Attachment_A_-_Statement_of_Work.pdf

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SECTION C – DESCRIPTION/SPECIFICATION/STATEMENT OF WORK

PANTOGRAPH OPERATIONS LASER ENGRAVING MACHINES

C.1 BACKGROUND

The Bureau of Engraving and Printing (BEP) a component of the Department of the Treasury designs, engraves, and prints U.S. banknote currency and other U.S. security products. Banknote currency manufacturing occurs at BEP’s Washington D.C. facility (DCF) and the Western Currency Facility (WCF) in Fort Worth, TX. BEP’s primary customer is the Federal Reserve Board (FRB). The Office of Engraving, Plate Manufacturing Division seeks a new Laser Engraving Machine (LEM) for use in its pantograph operations.

C.2 PURPOSE

C.2.1 Product, Service or Outcome Needed The BEP requires a complete turnkey LEM system suitable for the direct-to-plate laser engraving process. The turnkey package shall include the required hardware, software, service support, tools and training necessary to maintain production in the engraving process. This equipment shall allow the BEP to remain ISO 9001, or better, compliant and must maintain critical tolerances to ensure repeatability of printed features during operations for currency manufacturing.

C.2.2 Scope of the Product, Service, or Outcome The Contractor shall provide a turnkey LEM and an additional one (1) year for extended preventive and emergency maintenance for one (1) Laser Engraving Machine (located at the BEP’s Washington, DC facility. A second optional system may be provided for delivery to the DCF within a year of contract award, and an optional third system may be provided for delivery to the WCF within one year of contract award. This equipment is covered under ISO 9001 standards and must maintain critical tolerances to maintain repeatability of printing operations for currency manufacturing.

The Contractor shall provide all labor, travel, parts, materials, transportation, equipment, tools, supplies, management and supervision and all other items and services necessary to supply, deliver, and install new direct-to-plate laser engraving machine.

C.3 TECHNICAL REQUIREMENTS

The following represent the requirements and responsibilities for the LEM procurement.

Please note all measurements provided in this SOW are denoted in metric terms.

C.3.1 Machine Requirements

C.3.1.1 The Laser Engraving Machine shall include standard electrical service connection (220v or 440v 3 phase AC).

C.3.1.2 The laser must have a fume/particulate extraction that is self-contained. The system must have mechanical filter elements for internal scrubbing of the air to minimize hazardous waste generation. The system shall not exhaust untreated emissions to the interior or

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C.3.1.3 The laser shall be a pico second laser of the ultrafast or ultra-short pulse category.

C.3.1.4 The laser shall be capable of burning from a minimum depth of 5 microns deep to at least

500 microns deep.

C.3.1.5 The laser shall be fully self-contained in a laser safety class 1 enclosure to meet ANSI

Z136.1.

C.3.1.6 The laser shall have a scan head mounted to the laser head.

C.3.1.7 The laser shall have z axis servo control with a minimum z travel allowance for rotary axis of 610mm.

C.3.1.8 Marking field size acceptable up to 120mm X 120mm and a stage (X/Y) working area of

1254.4-1300 mm. Majority of marking will occur within a 16mm x 16mm window.

C.3.1.9 The (X/Y) stage shall be capable of +/- 5 microns repeatability.

C.3.1.10 The laser shall have a machine stage capacity of 45kg load.

C.3.1.11 The laser shall have a machine vision system with a camera looking through the same mirrors that navigate the laser beam. The laser shall also contain a self-inspecting function that provides the ability to inspect depth and location during and/or after processing the burning function.

C.3.1.12 The laser shall have a camera system that enables part recognition for position alignment.

The laser shall have the ability to find the focal height on its own.

C.3.1.13 The system shall include a second ultrafast or ultra-short pulse laser (also known as a

Pico laser), that shall produce no burr from the burning process.

C.3.1.14 The system shall include embossing capabilities.

C.3.1.15 The laser software shall have the ability to read ASCII as well as binary stereolithography (STL) files.

C.3.1.16 The laser shall be capable of 3D marking with an imported STL file where STL files are created from any CAD software.

C.3.1.17 The laser shall possess the capability to laser engrave on 3-dimensional (3D) surfaces, as well as concave, convex, irregular and cylindrical surfaces.

C.3.1.18 The laser shall have a “smoothing” feature to minimize surface finish at bottom of marking field when performing 3D marking.

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C.3.1.19 The laser shall be able to replicate existing programs by scaling factors as needed to meeting the acceptance criteria stipulated herein.

C.3.1.20 The contractor shall provide the smallest spot size in (microns) laser is capable of when marking in a 16mm X 16mm filed as stated in section 4.0.

C.3.1.21 The contractor shall provide the beam quality in (M2).

C.3.2 Contractor Responsibilities

The following represent the Contractor responsibilities (at minimum) for the LEM:

C.3.2.1 General: Furnishing, delivering, installing and conducting the commissioning of the

LEM.

C.3.2.2 Installation: Installation for the first LEM shall be completed no later than one (1) year after award. Should the Government exercise options for any additional LEMs, installation shall be completed six (6) months after the option is exercised.

Installation shall include, at minimum, making the necessary service connections (e.g.

electrical and water), assembling, setting-up, conducting start-up and making adjustments as necessary to the equipment. In general, the Contractor shall ensure new LEM is operational in accordance with the original equipment manufacturer (OEM) requirements (e.g. factory system start-up, run tests, etc.) so as to prepare for the performance of the acceptance test.

C.3.2.3 Commissioning/Bureau Acceptance Testing (BAT): The Contractor shall start the direct-to-plate laser, operate it, make adjustments and verify that it is operating within the OEM requirements. Once the equipment is operating properly and is stable, the Contractor shall commission the equipment. The Contractor shall document the results of commissioning in a written report as outlined in Section 5.0 below.

C.3.2.4 Consumables: The Contractor shall provide one year of consumables, such as filters, filter bags, etc., upon installation.

C.3.2.5 Preventive and Emergency Maintenance: Contractor shall perform all preventive maintenance according to manufacturer recommended schedule. Repairs shall be initiated by phone or email. Upon receipt of notification for emergency maintenance the contractor shall respond within twenty-four (24) hours and provide service/technician within forty-eight (48) hours after the response period or as negotiated. Emergency maintenance is considered an event in which the hardware and/or the software of the LEM becomes inoperable during peak or other planned production periods where the unit Supervisor has deemed that service is necessary. Examples of exclusions may include loss of electrical power to the machine or loss of communication from the BEP’s network (as applicable).

C.3.2.6 Deliverables: Providing the deliverables specified in Section 5.0 below.

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C.3.2.6.1 Regulations/Publications/Codes: The Contractor shall comply with the BEP’s

Environmental Health and Safety (EHS) requirements, Attachment B, 75D-07.0-06 EHS Requirements for Large Equipment Purchases document.

The Contractor is solely responsible for ensuring it is complying with and performing in accordance with any such amendments, supplements to such Regulations/ Publications/Codes as well as any and all superseding documents issued or enacted during the period of performance of the work.

C.3.2.6.2 The Government reserves the right to request copies of the company license(s) and other certification documentation that demonstrates their company and personnel have the ability to perform the services at any time during performance. The Contractor shall provide the requested information within five (5) business days of the request.

C.3.2.7 Schedule and Coordination: Within 15 days after the award, the Contractor shall submit a Delivery and Installation schedule to the Contracting Officer’s Representative (COR). Upon review and acceptance of the schedule, the COR and the Contractor may coordinate activities to ensure successful completion. Altogether, it is critical for the Contractor to maintain communication with the COR of the on-going status of project and is notified of any concerns or issues that may arise and can result in delay.

C.3.2.8 Training: The Contractor shall perform on-site training at both BEP facilities following a successful BAT. Training shall be coordinated and scheduled with the COR prior to performance. Estimated training is 2.5 days. Up to four (4) BEP staff will receive LEM operator training (estimated 16 hrs.) and up to four (4) BEP Electromachinists (EMs) will receive maintenance training (estimated 4 hrs.).

The Contractor shall submit to the COR within fifteen (15) business days after award a Training Plan. The Training Plan shall include, but not limited to:

Installation and Training Duration Number of training personnel Training materials to be provided Training agenda shall include at a minimum, but be not limited to:

o Basic equipment operations o Safety measures, including emergency shut off o System setup, user configuration, common errors o Troubleshoot techniques to obtain optimum finished parts o Performing maintenance training o General repair of the LEM system

If a subcontractor is to be used for training, then the Contractor shall inform the COR immediately. The name of the subcontractor who will be performing the work, along with a description of their experience in performing this type of work shall be submitted. The COR will respond within five (5) business days with any comments and/or suggested changes.

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C.3.2.8.1 Advanced Training: The Contractor shall provide 2.5 days (20 hours) training for up to four (4) BEP designated individuals in regards to the advanced operation and operator maintenance procedures of the LEM approximately six (6) months after installation and initial training are completed. Scheduling will be coordinated between the Contractor and the COR.

C.3.2.8.2 Personnel Qualifications: Contractor personnel shall be competent, dependable, knowledgeable, trained, inclusive of any necessary or applicable certification and/or license and related experience, thereby qualifying them to perform their specific duties in supporting this effort.

C.4 INSPECTION AND ACCEPTANCE:

C.4.1 Bureau Acceptance Testing A Bureau Acceptance Test (BAT) will be scheduled no later than two weeks after the completion of commissioning of the LEM, at a time mutually agreed upon by both parties.

C.4.2 Test Plan The Contractor shall provide a Test Plan to fully demonstrate the capabilities of the LEM system.

The test plan shall be provided to the government at the time of proposal submission. The testing shall encompass the following BEP process /procedures:

Engraving of Plate numbers into electroformed nickel substrate – Evaluated for location, depth, finish

Focal point/surface recognition – Engraving into electroformed nickel substrate with 3-5mm

Z axis deviation for Focal point/surface recognition and automatic compensation for maintaining depth of engraving.

In process Laser scanning for location and depth with automatic compensation for shallow burning.

Analysis of data record for automatic location by scan head for both focal point and in process engraving.

Engraving of exotic medals including Gold, Silver, Bronze, Brass, Nickel and Steel.

Evaluation of location, depth, finish. System’s ability to burn V groove and other bottom textures at the bottom of the crater.

Embossing features – Test images would be burned at approximately 250 - 300 microns deep. The ability of the laser to keeping the image in tacked will be evaluated.

Embossed border - 100-150 microns deep.

Plaque Lettering - Evaluate maximum laser work area and laser ability to burn within that area as well as registration of features/images burned from one area to the next.

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Evaluation of the processing time for all operations tested.

Digital conversion and scaling may be required and will be acceptable if the conversion maintains the integrity of the image, measured within 0.0002” of any datum chosen.

Demonstrate particular frosting capabilities, both standard and custom.

C.4.3 Visual Inspection The LEM system shall be visually inspected by BEP personnel at a minimum for possible damage as well as to ensure that all parts have been provided and properly installed.

C.4.4 Operation Inspection The LEM shall at a minimum be inspected for operational soundness, doors operate smoothly, lights and interlocks fully functional. The Contractor shall provide an Operational Inspection Report to the COR within three (3) business days after the inspection has been completed.

C.4.5 Defects If any damage, defective workmanship or materials, issues with system operability or missing parts, are identified during visual or operational inspection the Contractor shall be responsible for replacing and/or correcting the damaged, defective part(s), and/or providing the missing parts and making adjustments.

C.4.6 Acceptance Acceptance for the LEM will be considered complete when all the requirements described in the test plan have been completed and signed off by the COR, as having met the established acceptance criteria. The COR will provide the Contractor a written document stating BEP’s acceptance of the direct-to-plate laser.

C.5 DELIVERABLES

C.5.1 Commissioning Report Contractor shall provide a written Commissioning Report describing the commissioning process to be performed, along with the resources involved. This deliverable is to be submitted to the COR for review and approval at the time of proposal submission.

C.5.2 Consumables List Contractor shall provide a consumable list and recommended replacement intervals for the laser at the time of installation. The list of estimated yearly consumables should be based on the laser engraving machine operating 16 hours (or 2 shifts) a day, 5 days a week. As part of the consumables a detailed parts list shall be provided listing all system parts with part numbers and the accompanying description of each. Any proprietary items shall clearly be identified within the documentation.

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C.5.3 Insurance Certificate Contractor shall provide a certificate of insurance reflecting the coverage description and amounts. This deliverable is to be provided to the Contracting Officer (CO) within thirty (30) business days after award.

C.5.4 Operation and Maintenance Manuals Contractor shall provide three (3) hardcopies of manuals and one (1) searchable electronic manual (PDF) detailing Operation and Maintenance requirements and troubleshooting guide to be delivered to the COR by date of installation of the Direct-to-plate laser. These manuals shall provide at a minimum a discussion and description of the operation and preventative maintenance tasks required to operate and maintain the LEM and associated equipment. These will also include electrical, pneumatic, and hydraulic schematics if applicable.

C.5.5 Preventative/Emergency Maintenance Schedule Contractor shall provide a recommended Preventative Maintenance Schedule. The extended service shall also address the following:

a) 24 hours a day, 7 days a week phone tech and service

b) Spare parts availability to include if the parts are local, nationa1, or from overseas

c) A list of spare parts the BEP should maintain in inventory

d) The BEP will not provide direct line internet connection to the machine. Please describe if and how that will affect maintenance service.

e) Emergency Maintenance: In response to troubleshooting via phone tech support, repair parts will be shipped to the BEP within 48 hours. Generally, repairs should be completed within three (3) business days. However, in cases where the repair will take longer, the Contractor will inform the COR of the delay. . On-site tech support will be provided within 10 working days of initial emergency maintenance call if issue is not resolved. The Contractor shall provide an emergency maintenance report on the machines to the BEP after completion of the required maintenance.

f) LEM upgrades including software, firmware, and hardware components shall be listed in the

Preventive Maintenance Schedule. Scheduling upgrades will be coordinated between the Contractor and the COR.

C.5.6 Primary Personnel Point of Contact Information The Contractor shall provide the name of an individual(s) along with their corresponding contact information (e.g. telephone number, fax number, address and cell number) who will perform as the Contractor’s primary point of contact in support of this effort, along with a back-up point of contact as well. This deliverable is to be provided within five (5) business days after award and within five (5) business days after any changes.

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C.5.7 Warranty Information Information or documentation regarding the warranty of the new direct-to-plate laser. Contractor shall provide a point of contact for any warranty issues or concerns. This deliverable shall be provided to the COR within fifteen (15) business days after delivery. Warranty shall begin at the completion of BEP testing and acceptance of the equipment.

C.5.8 Installation Plan The Contractor shall submit to the COR within fifteen (15) business days after award a draft Installation Plan. The Installation Plan shall include but not be limited to:

Schedule and duration, Number of personnel to be used Travel restrictions (if applicable) List of tasks to be performed Contractor and if applicable BEP requirements Equipment needed to install the system (hand tools and tool kits excluded) If a subcontractor is to be used, the name of the subcontractor performing the work, along with a description of their experience with performing this type of work.

The COR will respond within five (5) business days to the draft with comments and feedback.

The Contractor shall coordinate with the COR in finalizing the Installation Plan prior to the installation of the LEM system.

The Contractor shall submit to the COR within 15 business days after the award documentation that describes the Original Equipment Manufacturers (OEM) installation requirements. This documentation is necessary so that BEP can properly prepare the place of installation for the installation of the LEM system.

The Contractor may participate in a pre-site evaluation of the facilities up to and including loading dock and freight elevator services.

C.5.9 Deliverables Table

Paragraph Deliverable Due Date Deliverable Recipient1

Deliverable Format2

C.3.2.7 Delivery and Installation Schedule

Within 15 business days after award

COR (1) Hardcopy and

(1) Electronic

C.3.2.8 Training Plan Within 15 business days after award

COR (1) Hardcopy and

(1) Electronic

C.4.2 Test Plan At time of proposal submission

COR (1) Hardcopy and

(1) Electronic

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Paragraph Deliverable Due Date Deliverable Recipient1

Deliverable Format2

C.4.3 Operational Inspection Report

Within 3 business days of completing the inspection

COR (1) Hardcopy and (1) Electronic

C.5.1 Commissioning Report One (1) Hard copy due at time of proposal submission

COR (2) Hardcopies and (1) Electronic (after award)

C.5.2 Consumables List At time of proposal submission

COR (2) Hardcopies and (1) Electronic

C.5.3 Insurance Certificate 30 business days after award

COR (1) Hardcopy and (1) Electronic

C.5.4 Operation and Maintenance Manuals with troubleshooting guides

No later than 15 business days of equipment delivery

COR (3) Hardcopy manuals and (1) Electronic

C.5.5 Preventive Maintenance Schedule

Within 15 business days after award

COR (1) Hardcopy and (1) Electronic

C.5.6 Primary Personnel Point of Contact Information

Within 5 business days after award

COR (2) Hardcopies and (1) Electronic

C.5.7 One year warranty information

Within 15 business days after delivery

COR (1) Hardcopy and (1) Electronic

C.5.8 Installation Plan Within 15 business days after award

COR (1) Hardcopy and (1) Electronic

C.5.8 Original Equipment Manufacturers (OEM) installation requirements document

Within 15 business days after award

COR (1) Hardcopy and (1) Electronic

1 Include Contact information with all Deliverables 2 Deliverable Electronic formats may include Microsoft® WORD, EXCEL, PROJECT, or VSIO or Adobe® Portable Document Format (PDF).

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C.6 GOVERNMENT RESPONSIBILITIES

C.6.1 Access BEP shall provide access to areas necessary for installation to be performed by the Contractor.

C.6.2 Service Connections BEP shall provide normal service connections.

C.6.2.1 Main power source disconnect switch (220v 3 phase)

C.6.2.2 Pneumatic connection to house air as needed.

C.7 INSTALLATION/PLACE OF DELIVERY

C.7.1 Place of Installation The LEM shall be installed in the Room 702 space in the BEP’s DCF. It must meet all of the DCF EMS requirements as stipulated in Section C.7.10 Attachment A).

C.7.2 Place of Delivery

C.7.2.1 BEP Washington, DC facility address:

Bureau of Engraving and Printing 14th and C Street S.W.

Washington, DC 20228 Attn: To-be-completed upon award

C.7.2.2 BEP Fort Worth, TX facility address:

Bureau of Engraving and Printing 9000 Blue Mound Road Fort Worth, TX 76131 Attn: To-be-completed upon award