listed above may vary and impact the performance of the system.

C.3.5 CURRENCY SKIDS

The ns-LEPE shall utilize the existing Bureau of Engraving and Printing-Federal Reserve Board (BEP-FRB) Currency Skids for the stacking of up to forty (40) cash-packs and stretch-wrapping in preparation for shipment to the Federal Reserve. The drawing of the skid is provided as Attachment 005.

C.3.6 BAND SPOOLS (Strap and Bundle)

The ns-LEPE shall use the BEP’s spools of paper bands for application around the 100 notes to form a Strap and around the 10 Straps to form a Bundle. Strap bands are printed. Bundle bands are plain unprinted bands. The specifications for the paper bands are provided as Attachment 006.

C.3.7 PACKAGING FILMS (Bundle, Brick, Cash-Pak and Skids)

The ns-LEPE shall use the BEP’s Bundle, Brick and Cash-Pak shrink-wrap films for the packaging of the notes. The Bundle film is a Linear Low Density Polyethylene (LLD-PE) material. The Brick film is a Polyvinyl Chloride (PVC) material. The Cash-Pak film is a LLD- PE material that has been printed and laminated. The specifications for the films are provided as Attachment 007.

The ns-LEPE shall use the BEP’s stretch-wrap film for the wrapping of the skids of Cash-Paks after palletizing. The BEP’s stretch-wrap film specification is included in Attachment 007.

C.3.8 LABELS (Bundle and Cash-Pak)

The ns-LEPE shall use the BEP’s Labels for the Bundles and Cash-Paks. One label is applied to each Bundle that contains bar-coded information applied over the face of the Bundle. Each Cash-Pak has two (2) labels applied, a shipping label that contains bar-coded information applied over the face and a BEP-FRB label that covers the window on the back of the Cash-Pak. The specifications and drawings of the labels are provided as Attachment 008.

C.3.9 PRINTING BLANKETS AND PACKING

The ns-LEPE shall use the BEP’s printing blankets and packing for the impression cylinder.

Blankets = 0.030” or 0.028” thick (0.76 or 0.71 mm) Packing = 0.032” or 0.034” thick (0.81 or 0.86 mm) BEP Typical Total Packing Thickness = 0.066” (1.68 mm)

Specifications for the blankets and packing used by the BEP are provided as Attachment 009.

11 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

C.4 PRODUCT REQUIREMENTS

The following are the product requirements for currency produced by the ns-LEPE. All currency and packages produced on the ns-LEPE shall have an identical appearance, durability and strength to existing currency and packages produced by the BEP.

C.4.1 CURRENCY NOTES

Federal Reserve Currency Notes shall have a nominal width of 156 mm +/- 2 mm (6.14 inches +/- 0.079”) with a nominal height of 66.5 mm +1.1/-2.5 mm (2.62 inches +0.043”/-0.098”).

Notes shall be cut so that the printed images are centered within +/- 1.5 mm of the centerline of the notes, taking into account the placement of the printed images on the sheet (Step and Repeat).

The following graphical illustrations, Figures 1 and 2, show the Typographic, “Letterpress”, printing that is required for the different currency designs presently in production at the BEP.

The illustrations are intended to only show the printing required, not the exact locations or scaling nor the exact colors of the inks to be utilized. The color coding of the typographic printing represent individual inks utilized. Printing shown with the same color coding is to be printed with the same ink.

Figure 1 ‐ $1 and $2 Denominational Currency Letterpress Printing

A T A12345678A

A12345678A

Serial Number

( l )

Federal Reserve Bank Seal &

Numerals (Color #1)

Serial Number

( l )

Treasury Seal

( l )

Federal Reserve

Designation Numerals

12 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

Figure 2 ‐ $5, $10, $20, $50 and $100 Denominational Currency Letterpress Printing

Each note shall have the following typographic printing applied:

(1) Serial Numbers

Two (2) alpha-numeric identifiers for every note produced for a denominational series consisting of between ten (10) and twelve (12) alpha-numeric characters. The length of serial number varies by the denomination and design series. Current $1s and $2s contain a ten (10) digit serial number; where $5s - $100s contain an eleven (11) digit serial number.

Serial numbers consist of one up to three prefix letter(s), eight numerals and one suffix letter. The following figure specifies the characters for the individual positions.

AA12345678A

AA12345678A

A1

Serial Number

( l )

Federal Reserve

Universal Seal

Serial Number

( l )

Treasury Seal

( l )

Federal Reserve Designation

Letter/Numeral

U T

13 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

The suffix position shall print English language letters ranging from the capital letter “A” through the capital letter “Z” with the exception of the letter “O”, and shall have the ability to print the star “” character. If multiple wheels are used, a star character shall be on each wheel.

The eight numeral positions shall range from 00000000 to 99999999.

The first prefix position (P1) shall print English language letters ranging from the capital letter “A” through “L” plus the capital letter “Z”. If multiple wheels are used, a “Z” shall be on each wheel.

The second and third prefix positions (P2 and P3) shall print English language letters ranging from the capital letter “A” through the capital letter “Z”, excluding the use of the capital letter “O”.

(2) Federal Reserve Seal (Universal or Individual Bank)

One (1) Letterpress printed seal per note location. Refer to the Attachment 003.

(3) Treasury Seal

One (1) Letterpress printed seal per note location. Refer to the Attachment 003.

P re fi x

Fu tu re

Te n

M il li o n s

M il li o n s

H u n d re d

Th o u sa n d s

Te n

Th o u sa n d s

Th o u sa n d s

H u n d re d s

Te n s

O n e s

P3

1 1 2 3 1 2 1 1 1 1 1 1 1 1 1 2 3

1 A G N A B 0 0 0 0 0 0 0 0 A H P

2 B H P B C 1 1 1 1 1 1 1 1 B I Q

3 C I Q C D 2 2 2 2 2 2 2 2 C J R

4 D J R D E 3 3 3 3 3 3 3 3 D K S

5 E K S E F 4 4 4 4 4 4 4 4 E L T

6 F L T F G 5 5 5 5 5 5 5 5 F M U

7 G M U G H 6 6 6 6 6 6 6 6 G N V

8 H N V H I 7 7 7 7 7 7 7 7 H P W

9 I P W I J 8 8 8 8 8 8 8 8 I Q X

10 J Q X J K 9 9 9 9 9 9 9 9 J R Y

11 K R Y K L K S Z

12 L S Z Z Z

__ = Blank (non‐printing space)

= Star Character

= unused position

= "Optional", not to be ordered with base machines ns‐LEPE Serial Number Characters C h ar ac te rs o n W h ee l

Blank Space

P2

P re fi x

Se ri e s

Wheel

Position P re fi x

B an k

P1

Su ff ix

SSerial Number

14 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

(4) Federal Reserve Designation Numerals ($1 and $2 Denominational Currency)

Four (4) numbers designating the Federal Reserve District for which the currency is printed. Federal Reserve Designation Numerals range from “1” through “12”.

(5) Federal Reserve Designation Letter/Numeral ($5, $10, $20, $50 and $100 Denominational Currency)

One (1) letter/numeral designating the Federal Reserve District for which the currency is printed. Federal Reserve Designation Letter/Numerals shall consist of the following combinations: “A1”, “B2”, “C3”, “D4”, “E5”, “F6”, “G7”, “H8”, “I9”, “J10”, “K11”, “L12”, the word “TEST” and a blank, non-printing, space.

C.4.2 STRAP

A Strap is one hundred (100) currency notes bound together face up, held together with a paper band. The paper band shall be tight enough to hold the notes together for processing and packaging. Position of the band on the Strap is shown.

Strap

Straps contains 100 notes.

Strap are held together with 39.0 mm +/- 0.2 mm wide paper band.

Image on paper band may be registered around strap.

31.8mm 1.25"

39.0mm 1.535"

The Strap with paper band is shown in the attached drawing, Attachment 010. The appearance, strength and durability of the Straps produced on the ns-LEPE shall be identical to the existing Straps produced by the BEP.

15 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

C.4.3 BUNDLE

A Bundle is ten (10) Straps, one thousand (1000) notes, bound together face up, held together with a paper band, shrink-wrapped and labeled. All Straps within a Bundle shall be face up with every other Strap rotated 180°. A Bundle with paper band is shown in Attachment 011. The paper band shall be tight enough to hold the Straps together.

Bundle

10 Straps, every other strap rotated 180'.

2 5/16" wide paper band applied around 10 straps, centered on bundle

58.7mm 2 5/16"

The Bundle shall be shrink-wrapped as a total enclosure package with plastic film. The film shall be shrink-wrapped tight around the Bundle without wrinkles. All edges of the film shall be sealed together. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The appearance, strength and durability of the Bundles produced on the ns-LEPE shall be identical to the existing Bundles produced by the BEP.

The shrink-wrapped package shall be labeled with unique labels designating the individual Bundles. The labels shall be applied over the top note. The font shall be “Impact” and the bar code shall be code 39. A bundle label with printed information is shown in Attachment 008.

16 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

Bundle with Label

Shrink wrapped in LLD-PE film, totally enclosed.

Bundle Label applied on face of bundle over shrinkwrap film.

C.4.4 BRICK

A Brick is four (4) Bundles, four thousand (4000) notes, shrink-wrapped together. A Brick is shown in Attachment 012. Only the two ends of the film need be sealed, the overlap of the film does not require sealing.

Brick

Four Bundles shrinkwrapped together in PVC Brick film.

Film is not sealed on overlap.

Bricks typically vary between 17" and 20" in length.

The package shall have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. All Bundles shall be face up within the Brick. The Brick wrapping film over the Bundle label shall not prevent scanning of the bar code on the Bundle label or reading of the information printed on the

17 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing label. The Brick film shall not fuse to the Bundle film. The appearance, strength and durability of the Bricks produced on the ns-LEPE shall be identical to the existing Bricks produced by the

BEP.

C.4.5 CASH-PAK

A Cash-Pak is four (4) Bricks, sixteen thousand (16,000) notes, shrink-wrapped together using a polyethylene laminated film as a total enclosure package, with labels applied. The attached drawings show the Cash-Pak, including placement of the labels, Attachment 013. The ns-LEPE shall have the ability to handle up to 24 ½” long Cash-Paks.

Cash-pak

Four Bricks to be packaged together as Cash-pak

All edges of the film shall be sealed together. The film shall be shrink-wrapped around the Cash-Pak tight without wrinkles. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The clear windows along the top and bottom of the Cash-Pak shall allow counting of the Straps paper bands contained within the Cash-Pak.

Labels shall be placed over the clear windows at both ends of the package covering the currency within the package. The Cash-Pak film shall not fuse to the Brick film nor cause the Brick film to fuse to the Bundle film. The appearance, strength and durability of the Cash-Paks produced on the ns-LEPE shall be identical to the existing Cash-Paks produced by the BEP. The performance requirement for Cash-Paks, drop test, is Attachment 014.

18 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

Cash-pak

Bricks shrinkwrapped together in LLD-PE Cash-pak film.

Film is sealed on all sides.

Regular Cash-pak film used; film color matches denomination.

Labels applied over window.

BEP-FRB Eagle Label applied to back of package

Cash-pak Shipping Label applied to front of package

XX####X

At operator initiation, a partial Cash-Pak at the end of a process to empty out the machine may be produced. The system shall be capable of either producing complete Cash-paks with manual removal of any partials (preferred) or producing a partial Cash-pak at the end of a process. A partial Cash-Pak may contain 1 to 3 bricks and cannot meet the tightness of the film or wrinkle requirements. Labels for partial Cash-paks would be hand applied by the operator.

C.4.6 SKID

A skid is forty (40) Cash-Paks, six hundred forty thousand (640,000) notes, stacked and stretch-wrapped on a BEP provided currency skid. The Cash-Paks shall be stacked as shown in Attachment 015. The appearance, strength and durability of the skids produced on the ns-LEPE shall be identical to the existing skids produced by the BEP.

C.4.7 FUTURE CURRENCY

To accommodate future changes to United States currency and allow for the production of other products by the BEP, the ns-LEPE shall have the capability of accommodating the following sheet sizes, sheet formats and note sizes.

To accommodate the entire ranges specified, replacement of some components may be required;

e.g. numbering blocks may limit the minimum length of notes, banders may need to be changed to apply narrower bands for notes with a shorter length, shrink-wrap formers may require replacement and samples/muts cassettes may require replacement. The contractor shall specify all items that would be required to accommodate the entire note size range and shall provide information on the range allowable with the components proposed.

19 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

(1) Substrates:

The ns-LEPE shall accommodate a wide range of substrates for the production of currency and other security documents, including polymer or combinational substrates that include both paper and polymer materials.

(2) Sheet Sizes:

The ns-LEPE shall have the capability of processing sheets ranging from a minimum size of 500 mm wide by 500 mm long (19.69” by 19.69”) up to a maximum size of 820 mm wide by 700 mm long (32.28” by 27.56”). The maximum print area for the ns-LEPE shall be 800 mm wide by 666 mm long (31.496” x 26.22”).

(3) Sheet Formats:

The ns-LEPE shall allow for variations in the format of the sheets. The ns-LEPE shall accommodate between three (3) and five (5) notes across the sheet (columns) and between five (5) and ten (10) notes down the sheet (rows); minimum of fifteen (15) subject up to fifty (50) subject.

(4) Note Sizes:

The ns-LEPE shall have the capability of producing currency notes ranging from a minimum of 100 mm wide by 50 mm tall (3.93 inches by 1.97 inches) up to a maximum of 180 mm wide by 90 mm tall (7.09 inches by 3.54 inches).

(5) Future Features:

A Raised Tactile Feature (RTF) and/or other features may be added to future currency designs that may impact the heights of stacks of sheets and straps as well as other packages. The placement, height and nesting characteristic of the feature are unknown at this time. The inclusion of the feature onto denominations is expected to increase the height of a stack of 100 sheets, uncompressed, up to 25 mm. The compressed height of 10 straps, a bundle, is expected to be up to 165 mm. The inclusion of this feature would also change the length of Bricks and Cash-Paks that can be produced by its equipment.

C.5 ns-LEPE SPECIFICATIONS

The following are the Government’s minimum specifications requirements for the ns-LEPE to be delivered to the BEP.

C.5.1 FUNCTIONAL REQUIREMENTS

The following specifies the functional requirements for the system to be supplied to the BEP.

The contractor shall utilize Government Furnished Materials (GFM) in C.3 and produce currency in accordance with the Product requirements in C.4.

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C.5.1.1 PRODUCT TRACKING

The ns-LEPE shall track the movement of product (Sheets, Straps, Bundle, Bricks and Cash- Paks) through the production process and ensure that no product is missing from the production process. If the ns-LEPE detects that any product is missing without identification, the system shall stop and signal the operator for corrective action and not allow continued operation until corrective action is complete.

With the elimination of the numeric sequence of the product, the accountability of the sheets and straps is of paramount importance. The system shall record and display on the reports all sheets and straps removed from the production process and not packaged into Cash-Paks as finished goods. The system shall be designed to ensure that no product is removed from the system without recording of the serial number for later verification.

The ns-LEPE shall have three (3) Optical Character Recognition (OCR) stations for the removal of printed material; Sheets or Straps. OCR #1 shall be at the COS station on the main console.

OCR #2 shall be at the TPIS station. OCR #3 shall be at the exchange station. OCR #1 and #2 shall be used for either sheet or strap removal; OCR #3 for strap removal only.

The vendor is required to provide within their proposal how they intend to ensure product tracking. Within their concept, the vendor is to demonstrate their understanding of the complexity of the issue and how their institutional knowledge of manufacturing machinery will address issues associated with implementation. The vendor is encouraged to provide sufficient detail to ensure a complete understanding by the government of their capabilities, experience and knowledge that will support this effort to minimize the risk of non-conformance.

C.5.1.2 FAULT RECOVERY

The ns-LEPE shall have detection components to detect whenever a fault, i.e. jam or error, occurs that could cause damage to the equipment, produce unsatisfactory product or operation would pose a safety hazard to operational or maintenance personnel. The ns-LEPE shall take appropriate actions when a fault is detected to stop and notify the operators. The ns-LEPE shall display specific detailed information on operator stations for trained operators to locate and take corrective actions to correct the fault. The ns-LEPE shall record the event and all associated data into the Data Collection System (DCS).

The ns-LEPE shall have provision to recover from all faults. A fault shall not negatively impact the continuous production of Straps, Bundles, Bricks, Cash-Paks or skids, or create a hazard to operational or maintenance personnel.

If the operator determines that the product was damaged or unacceptable for further processing from an error/jam, the ns-LEPE shall allow the operator to remove the product from the production stream. The operator shall be required to OCR in the serial number of sheets or Straps removed from the product stream.

21 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

The contractor shall provide detailed plans on each operator station detailing the step-by-step activities and corrective actions required to correct the fault condition and return to production.

The vendor is required to provide within their proposal the control system design for the nsLEPE system, including the details of the fault recovery process. They shall provide information on the robustness of their control system design to enable the timely return to operation without loss of product tracking. The vendor is encouraged to provide sufficient detail to ensure a complete understanding by the government of their capabilities, experience and knowledge that will support this effort to minimize the risk of non-conformance.

C.5.1.3 SAFETY REQUIREMENTS (Mandatory Minimum Element)

The following safety requirements shall be met:

(1) Noise Level:

The noise produced by the operation of the press within specified speed range shall not exceed 85 Decibels A-weighted Sound Level (dBA) when measured at 914 mm (3 feet) distance along the plan view of the press from the press and at an elevation of 1,524 mm (5 feet) including the wiper and inking areas of the press. These noise level limits do not apply to the warning horn levels described in C.5.1.31.

(2) General Safety:

The press shall be designed to prevent injury to operation and maintenance personnel at all times. The press shall be equipped with service access equipment; such as, catwalks, access platforms, access ladders, lifts, and other equipment for operation and maintenance. Fixed stairs shall be provided in compliance with OSHA 29CFR 1910.24, Fixed Industrial Stairs. All catwalks, access platforms, access ladders, lifts, hoists, and any other equipment that are furnished, shall be built and tested to comply with ANSI and OSHA standards. Special attention shall be given in providing proper ‘angle of steps’ as indicated in paragraph (e) of the referenced standard. All press and service access equipment shall be guarded as required by applicable portions of OSHA Regulations.

The presses shall comply with ANSI Standard B65.1, Safety Standard-Printing Presses.

(3) Sharp Edges:

All sharp edges and corners, which present personnel hazards, shall be guarded or padded. All covers and safety guards shall be interlocked with the press control to prevent its normal operation while any cover or guard is open or absent. Only local jogging control at a reduced speed is allowable provided no other covers are opened or removed. The location of opened switches shall be displayed on the Master Control Station. Covers and guards shall be manufactured for easy removal by Bureau personnel with tools to facilitate removing mechanical and electrical parts for repair. All rotating

22 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing and reciprocating parts shall be guarded as specified by OSHA regulation 29 CFR 1910.212.

(1) Heated Surfaces:

Prevent heated surfaces from causing burns to personnel during operation.

(2) Asbestos:

Materials containing asbestos shall not be used.

(3) Airborne Contaminants Employee Exposure:

Operation of the press shall not result in worker exposure to airborne contaminations exceeding current maximum allowable concentrations established by the Occupational Safety and Health Administration (OSHA) (29 CFR 1910.1000)

(4) Press Locking Arrangement:

The press shall be equipped with a locking arrangement that will prevent unauthorized manual or power operation of the press. An electrical interlock shall be provided to prevent accidental starting with the mechanical lock engaged.

(5) Safety Data Sheets:

Safety Data Sheets (SDS) for all contractor supplied and specified chemicals that are part of the process shall be supplied by the contractor and must be approved by WCF EHS Branch and/or DCF OEHS prior to bringing onto the respective site. The SDS shall comply with the OSHA, as listed in standard 29 CFR 1910.1200, with particular emphasis on paragraphs (g) and (i).

(6) Overload Protection:

Press shall be equipped with overload protection and power factor correction devices to prevent damage to its components and operating personnel.

(7) Safe-Ready:

All control stations shall include a "safe-ready" collar or equivalent. Upon turning the collar to the safe position, it shall be impossible to start the press from any other station.

Console shall indicate that the particular interlock including emergency stop buttons causes the press to start or not.

23 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

(8) Emergency Stop:

Whenever an Emergency Stop is activated, the machine shall stop within one (1) second to reduce damage to the machinery and injury to personnel. An Emergency Stop may be initiated due to the machine’s internal control logic detecting an emergency situation, activation of personnel safety devices (i.e. safety curtains, cover interlocks or other devices designed to protect personnel), or by personnel manually activating an Emergency Stop Button.

Emergency Stop Buttons shall be provided at strategic locations, including the drive side of the machinery in the areas of the drive motors and delivery, to minimize the time required to reach them. Emergency Stop Buttons shall be of the pronounced mushroom type, red in color, with no raised guards to prevent accidental depression. Emergency stop buttons shall remain activated once depressed until manually reset.

(9) Inching Interlock:

Whenever an inching of the press occurs, only the control station from where the inch was performed shall be able to cause the press to move until the safe-ready is activated and deactivated.

(10) Energy Isolation:

Disconnect or lockout devices shall be provided and identified with signage for all sources of energy on the presses. This includes electrical, hydraulic, pneumatic, and kinetic sources of energy. All isolating devices (levers, breakers, valves, etc.) for all associated energy sources (electrical, hydraulics, pneumatics, gravity, etc.) shall be identified by a color coded tag which indicates the type of energy source, the magnitude of the energy and an ID number. All isolating devices shall be capable of being locked out with a standard locking device and/or padlock. Stored sources of energy such as pneumatic and hydraulic forces shall be automatically bled and returned to a zero energy state when an interlocked device (i.e. a guard or a door) is opened.

C.5.1.4 ENVIRONMENTAL PROTECTION REQUIREMENTS (Mandatory Minimum Element)

All equipment installed at the Bureau shall meet all local, state, and federal environmental regulations, including but not limited to air quality, industrial solid waste, hazardous waste, and wastewater.

The equipment installed at the Bureau shall comply with the following regulations:

Federal Regulation: Environmental Protection Agency, EPA

Clean Air Act Amendments of 1990, Section 112-Air Toxics (http://www.epa.gov/air/oaq_caa.html);

24 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

40 CFR 403-General Pretreatment Regulations for Existing and New Sources of Pollution (http://www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm);

30 TAC (Texas Administrative Code) - Chapters 101, 115, and 116 for Air Quality Rules and air permitting

City of Forth Worth Code – Chapter 12.5 for Industrial Wastewater 30 TAC – Chapter 335 for Industrial Solid Waste and Municipal Hazardous

Waste

C.5.1.5 PRE-STACKER

An area and components for the preparation of the currency sheets for processing on the ns- LEPE shall be provided. The area shall be sufficient to accommodate at least two (2) loads.

The ns-LEPE shall be supplied with a pre-stacker unit for BEP personnel to stack and align up to 10,000 sheets at one time. Carts shall be supplied by the contractor for the stacking of the sheets and transportation of the stacks from the pre-stacker into the feeder. At least three (3) carts shall be supplied with each ns-LEPE. Means to maintain alignment of the carts from the pre-stacker into the feeder shall be included. The use of guides secured to the floor to maintain alignment is acceptable but the guides shall be positioned to prevent being a trip hazard.

C.5.1.6 FEEDER

The ns-LEPE shall have a continuous sheet feeder with the ability to accept both stacks of 10,000 currency sheets from the pre-stacker as well as manual insertion of 10,000 sheets on a skid by the operator. The feeder shall have provisions to maintain the stack alignment during processing. Note: Sheets containing threads and watermarks have a tendency to lean and must be supported by side guides.

The feeder shall automatically feed the sheets in registration utilizing the front and side edges of the sheets. The feeder shall detect feeder faults and stop if possible to prevent the production of spoilage (i.e. two or more sheets fed together, sheet not registered correctly on feed-board, sheet is early, missing or late, etc. If a sheet cannot be stopped on the feed-board, then the sheet should not be printed and delivered to the waste bin (e.g. side-lay fault or transfer fault).

C.5.1.7 SHEET INSPECTION SYSTEM

The ns-LEPE shall include a Sheet Inspection System to verify the quality of the sheets being fed into the system prior to overprinting. The system shall at a minimum perform the following:

(1) Front and Back Reflective Print Inspection

The system shall perform front and back print inspection via reflective lighting. The system shall use Red, Green, and Blue (RGB) Color Cameras with a pixel size no greater than 0.4 mm. The system shall compare each sheet against a ‘golden’ or reference sheet generated by the operators. Deviations beyond those designated by the operator shall be displayed as detected.

25 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

The operator shall be able to specify Regions-of-Interest (ROI). The system shall allow for up to twenty (20) ROIs per note and twenty-five (25) ROIs within the sheet. The size and location of the ROIs shall be specified by the operator tracing the outline of the region. The system shall allow for up to four (4) non-continuous areas within a note being specified as the same region. A ROI may be specified as a region to ignore or as a special region for independent weighting under the flaw evaluation process. Any areas within a note/sheet not selected shall be combined into one unit with user defined accept/reject settings. The system shall allow for the operator to individually set the allowable variations for rejection by color, intensity, shape and contrast.

The system shall utilize a landmark (tie-point) alignment system to compensate for the presentation of the sheets. At least one tie-point for each note location shall be utilized.

The system shall have individual tie-points for the Offset and Intaglio printing at the corners of the sheet to allow for the defining of regions of either Offset or Intaglio landmarks and for the system to report when the locating algorithm fails to find the tie-point.

The system shall be capable of determining registration variation with respect to print to paper, print to presentation, and print to print. The system shall be able to reject sheets when any of the limitations for these measurements occur.

In addition to quantifying each variation, the system shall compare the actual differences to the allowable variations set within the system by the operator. For those flaws exceeding the allowable variances, the system shall respectively designate the quality of that attribute and the associated note as acceptable or unacceptable. Sheets shall be delivered to their respective delivery consisting of acceptable or unacceptable sheets while reporting flaws to the note level for each flaw detected. The flaw reported will also contain the region or group that was defined for this area of the note. When the mouse is over any area of the image displayed, a separate readout shall exist showing the RGB values for the pixel selected by the mouse position. The display shall show the RGB values for the Master Image and the displayed image for comparison. The display shall also contain the X and Y coordinates from 0, 0 in the Field of View.

The system shall have a means to capture and replay sheet images for tuning and evaluation purposes. The system shall have the ability to store images. The system shall be capable of storing an image of the Master sheet with all ROIs graphically represented by an outline. The system shall allow the saving images of the reference after learning is complete and after any expansion of the reference.

(A) Calibration: The Contractor shall supply all targets to effectively calibrate the system. The calibration shall consist of a means to align the camera to the transport, a means to teach the bias (black), and a means to teach white with a consistent value. It is desirable to have the targets with red, green, and blue with a known value to effectively apply settings to achieve these values.

26 RFP No. 2031ZA17R00001 Bureau of Engraving and Printing

(B) Sheet Stability: The Contractor shall provide a means to stabilize the sheet while passing under the inspection that will not result is false rejects or false accepts due to instability of the sheet as it passes.