Attachment 1 - Draft Specification.pdf

TABLE OF CONTENTS

SECTION 1.0 GENERAL

1.1 PURPOSE

1.2 BACKGROUND

1.3 OWNERSHIP / OWNER

1.4 SCOPE OF WORK

1.5 DRAWING REFERENCE

SECTION 2.0 STANDARDS FOR DESIGN / INSTALLATION

2.1 DESIGN AND DOCUMENTATION STANDARDS

2.1.1 Design Standards

2.1.2 Documentation Standards

2.1.3 Clarification

2.1.4 Solicitation

2.1.5 Ownership

2.1.6 Deviation from Product

2.2 CONFORMANCE TO DESIGN CRITERIA

2.2.1 Value Engineering

2.2.2 Workmanship and Quality

2.2.3 Fabrication

2.3 BID CONDITIONS

2.3.1 Bid Information

2.3.2 Bid Award

2.3.3 Tax Exemption

SECTION 3.0 DELIVERY AND INSTALLATION

3.1 DELIVERY

3.2 INSTALLATION STANDARDS

3.3 ON SITE REQUIREMENTS

3.3.1 Safety

3.3.2 Base Security

SECTION 4.0 SYSTEM ACCEPTANCE AND APPROVAL

4.1 ACCEPTANCE TESTING

4.2 STRESS TESTING

4.3 OPERATIONS TRANSITION

SECTION 5.0 SERVER / HOST

5.1 LMP HOST INTEGRATION

5.1.1 Terminology Used

5.1.2 Overview / Introduction

5.1.3 LMP / ASRS Current Interfaces

5.1.4 PI Middleware

5.1.5 Interface Details

5.1.6 LMP Interface Communications and Messaging

5.1.7 Outbound Messaging

5.1.8 Inbound Messaging

5.1.9 Future Operational Functionality

DRAFT

5.2 LMP TEST PROTOCOL

5.2.1 Unit Testing

5.2.2 System Testing

5.2.3 Documentation

5.3 SERVER REQUIREMENTS

5.3.1 Overall

5.3.2 Hardware

5.3.3 Peripherals

5.3.4 DOD Cybersecurity Requirements

5.3.5 Miscellaneous

SECTION 6.0

DETAILED EQUIPMENT SPECIFICATIONS

6.1 DESCRIPTION OF OPERATIONS

6.1.1 General Receiving & Put-away

6.1.2 UL Receiving

6.1.3 ML Receiving

6.1.4 Cross Dock Receiving

6.1.5 AGV Put-away – Unit Load

6.1.6 Turret Truck Put-away – Unit Load

6.1.7 UL Pallet Retrieval

6.1.8 Unit Load Picking

6.1.9 AGV Put-away – Mini Load

6.1.10 Mini Load Put-away

6.1.11 Mini Load Pick

6.1.12 AGV Pallet Pickup to Shops

6.2 OVERALL SYSTEM DESIGN

6.2.1 Product to be Handled

6.2.2 Throughput / Design Criteria – Unit Load

6.2.3 Throughput / Design Criteria – Mini Load

6.2.4 Key Design Elements

6.3 AGV SYSTEM

6.3.1 Description

6.3.2 General Requirements

6.3.3 Mechanical

6.3.4 Electrical / Controls

6.3.5 Safety

6.4 MINI-LOAD REPLACEMENT

6.4.1 Description

6.4.2 General Requirements

6.4.3 Mechanical

6.4.4 Electrical / Controls

6.4.5 Safety

6.4.6 End Aisle Work Station

6.4.6 Dashboard Monitors

6.5 UNIT LOAD – PICK AND DROP (PND) STANDS

6.5.1 Description

6.5.2 General Requirements

6.5.3 Mechanical

6.5.4 Electrical / Controls

6.5.5 Safety

6.6 UNIT LOAD – MAN UP TURRET TRUCK

6.6.1 Description

6.6.2 General Requirements

6.6.3 Equipment Requirements – Turret Truck

6.6.4 Specification Data Sheets – Turret Truck (sample)

6.7 UNIT LOAD – STORAGE RACK

6.7.1 Description

6.7.2 General Requirements

6.7.3 Equipment Requirements

6.7.4 Specification Data Sheet

6.8 SUPPORT EQUIPMENT

6.8.1 Unit Load Lift Tables

SECTION 7.0

WCS / SOFTWARE FUNCTIONALITY

7.1 SYSTEM FUNCTIONALITY OVERVIEW

7.2 EQUIPMENT INTEGRATION

7.3 DETAILED SYSTEM FUNCTIONALITY

7.3.1 Functional Matrix

7.3.2 System Reporting

SECTION 8.0 IMPLEMENTATION & TRAINING

8.1 IMPLEMENTAION ROADMAP

8.2 TRAINING REQUIREMENTS

8.2.1 General Training Parameters

8.2.2 Training Requirements

SECTION 9.0

SERVICE

9.1 SUPPORT REQUIREMENTS

SECTION 10.0

PHYSICAL AREA IMPROVEMENTS

10.1 FLOOR FLATNESS

SECTION 11.0 BID CONFORMANCE

11.1 CONFORMANCE REQUIREMENTS

11.1.1 Site Inspection

11.1.2 Site Conditions

11.2 VENDOR BID SCOPE CONFIRMATION CHECKLIST

11.3 CONFORMANCE REQUIREMENTS

APPENDICES APPENDICES:

A. DESIGN SUBMISSION REQUIREMENTS MANUAL

B. TYAD CADD STANDARDS MANUAL

C. STANDARD NEPA SPECIFICATIONS FOR PROJECTS

D. ENVIRONMENTAL CONCERNS FOR CONTRACTORS

E. ELECTRICAL DESIGN CONSTRUCTION STANDARDS

F. CONTRACTOR SAFETY STANDARDS

G. BUILDING COMMUNICATION STANDARD

H. NETCOM TECHNICAL AUTHORITY (TA) FOR IMPLEMENTATION OF ARMY END-

USER COMPUTING ENVIRONMENT

I. ADVANCED CYBER INDUSTRIAL CONTROL SYSTEM TACTICS, TECHNIQUES, AND

PROCEDURES (ACI TTP) FOR DEPARTMENT OF DEFENSE (DOD) INDUSTRIAL

CONTROL SYSTEMS (ICS)

J. CURRENT SYSTEM PROCESS MAP

K. DRAWING REFERENCE – EQUIPMENT, ELEVATIONS, CURRENT CONDITIONS

L. DRAWING REFERENCE – FLOOR FLATNESS SURVEY

1. GENERAL

1.1. PURPOSE

Tobyhanna Army Depot (TYAD) intends to repair, replace and upgrade its Automated Storage and Retrieval System (ASRS), Automated Guided Vehicles (AGV) system and supportive

Warehouse Management and Control Systems (WMS & WCS) located on the Tobyhanna, PA campus of buildings.

1.1.1. This Army base facility contains inventory and parts used for repair of parts, assembly and prototype missions for the United States Army, Department of Defense, government agencies and allied forces worldwide.

1.1.2. The current ASRS system and AGVs are antiquated, with several parts dating back to the mid-1980’s. The AGV system has not been reliable and can not get parts, so the system was taken off line earlier this year and is no longer responsible for delivering parts and pallets.

1.1.3. The purpose of this document is to solicit bids for replacing key software components, integrating software into the current mainframe, replacement of mini-load cranes, and execution of improved material handling systems through the replacement of Automated

Guided Vehicle (AGV) systems.

1.1.4. This RFP intends to detail the technical installation and depot requirements in order to successfully transition in place from the current systems to the new systems.

1.1.5. The operation will still need to maintain and serve its mission throughout the entire project execution.

1.1.6. The award of this contract will be directed by Tobyhanna Army Depot ACC-APG.

1.2. BACKGROUND

1.2.1. TYAD is a communications electronics maintenance supply depot in support of the United

States Army, and other branches of the Department of Defense. Support is provided worldwide on equipment ranging from radios to satellite communications systems. TYAD covers an area of approximately 1,300 acres, located in northern Pennsylvania.

1.2.2. TYAD provides for the receipt, storage issue and life cycle maintenance of army-based electronic equipment. Mission functions are in support of the army, other military services, government agencies and allies.

1.2.3. TYAD handles maintenance, fabrication and manufacturing support of electronics, repair and prototype systems. Consequently, there are a tremendous number of SKUs with a great variety of sizes.

1.2.4. In the 1980’s, TYAD issued a bid solicitation for a new automated storage and retrieval system. This system known as ASRS (Automated Storage Retrieval System), was implemented over the course of the following few years and involved a structure / rack supported facility handling both unit load and mini-load systems. The mini-load system was a crane-based operation using a series of conveyors to load and unload trays. The pallet support is a unit load system with approximately 4,550 pallets. This system also operated with inbound and outbound vehicles using an AGV system, also original to the

1980s installation.

1.2.5. Since that time, an updated Warehouse Control System (WCS) was layered into this. The current system, supplied by George Cook and Associates (GCA) has been in place since the early 2000’s.

1.2.6. The dated systems and equipment have gone through a series of evaluations of new and replacement equipment and systems to best serve it’s needs since the original installation.

The attached specification indicates the intent to move forward to replace select system components technology, systems and hardware currently within the ASRS system. Section

1.4 will become more descriptive as an overview of the proposed scope.

1.3. OWNERSHIP /OWNER (for delivery information – see Section 3)

The equipment within this specification will be purchased and operated by:

Company: Tobyhanna Army Depot

Address: 11 Hap Arnold Boulevard

Tobyhanna, PA 18466

Phone: (570) 615-7000

Additional information on this location and procurement details can be found in the following sections of this specification document.

1.4. SCOPE OF WORK

1.4.1. The following equipment, materials, software and installation is required to be provided by the selected Contractor. The following is intended to be an overview and should be meant to guide the understanding of the project.

• Replace five (5) mini-load cranes with new cranes, rail, hardware and software controls. Replacement for the 6th mini-load crane aisle is seen as a likely and should be priced as optional.

• Repair any existing mini-load trays such that six (6) aisles can be successfully used. It is believed that appx 400 bins will need to be replaced or used as spares.

• Replace current AGV system with new AGV systems that meet system throughput and functionality requirements.

• Replace unit-load stands with new unit-load conveyance / pallet handling systems.

• Install new mini-load work stations.

• Install new unit-load work stations.

• Implement new Warehouse Control System (WCS) to manage conveyor operations, AGV path, material identification, demand request, inventory visibility and control future integrated equipment.

• Replace George Cook and Associates WMS with new WMS system with functionality to improve cycle counting, order management and inventory management functions.

• Integrate software with current LMP host system.

• Provide all support equipment including work stations, servers, message boards, work station PCs, scanners and any other control devices required.

• Make repairs to floor within the mini load and unit load aisles, as necessary, to ensure that replacement cranes and turret trucks operate properly.

• Replace epoxy flooring within the ASRS core area.

• Replace three (3) current turret trucks with (4) new turret trucks, each with Lithium

Ion batteries and Opportunity chargers.

• Provide all labor for successful removal of existing non-use equipment and implementation, specifically crane rails & electrical raceway/bars, automated guided vehicles, weigh and size AGV station, turret trucks, battery charger racks and charging stations.

• Provide and intensively manage overall transition plans to assure up time and effective continued support to Mission Cost Centers.

• Provide all project management and implementation support prior to and during the implementation.

• Provide all permitting for the project.

• Provide all supporting installation including the use of fire watch and security details as needed.

1.4.2. This specification will attempt to identify each of these components in detail along with the overall transition plan.

1.5. DRAWING REFERENCE

The Contractor shall refer to the following for equipment requirements for this project.

Drawings are included in the appendix and can be provided electronically upon request.

Drawing Number Description Origin

DD01-01D Equipment Detailed Design – ASRS & Phasing Plan Boston Industrial

EL01-01B Elevation Plans Boston Industrial

CC01-01B Current Conditions, ASRS Boston Industrial

A-1 Floor Flatness Survey Michael Baker

1.5.1. Drawings do not show all details of the work intended and are only to illustrate the characteristics and general extent of the work to be performed.

1.5.2. The Contractor shall be responsible for checking and verifying all dimensions prior to providing bidding and installation, especially as it relates to current conditions.

2. STANDARDS FOR DESIGN / INSTALLATION

2.1. DESIGN AND DOCUMENTATION STANDARDS

2.1.1. Design Standards

The standards used for design shall include, but are not limited to, the latest versions of industry codes listed below. This list is intended to identify common codes that will apply to this project. It is not intended to identify all codes and standards. The

Contractor is responsible for providing equipment and systems to meet all appropriate industry codes.

Code Description

BOCA Building Officials and Code Administrators International, Inc.

IBC-2018 International Building Code 2018 Edition

CEMA Conveyor Equipment Manufacturers Association

OSHA Occupational Safety and health Act of 1970 (OSHA)

NFPA 101 NFPA 101- 2018 Edition

NEC National Electric Code – NEC (2017 Edition)

NPA - 70 National Electrical Code

ANSI MH16.1 2012 Seismic Zone Requirements

ANSI American National Standards Institute

UL 508 Underwriters Laboratories, Industrial Control Equipment

NEMA National Electrical Manufacturers Association Standards

EIA Electronic Industries Association

IIIE Institute of Electrical and Electronics Engineers

IEEE STD 142-1991 Grounding of Industrial and Commercial Power Systems

AGMA American Gear Manufacturers Association

ATME American Society of Testing and Materials (ASTM)

AISC American Institute of Steel Construction

ASW American Society of Welding CFR Code of Federal Regulations

• The above specifications in effect on Date of Invitation for Quotes / Request for

Proposal form a part of this purchase description. The contractor shall perform the work stated in this purchase description while complying with the above statutes, regulations and standards.

• In the case of conflicting requirements, the more stringent standard shall apply.

• Refer to Appendix C, D, E and F for additional and more defined standards that apply to the project Electrical, Fire Suppression Environmental and Fire Detection while working at TYAD.

2.1.2. Documentation Standards

All documentation must be submitted in English per the list below:

X Item Specifics

Proposal Documentation

X Electronic

X Hard-Copy 2 Sets, bound with ID on front and bound edge

X Detailed project Schedule including equipment lead time

Included within Bid

Drawings

X Installation Drawings 2 Sets – D Size Minimum

X Assembly Drawings Submitted to Scale

X Component Drawings To be reviewed with Owner prior to order – must include sections, dimensions, relevant notes, materials list and scale

X AutoCAD or .dxf Format Drawings 2 hard copies of all to Owner + Digital copy – D Size Minimum

X Wiring / Control Panel Drawings

Permitting

X Permit for Installation

X Cost of Permit

X Drawings with Seismic Calculations Must be approved and stamped by a licensed Professional Engineer

Installation Affidavit

System Documentation (Letter Size Minimum)

X Spare Parts List 2 Sets, plus PDF

X Operator’s Manual 2 Sets, plus PDF

X Safety Manual 2 Sets, plus PDF

X Maintenance Manual 2 Sets, plus PDF

X Bill of Materials 2 Sets, plus PDF

MSDS Sheets 2 Sets, plus PDF

X Safety Plan 2 Sets, plus PDF

Environmental Protection Plan 2 Sets, plus PDF

X Equipment Warranty 2 Sets, plus PDF

X PM Schedule 2 Sets, plus PDF

Risk Management Plan 2 Sets, plus PDF

X Contact List Vendor Contact List, Emergency Info

• Refer to Appendix B for additional and more defined standards that apply to development of CAD drawings for equipment and physical modifications to TYAD.

• Refer to Appendix A: Design Submission Requirements manual for addition details in developing proper design submittals to TYAD.

2.1.3. Clarification

Any ambiguities, questions, request for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the offeror in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF THE

SOLICITATION / receipt of proposal.

2.1.4. Solicitation

Submission of a proposal or quote shall be construed as evidence that a total examination of the scope has been made with noted exceptions or call outs in the vendor submission. All questions to properly define the scope will have a defined and proper protocol as contained in the TYAD Statement of Work (SOW). Therefore, later claims for labor, material or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

2.1.5. Ownership

The ASRS is a custom design system and is to be designed for use by TYAD by the supplier. Components installed as part of the ASRS rebuild may be designed by others in which case ownership of design data for those components or items remains with the contractor.

2.1.6. Deviation from Product

Modifications to the manufacturer’s standard design to achieve requirements as specified in this document are only permissible as dictated by good design practice.

Additionally, any changes in standard drawings, designs, schematics, etc. must be provided to TYAD.

2.2. COMFORANCE TO DESIGN CRITERIA

2.2.1. Value Engineering

This specification defines the equipment required and provides the parameters for purchase and installation of listed equipment. Contractors are encouraged to submit improvements that do no compromise the intended use of the system, especially where equipment / processes can be simplified.

• Any and all value engineering suggestions or ideas should be presented and reviewed with the Owner at least one week prior to quote due date, or they will not be considered.

• If improvements are recommended, Contractor shall submit a bid based strictly on this specification and the layout cited, as well as an option for the recommended modifications.

2.2.2. Workmanship and Quality

Workmanship and governing codes shall apply when a specification is not clearly stated.

• All equipment and work performed shall be free of defects and performed in a professional manner.

• All cutting and welding marks shall be ground smooth to allow all exposed parts to be cleaned thoroughly by wipe down.

• All electrical parts should be enclosed or covered.

• All exposed parts must be capable of withstanding routine cleaning.

• Contractor will be responsible for correcting any regulatory deficiencies without any additional cost or expense by the Owner.

• Contractor will be held liable for reimbursing the Owner for any fines levied either against them or the Owner as a result of non-compliance with any local fire, safety, seismic and other regulations and requirements, or project delays.

2.2.3. Fabrication

The Owner has the right to inspect the Contractor’s factory or origin of equipment supply during the manufacturing of the components to be used on this project. The

Owner will be provided the opportunity to review all stages of the manufacturing process and the Vendor’s Quality Assurance procedures and documents. The Owner has the right to request visits to the Vendor’s operation to perform factory acceptance tests, quality checks and progress reviews, especially if compensation is based on percentage of completion.

2.3. BID CONDITIONS

2.3.1. Bid Information

2.3.1.1. Information provided by TYAD purchasing shall supersede any comments in this section.

2.3.1.2. The Owner reserves the right to modify the timetable throughout the course of this project, with proper notice and approval of the selected Contractor. Project schedule is provided for planning and quoting purposes, final schedule to be determined after contract award, but in general, should not deviate significantly from the project schedule proposed for award.

2.3.1.3. Receipt of product in advance of indicated installation schedule will not be allowed unless authorized by the Owner.

2.3.1.4. Product must arrive as shown on the installation schedule, if product is due to arrive earlier than schedule, approval from TYAD must be authorized. This is required to ensure that proper staging and material flow is coordinated. Generally, at least one week of notice is required to consider early receipt of items/materials.

2.3.1.5. Ownership of all data, materials and documentation originated and prepared for the purposes of this RFP shall belong exclusively to the Owner.

2.3.1.6. All information contained in this specification is to remain confidential and shall not be referenced or used beyond this bid.

2.3.2. Bid Award

2.3.2.1. Evaluation Criteria

The Vendor will be evaluated based on the following key items:

- Quantity of equipment presented

- Quality of bid preparation, conformance to instructions, and amount of detailed information provided for proper evaluation of each element

- Plan / Approach: Compliance to operating specification, run rates, ease of maintenance

- Price, service support coverage program and warrantees

- Confidence in solution / equipment delivery

- Demonstrated post-delivery support

- Detailed Schedule and Phasing Plan

2.3.2.2. Bid Submission:

The vendor must demonstrate past success on the following project types in order to be considered for this project. Failure to demonstrate any of the following key and absolute criteria may result in automatic rejection of the bid

1. Implementation of an SAP based system. Special consideration will be prioritized for any vendor with successful project LMP interface within the past 3 years.

2. Implementation of no less than (3) Mini-load replacement projects in the past

3 years, total at least $1M in project costs

3. Implementation of no less than (3) Pallet AGV or Pallet AMR systems in the past 3 years, total at least $1M in project costs

4. Demonstrated success in of a minimum of (3) WMS and WCS implementation or conversion projects in the past 3 years, total at least $500K in project costs

5. Implementation of a minimum of (5) Integrated Automation projects of at least $10M over the past 3 years

6. Special consideration will be paid to any experience with conversion or implementation of any Government based application of similar scale and scope to this project.

2.3.2.3. The submission must address the 6 key points as stated above as to successful conformance to each item, with supporting information to prove contractor capabilities to the selection team.

2.3.2.4. Vendors are encouraged to submit a separate section in their submission to address and prove conformance to each item above using specific examples.

2.3.3. Tax Exemption

2.3.3.1. Tax Exemption Certification – Contracting Officer’s Instruction:

In accordance with the supremacy clause of the United States Constitution, Federal

Acquisition Regulations and Pennsylvania State Law, Tobyhanna Army Depot, as an instrumentality of the United States Government, is generally immune from taxation by State and local jurisdictions. In lieu of an exemption certificate, and as provided for in paragraph 1.b. of Pennsylvania Sales and Use Tax Regulation Number 200, it is suggested that you retain a copy of this purchase order and this notice as documentary evidence that Tobyhanna Army Depot is immune from State and local taxation. If your state is other than Pennsylvania and requires certification other than this form, or should you have questions concerning the parameters of immunity from taxation, contact the person identified as the contract administrator in the contract.

3. DELIVERY AND INSTALLATION

3.1. DELIVERY

This section intends on providing overview summary information to vendors. Additional information on Delivery requirements and conformance documentation is contained in the

Master SOW and should be read carefully by submitting vendors in order to understand strict regulations in delivering and moving product to and throughout TYAD.

Delivery of all products should be made to:

Company: Tobyhanna Army Depot

Address: 11 Hap Arnold Boulevard

Tobyhanna, PA 18466

Phone: 570(615) 7000

Scope Comments

A. Owner Responsibility:

Designated staging area Will be provided

Dock height door for unloading of product One door available

Drive-in door One door available

B. Contractor Responsibility:

Freight delivery for new equipment to site FOB Factory

Unloading of equipment at owner’s facility

Providing a fork truck to unload and move equipment / installation

Written notification of delivery prior to arrival 1 week

Cost of repairs / replacements for any materials damaged

C. Specific Delivery Instructions:

Hours M-F 7:30 am – 4:00 pm

Special Instructions

3.2. INSTALLATION STANDARDS

3.2.1.1. This section intends on providing overview summary information to vendors.

Additional information on Installation requirements and conformance documentation is contained in the Master SOW and should be read carefully by submitting vendors in order to understand strict regulations in installing equipment at TYAD

The Contractor is Responsible for: Comments

Labor Type Union ☒ Non-Union ☐

Power and air for installation purposes Temporary power and air, if required, to be provided by contractor.

Providing a dumpster for trash removal Dumpster, if required, to be provided by contractor. Price of dumpster and trash removal to be provided in quote.

Providing a fork truck to unload and move equipment / installation

Propane fork trucks are prohibited

Providing Safety procedures / plan in compliance with Owner Requirements

Providing personal protection equipment (PPE) for all crew members

Providing a list of installer crew names, crew size, working hours and overtime provisions

Provide an installation schedule. Schedule could be phased if it improves delivery time and / or implementation of equipment.

Phased ☒ Single ☐ Phased by area, reference project schedule for installation timing.

Participating in project management / coordination meetings

Installation will be on off shifts and weekends only Contractor to adhere to install schedule. Adjustments may be made to meet schedule as required.

Building Construction Retrofit

Operating Environment Operational temperature will be fixed between 68F – 75F. Humidity will be controlled at less than 85%.

Storage Environment Prior to Installation 0F to 120F

Heights:

Ceiling Clear Height

Height Below Sprinkler

Varies, reference equipment plan drawings.

Varies, reference equipment plan drawings.

Electrical / Data Supply:

Main Power Supply

Power Termination Point

Lan / Data Supply

Power will be provided through the main panel breaker box located adjacent to ASRS, contractor is responsible any additional distribution, disconnects, etc.

Contractors shall make final connections and provide all internal equipment wiring.

Owner to provide data jacks.

Contractor to provide patch cords

Compressed Air Supply:

Compressed Air

Temporary air can be provided during installation.

Air Termination Point Building air will be provided, Contractor to make final connections.

Quality and Safety:

PPE Including: Hard Hats, Safety Glasses, HI-Viz Vest, Long

Pants, Steel Toe protection if working with heavy equipment

Barricades and Warning Signs Around Work Area

Fire Watchperson / Stand-by Fire Extinguisher

Smoking

All must be approved and worn.

Must be provided.

Must always be present.

When required

Forbidden on-site except in designated areas.

3.2.1.2. All removed metal components shall be transported to a local recycling facility.

Facility will need to be approved by a TYAD representative.

3.2.1.3. Type and tonnage of recycled materials will need to be certified by a TYAD project representative.

3.2.1.4. Vendors will need to assure that all packaging materials, installation debris and daily work is cleaned up and placed into trash receptacles. All trash shall be transported to the dock areas using vendor supplied vehicles. All trash removal shall be the responsibility of the vendor. All trash and debris shall be removed at the end of each work day and work area(s) set to a neat/orderly state.

3.3. ON SITE REQUIREMENTS

3.3.1. Safety

3.3.1.1. Vendors should refer to Appendix G: Contractor Safety Standards for detailed information that will govern the delivery, removal and installation safety protocol for this project.

3.3.1.2. Prevention and Protection

The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations. Proper approval, or burn permits, must be obtained for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment to be used on TYAD. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comply with fire prevention measure described by the terms of this purchase description.

3.3.1.3. Industry and Regulations

The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications

3.3.1.4. Material Exclusions

The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

3.3.1.5. Safety Regulation Compliance

The contractor shall comply with standard OSHA and Tobyhanna Army Depot safety standards, including conforming to confined space work requirements when applicable.

3.3.1.6. Safety Lockouts

Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.3.1.7. Loss of Pressure

Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.3.1.8. Trapped Energy

Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

3.3.1.9. Working Range

Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

3.3.1.10. Brakes

Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.3.1.11. Emergency Stops

The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset).

No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there are no other red buttons of any type. Reference Section 6.0 – Detailed

Equipment Specifications for equipment level emergency stop requirements.

3.3.1.12. Control Guards

Controls shall be guarded against accidental operation.

3.3.1.13. Operator Reach

Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

3.3.1.14. Audible Noise

The equipment noise level during normal operation shall not exceed 85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

3.3.2. Base Security

3.3.2.1. The Tobyhanna Army Deport is an Army installation subject to Department of

Defense safeguards, various precautions and plant protection measures. All of the requirements will be necessary of contractors visiting Tobyhanna Army Depot to satisfy requirements of this purchase description.

3.3.2.2. Additional requirements will be placed on contractors requiring access to the

Army Network, or Common Access Card (CAC), as specifically detailed below.

3.3.2.3. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage.

3.3.2.4. The contractor shall comply with all security requirements of the Tobyhanna Army

Depot. Tobyhanna Army Depot Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the facility.

3.3.2.5. Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-

9) as directed by Department of Defense (DoD), Headquarters Department of the

Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security process.

Access to Tobyhanna Army Depot: Contractor and all subcontractor employees performing work at Tobyhanna Army Depot shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification

Index (NCIC-III) and Terrorist Screening Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The

COR shall provide guidance to complete the Access Control Records Check Request

Form though the Tobyhanna Army Depot Directorate of Emergency Services.

Random Anti-Terrorist Measure Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Tobyhanna

Army Depot Police Department. The RAMP is discussed in the Tobyhanna Army

Depot Anti-Terrorism Training.

During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON

Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism

Level I Training.

Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. Tobyhanna Army Depot electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR, or paced in a drop box at a

Tobyhanna Army Depot access point.

3.3.2.6. Security Training: The contractor shall complete the following training:

3.3.2.6.1. Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The

COR will be provided a copy of the Tobyhanna Army Depot AT Level I

Awareness Training and assure that the training is complete. The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the Tobyhanna Army Depot Operations Center prior issuing any electronic keys, or access pass being authorized.

3.3.2.6.2. iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

4. SYSTEM ACCEPTANCE AND APPROVAL

4.1. ACCEPTANCE TESTING

4.1.1. Vendor to develop a detailed System Acceptance Test plan. The test plan shall be submitted to the Owner for review / comment and acceptance at least six (6) weeks prior to the start of the test.

4.1.2. The plan shall cover test procedures and criteria for successfully demonstrating the reliability and performance of each system module, e.g. conveyor routing, WCS interface and database reconciliation. Emphasis shall be placed on simulating the fully stressed system and measurement of system response time and system reliability. In addition, conduct the test in presence of the Owner.

4.1.3. The test shall be run until it meets all requirements of the test plan.

4.1.4. Test plan shall establish dates for submittal of test procedures for each phase of testing.

4.1.5. A functional demonstration shall be included in the test plan which will validate the correct installation and operation of each individual equipment sub-system.

4.1.6. The test plan shall include a demonstration of system integration, throughput and performance through the movement of materials throughout the system. Unless otherwise arranged, the system operational test will have a minimum duration of eight (8) hours.

4.1.7. Test plan shall include go / no-go criteria for approval to progress to next phase of testing, burn-in and transition to operations.

4.1.8. Test plan shall cover all subjects included in this specification.

4.1.9. Test plan shall be executed after mechanical testing, software debug and punch list are completed.

4.1.10. The System Acceptance Test plan shall cover the following four (4) key steps:

1) An inspection of all mechanical, electrical and control equipment for correct dimensions and tolerances, proper quality standards and workmanship and for proper installation in accordance with the specifications. This inspection step shall be performed at the completion of initial equipment installation.

2) A reliability and performance test on each major component of the system, e.g.

conveyor stands, SRMs, AGVs, etc. The purpose of this test shall be to verify that each individual component operates reliably and is capable of performing its intended function while operating alone. This reliability test shall last a minimum of eight (8) hours and shall be conducted following the inspection described in the preceding paragraph.

3) A software demonstration of the WCS and WMS computer system. This test shall simulate field conditions and shall successfully demonstrate that all software modules are available, that they are properly interacted, and that the system is capable of functioning as designed.

4) Upon completion of the three test steps above, a final demonstration test shall be conducted to verify that the system meets performance criteria as specified and that it is capable of integrated operation without product damage. This final test step shall last a minimum of eight (8) hours and shall be conducted using live loads under real operating conditions. The Owner will provide all loads and manpower to operate the workstations and the systems operations. Testing resulting in failure conditions in any step will require additional testing.

4.2. STRESS TESTING

4.2.1. Vendor shall provide a rigorous and detailed stress testing protocol for consideration within the submission, including the amount of time intended to stress test prior to turning over independent modules of the system.

4.2.2. All equipment will be properly stress tested prior to acceptance of any single component of the system, modules and total system.

4.2.3. Formal sign-off and approvals will only be made by a TYAD representative once the stress test results and punch list items have been successfully completed.

4.2.4. A punch list shall be maintained during stress-testing / burn-in that will be reviewed by the project team for approval allowing project to proceed from stress-testing / burn-in to

Transition to Operations.

4.3. OPERATIONS TRANSITION

4.3.1. Documentation of Testing / Transition

• Formal acceptance documents shall be prepared by the Vendor and signed by

TYAD personnel upon approval of the system.

• Hard copies of System and assembly drawings shall be provided in standard scaled print size.

• Hard copies of manuals and training materials shall be bound and labeled.

• Electronic copies of all training materials shall be provided.

4.3.2. Refer to Section 8.1 Implementation and Training for additional details in proper start-up and turn-over of the system to TYAD.

4.3.3. Vendor shall provide three (2) complete hard copy sets, and one (1) electronic copy of all

Technical Data Package (TDP) documentation to TYAD within ten (10) working days after equipment acceptance.

4.3.4. Any Manuals and/or documentation must be provided before on-site technical training so that TYAD personnel can utilize the books/manuals/schematics/etc. during the training.

4.3.5. Technical Data Package (TDP) shall include:

• As built drawings

• As built indented BOM

• Operator Use and Safety Training Session support documentation

• Maintenance Manuals and Training Materials

• Operating Training Manuals

• Schedule of routine preventive maintenance and inspection

• List of maintenance equipment and training required

• Equipment warrantees

• List and sufficient details about all consumable materials

• Recommended Spare Parts List

4.3.6. Vendor shall compile an indented Bill of Material (BOM) in MS Excel (current version) format listing items to the replaceable component level. Vendor shall provide a sample

BOM for approval showing information under the following column headings:

• Item or Tag Number

• Drawing or Part Number

• Quantity

• Unit of Measure

• Part Description

• Next Higher Assembly

5. SERVER / HOST

5.1. LMP HOST INTEGRATION

5.1.1. Terminology Used

Acquisition Source Code

The Acquisition Code is used as inventory-matching data when finding inventory to fill orders.

Condition Code A code used to identify the condition of the inventory (available, scrap, incomplete, repairable, etc.) used as inventory-matching data when finding inventory to fill orders.

Host Refers to the Host computer; also referred to as LMP

LMP U.S. Army’s Logistics Modernization Program system that is grown out of an SAP based platform

NSN National Stock Number. A part number with a length of up to 15 characters.

NIIN National Item Identification Number. A part number with a length of up to 40 characters.

Production Order Number (PO)

An optional 16-character “number” supplied by LMP that accompanies some orders.

SAP CAMS SAP Complex Assembly Manufacturing

SAP ECC SAP ERP Central Component

SAP EWM SAP Extended Warehouse Management

SAP SCM SAP Supply Chain Management

SAP WM SAP Warehouse Management

Transfer Order Number (TO)

A 14-character unique number generated by LMP that accompanies all expected receipt and order transactions. It is used to link the transactions sent by LMP with the responses that are eventually sent to LMP

Work Breakdown Structure (WBS)

An identifier that defines ownership of material; used as matching data when finding inventory to fill orders.

WMS New system designed to replace the current ASRS traditional WCS and WMS system

5.1.2. Overview / Introduction

5.1.2.1. TYAD’s host system, an SAP ERP system branded LMP (Logistics Modernization

Program), is a common host platform serving all United States Army Depots. The

LMP system maintains part information, inventory, and quantity information for items stored in the TYAD pallet and case storage system (called ASRS). The LMP is not responsible for understanding the individual storage locations.

5.1.2.2. LMP records all inventory activities including receipts, inventory adjustments, and requests for parts through Pick lists. Layered on top of the internal LMP system is a customer-supplied middleware called PI. In this document, LMP and PI will be considered a single entity, and is referred to as “LMP”.

5.1.2.3. The internal ASRS system is responsible for performing the on-site Warehouse

Control and Management System functions. This includes, but is not limited to, identifying part location, transaction processing, put-away confirmation, picking confirmation and execution. It is responsible for reporting back to LMP on these activities.

5.1.2.4. The proposed system (referred to as ASRS or WMS in this specification) will need to replace the current ASRS system seamlessly in the timeline identified.

5.1.2.5. The proposed ASRS system will need to replicate, validate and test all the interface, communications and functional requirements performed in the current

ASRS system. Data from ASRS is required to be exchanged with the LMP host.

5.1.2.6. Test and training protocols are identified in this document and need to be adhered to by the selected ASRS vendor.

5.1.2.7. The information contained in this section is for interface understanding. The selected ASRS vendor will need to validate this information and assure to TYAD that they can meet the Host interface requirements without issue.

5.1.3. LMP/ASRS Current Interfaces

5.1.3.1. The ASRS system currently performs functions and communicates information to the host on the processes associated with the picking, part issue, and put away functions. LMP is an SAP based solution which utilizes SAP ECC, SCM, EWM, WM and

CAMS as part of its support to the Army Material Command industrial sites, including

RIA-JMTC.

5.1.3.2. LMP sends files periodically (in batch format but very frequently) to the ASRS in the form of transactions identified in detail in this RFP, including messaging that identifies incoming and end of transmissions. Data passed from LMP to ASRS is via an IDoc file and is encrypted; these same formats will be adhered to with the new

ASRS system. ASRS vendor will need to assure that these file formats and interfaces can be performed based on prior experience with similar applications.

5.1.3.3. Data will be sent from LMP to the ASRS in a similar form to what was received;

more details on the transactions are contained in later sections of this RFP. The ASRS will need to be able to receive data in an SAP IDoc or agreed upon flat file format.

5.1.3.4. Data passed between the ASRS system and LMP must be encrypted. ASRS vendor will need to assure that these file formats and interfaces can be performed based on prior experience with similar applications. The ASRS system currently uses and will continue to operate on the Army NIPR network; additional information is provided on the Server Requirements in Section 5.3.

5.1.4. PI Middleware

Layered on top of the internal LMP system is a customer-supplied middleware called PI.

The graphic below shows how information will be transmitted in a high-level graphic form. The PI middleware also performs the functions of taking multi-line orders and breaks them into single line messages for the ASRS to process.

5.1.5. Interface Details

5.1.5.1. Connectivity

The proposed connection between LMP and ASRS system will use Ethernet network and TCP/IP sockets; this will continue in the future with the proposed ASRS provider.

Two sockets are available for communications by the new ASRS - Port 9000 for sending transactions to LMP and Port 9001 for receiving transactions from LMP. The

ASRS / WMS will be the server side of the connections with LMP for both sending and receiving transactions; LMP will be the client side of the connection

Data will be sent from LMP to the proposed ASRS host server; the ASRS solution will receive data in the SAP IDoc (Intermediate Document) format or in an agreed to file format. LMP sends all transactions though Port 9001 that it has in its queue, followed by an end of transmission. The new ASRS must acknowledge this end of transmission. LMP may establish multiple concurrent connections.

Data passed between the ASRS system and LMP must ride over a VPN encrypted tunnel to exchange data over the NIPRNET.

The ASRS system and LMP currently use the Army NIPR network; this will continue in the future with the proposed ASRS provider. ASRS vendor will need to provide assurances to TYAD that interfaces can be executed and maintained through similar successful SAP based interface connections.

5.1.5.2. Outbound Transactions (LMP to ASRS)

When the ASRS detects a message in its socket connection, it begins the process of receiving a transaction from LMP. After the transaction has been received, the ASRS will check the message number within the transaction. If it matches the last message number and the transaction is identical to the last one received, an acknowledgment

(ACK) message is returned on the same socket connection.

ASRS will than listen for another transaction or for a new connection on the port.

When LMP has nothing else to send, it will disconnect from the socket.

LMP can make multiple connections to the port. The ASRS system must support multiple connections and receiving transactions on all connections.

5.1.5.3. Inbound Transactions (ASRS to LMP)

The ASRS will send messages from its transaction tables to LMP through its socket connection.

Once a transaction is sent, LMP will send an acknowledgement message back to the

ASRS indicating receipt. Transactions should be logged in ASRS the transaction record. If an ACK is not received, the transaction is will need to be re-sent with the same message number.

Once an ACK is received, the ASRS can then send its next transaction. When transactions are complete, an EOT message will be returned with the transaction counter in the message set to the number of transactions sent since the last EOT.

The socket is disconnected and listening resumes on the port.

5.1.6. LMP Interface Communications and Messaging

5.1.6.1. The proposed ASRS vendor will be required to convert the current data from the existing ASRS and load materials into the new ASRS system. Data will be provided in an agreed upon format (Excel spreadsheet, CSV file or flat file). The required data record format and test protocol to assure this is done seamlessly will be determined during the detailed design phase of implementation.

The vendor will be responsible will be responsible for performing all data migration trial loads, and provide the proper validation record for each trial loads prior to final conversion.

5.1.6.2. Data Transaction and Messages

There are three (3) types of messages sent between LMP and the ASRS. A data transaction message (6 exist, that are depicted in detail), and End-of-Transmission message (EOT), and an Acknowledgment message (ACK).

All transactions are fixed length; all fields within each transaction are fixed length.

The LMP system is in complete control of the interface, as it decides when to connect to ASRS to send and receive messages.

Six (6) data transactions are sent between the ASRS and LMP systems. The EOT and

ACK messages are not considered data transactions, as they are made up of header information only with no message body.

5.1.6.3. Data Transactions

Three transactions are sent by LMP to the ASRS.

L – Expected receipt (store request)

F – Single component pick request

D – Transfer WBS-to-WBS (inventory ownership change)

Three transactions are sent by the ASRS to LMP.

3 – Gain…