Attachment 1 - SOW - Prev Mx Contract.docx

STATEMENT OF WORK

FOR

Preventative Maintenance Contract

1. SCOPE: Vendor will perform maintenance and preventative measures known hence forth within this Statement of Work as Performance Assurance (PA) on all Fabrication Support Equipment located within bldg. 252 for Aircraft Structural Maintenance and Metals Technology work centers. The equipment is listed below (Attachment A).

2. LOCATION: The project site is located at 3911 Tyndall Ave, Bldg 252. Nellis AFB, 89191.

3. DESCRIPTION OF WORK: PAs consist of all major maintenance checks that are recommended by Haas Automation Inc., OMAX Corporation, and LVD Strippit. All PAs will be completed by Haas, OMAX, and LVD Certified Service Technicians to ensure your machine is running at full capacity. (For all manufacturers not mentioned, the work will be performed by experienced technicians). PAs provide unique funding options with reactive service and spare parts support. A report will be left with the facility outlining work performed and the condition of the machine(s). This will include recommendations for any reactive service or spare parts necessary to bring the machine to full specs.

4. SCOPE OF WORK: Vendor’s technicians will repair and service all machinery as listed in Table 1 to fully operational and safety status as prescribed within the respected owner’s manuals and OSHA Standards. This will be accomplished through annual and bi-annual PAs. The scope breakdown is as follows:

5. Mills & Lathes – Vendor’s factory-trained technicians will perform comprehensive calibration analysis checks on all major machinery system to include:

5.1. Vibration Analysis: A vibration analysis will be performed on the spindle and tested up to maximum RPM. This data will be collected and analyzed to determine the state of health for spindle bearings, drive motors, drive belts, and overall performance.

5.2. Drawbar Force Test: A Drawbar Force Test will show the clamping force of the drawbar and measures how tight the drawbar can hold a tool in the spindle. The test will detect premature tool wear, damage to the spindle taper, and dropped tools.

5.3. Geometry Inspection: The Geometry Inspection is performed along each axis and ensures the machine is parallel and square. Inspections will follow your machine(s) specifications sheet.

5.4. Renishaw Ball Bar Test: Standard PA checks include an annual ball bar calibration. Renishaw ball bar testing generates a comprehensive diagnostic report to provide you with an overall assessment of machine performance (circularity).

5.5. Annual PA check machine areas include but are not limited to:

5.5.1. Way Lube System:

5.5.1.1. Clean filters

5.5.1.2. Inspect lines and fittings Check operation

5.5.1.3. Verify lube/pump operation

5.5.2. Pneumatic System:

5.5.2.1. Clean filters Replace filters

5.5.2.2. Check pressure/adjust the regulator Inspect system for leaks

5.5.3. Coolant System

5.5.3.1. Remove/Check pump and motor

5.5.4. Mechanical System

5.5.4.1. Check machine level Verify spindle sweep Verify spindle tram

5.5.4.2. Check gear shift operation*

5.5.4.3. Check spindle lube and airblast Check spindle orientation alignment Check shot pin operation*

5.5.4.4. Change gearbox oil**

5.5.4.5. Check backlash in X, Y, and Z-axis Inspect drive belt

5.5.4.6. Inspect and adjust tool changer

5.5.4.7. system

5.5.4.8. Inspect spindle taper condition Inspect way cover wipers Check drawbar height Drawbar dynamometer test Spindle run-out test*

5.5.4.9. Check drawbar stroke for correct tool

5.5.4.10. knockout dimension* Verify ATC tool change* Inspect ATC system*

5.5.4.11. Lubricate ATC mechanism bearings*

5.5.5. Electrical System

5.5.5.1. Check voltages

5.5.5.2. Inspect connections/terminals Inspect grounds

5.5.5.3. Check limit switches/safety locks Inspect and clean spindle sensor* Clean electrical cabinet

5.5.5.4. Check safety interlocks

5.5.6. Gib Adjustment

5.5.6.1. Adjustment of Gibs to maintain axis rigidity and accuracy*

6. Bridge or Cantilever Waterjets – Vendor’s OMAX certified and authorized technicians will perform annual inspections on the applicable machines listed in Attachment A. Time in plant will be limited to a maximum of 24 hours per OMAX machine. If additional parts are found to be defective or require replacement, the customer will be responsible for the cost of those parts. All used parts that are serviceable will be identified as such and left with the customer. Service does not include draining/cleaning garnet out of the tanks.

6.1. Annual PA Checks for OMAX/MAXIEM Bridges & Cantilevers include but are not limited to:

6.1.1. Inspect all ball screw and traction drive/bearing assemblies

6.1.2. Replace all servo drive belts

6.1.3. Scan servo card histories/confirm normal load limits

6.1.4. Precision calibrate Z-axis motion (included for A-Jet or Tilt-A-Jet accessories, as may be present)

6.1.5. Grease or oil all lubrication points

6.1.6. Confirm/recalibrate steps per inch of motion in X, Y and Z movement/square the equipment to primary HOME position

6.1.7. Rebuild the OMAX or MAXIEM pump (major pump rebuild kit included)

6.1.8. Clean low-pressure plumbing side within OMAX or MAXIEM pump

6.1.9. Inspect plungers, manifold, check valves and pump plumbing on ultra-high-pressure side

6.1.10. Replace all filters

6.1.11. Inspect/rebuild all swivels using swivel rebuild kits, including confirm torque settings for plumbing connections

6.1.12. Inspect and clean nozzle and abrasive flow components

6.1.13. Check and reset pressure settings

6.1.14. Install the latest revision of OMAX software (when authorized by Corporate/government IT protocols)

6.1.15. Review changes in software and machine settings with client operating personnel; e-Learning Site Introduction

6.1.16. Test cut for accuracy, re-adjust if necessary

6.1.17. Water sample taken/results provided post inspection

6.2. The Annual Service Parts List for OMAX/MAXIEM Bridges & Cantilevers includes:

6.2.1. (1) Major pump rebuild kit*

6.2.2. Swivel repair kits

6.2.3. X and/or Y Axis motor belt(s)

6.2.4. Pump and controller air filters*

6.2.5. Pump water filters*

6.2.6. On/off valve rebuild kits

6.2.7. Lubrication(s)

6.2.8. *Please note that parts not listed above may be required at additional cost depending on machine configuration (additional pumps, other machine options)

7. Water Treatment System Service – An OMAX factory trained technician will inspect Waterjet machines to ensure the water systems are functioning optimally.

7.1. The annual machine maintenance checks include but are not limited to:

7.1.1. Sump Pump Water out of Clean/Dirty Tanks into SRS Hopper

7.1.2. Wipe Out Clean/Dirty Tanks

7.1.3. Clean & Inspect Pump White Tank

7.1.4. Remove and Clean WRS Pump Suction Screen

7.1.5. Drain Filters Vessels, long handled Brush, and Rinse

7.1.6. Clean Ozone Stone

7.1.7. Clean & Calibrate TDS Probe

7.1.8. Clean Laminar Flow Filter

7.1.9. Replace all CLS, RO or Wall Mount Filters

7.1.10. Collect Updated Water Sample(s) for Analysis

7.1.11. Second sample to be collected at 60 days to monitor for changes

7.1.12. Phone call at two weeks from OMAX Phone Support to evaluate success

8. Biannual Punch Press & Press Brake Servicing – Field service technicians will thoroughly assess all punch press and press brake equipment listed in Attachment A to ensure they are in optimal condition. All settings and adjustments will be brought as close as possible to factory specifications, depending on the age and condition of the machinery. A complete checklist detailing results is provided after each inspection along with recommendations for any necessary corrective measures.

8.1. Biannual PA Checks for Punch Presses & Press Brakes inspections include but are not limited to:

8.1.1. Punch Press Checklist:

8.1.1.1. Examine press drive oil level and filter

8.1.1.2. Check hydraulic system radiator

8.1.1.3. Inspect ram TDC stopping point

8.1.1.4. Check no punch zones

8.1.1.5. Inspect turret guide bushing

8.1.1.6. Clean and lubricate turret drive chains

8.1.1.7. Check air lube system oil level and operation

8.1.1.8. Ensure proper operation of servo fans

8.1.1.9. Check operation of interlock switches

8.1.1.10. Run machine accuracy verification pattern

8.1.1.11. Inspect turret drive gearbox

8.1.1.12. Check auto index lubrication

8.1.1.13. Evaluate table lube system oil level and operation

8.1.1.14. Clean leadscrews and way bars

8.1.1.15. Inspect condition of leadscrews and guide bearing wipers

8.1.1.16. Examine flywheel V belts for tension, cleanliness and wear

8.1.1.17. Check workclamp functionality

8.1.1.18. Inspect table balls

8.1.1.19. Clean slugs from lower frame and auto index area

8.1.1.20. Clean shot pin bushings in turret

8.1.1.21. Check operation of auto index stations

9. Band Saw Inspection – Field Service Technicians will inspect Band Saws to ensure optimal operational capability.

9.1. Band Saw PA Checks include but are not limited to:

9.1.1. Check all safety devices, emergency stops, safety interlocks, guards, covers, awareness barriers caution decals and warning decals are properly installed and are in good working order.

9.1.2. Inspect gear reducer for external signs of bearing or gear ware, i.e. excessive shaft play or gear leash, seal leakage, or bearing noise. This is an external inspection only and does not guarantee the reducer from shaft, gear, or bearing failure.

9.1.3. Check gear oil in reducer and oil seals. Recommend replacement if necessary.

9.1.4. Check conditions of Vari-drive, pulley wear and alignment. Align if needed. Check condition of belt. Check operation of powered speed changer, if equipped. Recalibrate the blade speed indicator.

9.1.5. Change Hydraulic oil and filter, if needed.

9.1.6. Check the hydraulic system for leaks: inspect the solenoid valve, cylinders, gauges, fittings, etc.

9.1.7. On hydraulic saws: Inspect the oil cooler fan operation and change the filter, as needed.

9.1.8. On all double column machines inspect the saw arm roller chain and lubricate.

9.1.9. Service the blade tension assembly. Lubricate the slider plate and adjust the tension, if necessary

9.1.10. Grease or oil all lubrication points as required i.e. idle wheel bearings, pivot points, guide rails, lead screws, pillow blocks and roller drive chain.

9.1.11. On pneumatic machines: drain any water from system. Change or top off all hydraulic oil levels, i.e. tank, traverse control cylinder and feed rate control cylinder as required by manufacturer.

9.1.12. On pneumatic machines: fill and adjust all airline lubricators. Lubricate lift cylinder and adjust all system pressures and check for air leaks.

9.1.13. On hydraulic saws: adjust all system pressure and reset fine cutting pressure if so equipped.

9.1.14. Check powered blade brush for proper operation and replace wire brush, if needed.

9.1.15. Level saw base, feed and discharge table, if applicable

9.1.16. Inspect all vises for vise plate ware and proper operation. Check the operations of the bar feed, check alignment of fee to saw, if applicable.

9.1.17. Inspect the condition of carbide guides. Check the bumper block carbide for wear. Inspect band wheels for excessive wear, crowning of taper. Inspect the idle wheel bearings, and drive wheel run out.

9.1.18. Check the alignment of guide arm assembly, check that saw base is square to vise and that the fall of the saw arm is within manufacturer’s specifications, if applicable. Realign if needed.

9.1.19. Inspect the blade tracking and adjust if needed.

9.1.20. Check the coolant system, if applicable. Check the pump operation and coolant mixture.

9.1.21. Check the operation of all control switches and options. Check the alignment and operation of all limit switches. Test and run the machine in all operation modes.

9.1.22. Test cut and checks for squareness and correct part length. Recalibrate DRO and/or computer, if needed.

9.1.23. Provide recommended repair and spare parts list, if saw requires additional maintenance.

10. Grinding Machines – Technicians will perform PA checks on Grinding Machines to ensure safety and operational capability.

10.1. Grinding Machine PA Checks include but are not limited to:

10.1.1. Electrical:

10.1.1.1. Inspect for damage to switch gear, wiring and/or conduit.

10.1.1.2. Check isolator is lockable in off position.

10.1.1.3. Check operation of start/stop switch.

10.1.1.4. Check emergency stop where fitted.

10.1.2. Guarding:

10.1.2.1. Check all guards are secure and function correctly (includes latches, locks, fasteners and/or interlocks if fitted).

10.1.3. Fitment and Operation:

10.1.3.1. Clean machine of all foreign matter.

10.1.3.2. Check that wheels are not chipped, clogged (loaded), glazed or cracked. *

10.1.4. Machine Checks:

10.1.4.1. Adjust Gib strips on all slides.

10.1.4.2. Examine drive belts for flaws and correct tension, adjust if necessary.

10.1.4.3. Check gear train (Stud gear, change gear, etc.) for correct mesh and alignment, adjust if necessary.

10.1.4.4. Lubricate ways and slides.

10.1.4.5. Check and adjust saddle to apron screws.

10.1.4.6. Check operation of quick-change gear box if fitted.

10.1.4.7. Check machine operation.

10.1.4.8. Replace coolant at least once a year.

10.1.4.9. *Cracked wheels not to be used and are recommended for immediate removal.

11. Wire, EDM – Technicians will inspect and perform PA Checks for Wire EDM to validate functionality.

11.1. Wire, EDM PA Checks include but are not limited to:

11.1.1. Re-Level Machine:

11.1.1.1. Check Y Axis

11.1.1.2. Check X Axis

11.2. Circuit Isolation:

11.2.1. Check Nc Power Supply

11.2.2. Check Discharge Circuit

11.2.3. Check Heavy Duty Unit

11.2.4. Check Motor Drive

11.2.5. Check Relay Switching Circuit

11.2.6. Check Service Tank Circuit

11.3. Circuit Voltage Adjustments:

11.3.1. Check NC Power Supply

11.3.2. Check Discharge Circuit

11.3.3. Check Heavy Duty Unit

11.3.4. Check Motor Drive

11.3.5. Check Relay Switching Circuit

11.3.6. Check Service Tank Circuit

11.4. Filter & Fan Inspection:

11.4.1. Air-Flow Filters

11.4.2. Cooling Fans

11.4.3. Dielectric Filters

11.5. Aspirator Unit:

11.5.1. Clean & And Inspect

11.5.2. Clean & Inspect All Pump Intakes And Resistivity Probe

11.6. Solenoid Valves

11.6.1. Check Functionality

11.7. Discharge Cables:

11.7.1. Check For Cracks Or Breaks

11.8. Inspect Guides:

11.8.1. Check Wear (Lower, Awt & Split)

11.8.2. Inspect Guide Cyclinder

11.8.3. Check Hydraulic Levels

11.8.4. Inspect Conductivity Pieces

11.8.5. Inspect Nozzles

11.8.6. Adjust Lower Guide Height to Specifications

11.9. Inspect Wire Path System:

11.9.1. Wire Spool Backup Motor

11.9.2. Tension Clutch & Roller

11.9.3. Lower Ceramic Roller

11.9.4. Wire Ejection Pinch Rollers

11.9.5. Clean All Pulleys, Rollers, Float Sensor, Seal Jets

11.9.6. Inspect Wire Chopper (If Applicable)

11.9.7. Inspect Wire CHOPPER BLADES (IF APPLICABLE)

11.10. Taper Cutting Accuracy:

11.10.1. Adjust Table To Lower Value (If Applicable)

11.10.2. Adjust Table To Limits Value (If Applicable)

11.11. AWT Adjustment:

11.11.1. Inspect Awt Pipe

11.11.2. Inspect Cutters

11.11.3. Clean & Grease Pipe Guide Rail

11.11.4. Adjust Belts & Spring

11.11.5. Check Alignment & Perpendicularity

11.11.6. Check Awt Jet & U/V Offset (If Applicable)

11.12. Discharge Voltage:

11.12.1. Inspect All Fuses

11.12.2. Inspect Printed Circuit Board & Connections

11.12.3. Verify Output Voltages

11.12.4. Check Discharge Wave Forms (Oscilloscope) (If

11.12.5. Applicable)

11.13. Test Cuts:

11.13.1. Check Speed

11.13.2. Check Accuracy

11.13.3. Check Taper

12. Sander, Shears, Rollers, and Vacuums – Sander, Shears, Rollers, and Vacuums will be inspected to verify operational capability.

12.1. Sander, Shears, Rollers, and Vacuums will be inspected for, but are not limited to:

12.1.1. Electrical connections

12.1.2. Printed circuit boards

12.1.3. All voltages

12.1.4. Cables, switches, fans, motors, etc.

12.1.5. All machine functions and safety features

12.1.6. Check all bolts and screws for tightness

12.1.7. Calibrate or re-align geometric machine alignments

12.1.8. Check ram and table alignment, if applicable

12.1.9. Lubricate or grease all moving parts*

12.1.10. Check to ensure all safety features are in place

12.1.11. Operations of interlock switches, if applicable

12.1.12. Check all lines and connections

12.1.13. Replace and/or clean filters*

12.1.14. Check any hydraulic pumps, and pressure relief valve(s) for maximum pressure

12.1.15. Air lube system oil level and operation

12.1.16. Proper operation of servo fans

12.1.17. Run machine accuracy verification pattern

12.1.18. Inspect turret drive gearbox, if applicable

12.1.19. Auto index lubrication, if applicable

12.1.20. Check flywheel and/or drive belts for tension, cleanliness, and wear

12.1.21. Workclamp functionality

12.1.22. *Consumable items to be provided by customer

13. Additional Maintenance Components – The table below represents the additional maintenance components for Performance Assurance on all the machines listed in Attachment A.

13.1. Table 1:

System Service Clean and inspect all components of the WTSS Collect water samples for analysis

PM-2 QTY:2

14. Reactive Service Support – Based on the reports generated from the Technicians’ inspections from the Maintenance Checklists, and per the request by the customer, a reactive service and spare parts proposal will be provided for by an authorized representative.

14.1. All services may be subject to part software, and technician availability for machines that are no longer being supported by an original equipment manufacturer, distributor agreement, or after market source. Discretionary funds can be applied to Reactive Support.

14.2. Service time spend outside of the normal PA work will be charged in the

14.3. service rates in Table 4 during the corresponding period of performance. If reactive service is required while the PA technician is on site, every attempt will be made to diagnose and fix the problem, provided the service does not impede on the technician’s ability to finish the scheduled PA for the week. If it is determined that the technician will not be able to perform the PA due to reactive service needed, another technician will be called in to perform the necessary reactive service at the rates described in Table 2. Technician rates will be billed in per day increments. All estimates for reactive service needs will be provided at time-of-service repair request.

14.4. The following table displays the reactive service rate for additional service outside the scope of the preventative maintenance tasks in this Statement of Work. These services shall be quoted on an individual basis utilizing this rate. A 4% economic price adjustment is added to our Reactive Service rate for multi-year Performance Assurance contracts. This is included to compensate for inflation over the full period of performance.

14.5. Table 2:

Reactive Service Rate: Available Upon Request

*Travel & Living Expenses: Excluded

15. Spare Parts – A separate proposal will be provided for any failed components discovered during a PA that needs repair.

16. ANCILLARY SERVICES TO BE PROVIDED BY OTHERS: The vendor’s technicians will need to be escorted on base during normal business hours (0700 – 1600) to complete inspections.

17. ASSUMPTIONS / TERMS AND CONDITIONS: Customer will inspect and verify quality of service repair to machinery to ensure safety and reliability before the Vendor’s Technician departs the facility.

17.1. The maintenance inspection of the equipment covered by this agreement shall be performed during the period of performance of this agreement. The actual schedule of said maintenance and inspection shall be determined by the Vendor and the user at the time of the execution of this agreement.

17.2. Field Service Technicians will perform and complete maintenance inspection checks on one to two machines at a time before working on any other equipment to not interfere with the productivity of the customer’s facility.

17.3. All services may be subject to part software, and technician availability for machines that are no longer being supported by an original equipment manufacturer, distributor agreement, or after market source.

18. SECURITY: The Facility will be occupied by ASM and MT personnel. Coordination with the Vendor’s Technicians to ensure that no repair or servicing work is performed without prior notification.

19. CODES: The Vendor shall comply with current manufacture, Occupational Safety and Health Administration, Labor Department and Nevada codes, laws, and regulations as applicable to this statement of work.

20. FIRE PREVENTION AND PROTECTION: The vendor shall comply strictly with all base fire regulations.

21. FACILITIES DAMAGE: Vendor shall be responsible for any damage to the facility caused by their personnel and repair said damages to the satisfaction of the Contracting Officer at no expense to the Government.

22. COORDINATING AND SCHEDULING: The Technician will Coordinate all servicing and repair through Mr. Daniel Quimby, Quality Assurance Specialist @ 702-652-4257 or daniel.quimby.2@us.af.mil.

23. WORKING HOURS: Monday – Friday 0700 to 1530

24. FINAL INSPECTION: All repairs and servicing will be inspected by the Mr. Daniel Quimby, Quality Assurance Specialist, to ensure machinery meets safety and reliability specifications.

Attachment A Equipment Listing image1.emf