Attachment H1 - Hot Draft Test Plan.doc

FIT/BAT TEST PLAN

HOT FOIL MACHINE

FIT/BAT TEST PLAN

FOR HOT FOIL MACHINE

I – Introduction This document specifies the testing procedures for the Factory Inspection Test (FIT) and Bureau Acceptance Test (BAT) for the Hot Foil Machine. Testing shall be performed in accordance with section C of contract NO. .

The FIT will occur at the vendor’s _______________________ facility located in ______________________. The purpose of the FIT is to ensure that all functions of the system will conform to the specified requirements in the contract, prior to authorization for the vendor to deliver the equipment to the BEP. The BEP will only furnish the items listed as inputs that the government will provide for the operation of the equipment. The contractor shall supply any other materials for the preparation and performance of the FIT.

Sufficient advance notification shall be provided to the BEP to enable the arrangement of travel for BEP personnel to witness the testing and for shipment of materials in advance of the testing to enable the contractor to properly set up the equipment.

The contractor shall ensure that proper security requirements are implemented. Since security items will be present during the performance of the FIT, the contractor shall abide by the security plan as agreed by joint resolution. The contractor shall meet and comply with all requirements and instructions from the Bureau’s office of Security.

The BAT will occur at the BEP’s facility, after installation and startup of the equipment. The purpose of the BAT is for complete demonstration of all requirements by the vendor for acceptance by the BEP. The BEP will furnish all items listed as inputs that the government will provide for the operation of the equipment. The BEP will provide sheets of test or live currency for the performance of the BAT.

During the contractor’s presence within the BEP, the contractor’s personnel shall comply with all requirements and regulations of the BEP’s Office of Security and Office of Environment, Health and Safety.

II – Test Plan The contractor shall demonstrate equipment conformance with all requirements during FIT and BAT. The testing of the requirements shall be divided into three parts: Certification, Static Demonstration/Inspection, and Dynamic Inspection.

1) Certification:

Written documentation for design elements or any other requirements that cannot be reasonably tested or demonstrated during the performance of test shall be provided. Certifications shall be supplied on company letterhead, signed by officer with responsibility for the design of the equipment.

2) Static Demonstration/Inspection:

Static Demonstration/Inspection applies to any requirement that can only be verified while the equipment is not in operational mode or for which demonstration during operational mode would interfere with the operation of the equipment.

3) Dynamic Inspection:

Dynamic Inspection/Demonstration applies to any requirement that can be demonstrated or witnessed while the equipment is in an operational mode and does not impact the performance of the equipment.

An Excel Spreadsheet referencing each and every requirement in the contract shall be created. Within the spreadsheet, for each requirement the following shall be specified:

· Methodology of demonstration

· How compliance will be demonstrated

· During which session will compliance be demonstrated

The spreadsheet will be used to track all requirements.

Certification document(s) shall be supplied to BEP on or prior to conducting any testing. A universal certification document for all systems is acceptable.

All sampling of performance measurements shall be demonstrated via the following: (+ 3 σ < specified measurement tolerance). Where σ = standard deviation of the samples. The sampling plan shall be sufficient to provide an appropriate confidence that the equipment operates as specified.

For complex systems, overall reliability can be verified to the Bureau by certification(s) and/or demonstration(s) of the reliability of individual system components. This approach is recommended in the case of highly restrictive requirements or for systems that demonstration of the entire system reliability would require testing far beyond the intended testing time frame.

The production run on the equipment required the production of a specific quantity of sheets within a specific time period. During the production run, the spoilage and print registration will be tracked for analysis.

Each machine will be tested independently and acceptability will be solely based upon the performance of the individual machine to meet the requirements specified in the contract.

Prior to the testing, the contractor will process sheets to ensure the machine is ready for the performance of the test. Contractor will notify the COR when testing is to begin.

If for reasons beyond the control of the Bureau and contractor testing cannot occur on a given day; testing will be arranged to be performed on the next available day.

The test plan shall specify how testing will be performed. The test plan can be changed by mutual agreement between the Bureau and contractor.

During production runs all cabinets, panels etc. shall be closed. No test equipment shall be permitted to be connected to the system. There shall no more than three operators controlling the system.

All production runs shall be conducted as if they were actual production runs occurring. BEP will supply load tags and process cards to be scanned into the system. BEP will not interfere with the continuous operation of the machine during the production runs. However, Sample sheets, straps, bricks and bundles may be requested. If the BEP notices an issue with the system or operation of the system that would void the testing results, the BEP will notify the contractor’s representative to stop operation.

III – Factory inspection Test (FIT) The purpose of the FIT is to ensure that all functions of the Hot Foil machine will conform to the specified requirements in the contract, prior to authorization for the vendor to deliver the system to the BEP.

Materials: The BEP will provide those materials listed within the contract as Government Furnished Materials (GFM) for the performance of the FIT. The contractor shall provide any other materials required for the performance of the FIT.

Duration: The FIT is anticipated to require ten (10) days for the vendor to successfully demonstrate all requirements. Five (5) of the days will require the operation of the system in a simulated production mode. The daily plan for the FIT is attached.

Tests: During the performance of the FIT, the vendor will be required to demonstrate the following:

· Simulated 50-subject Sheet Production (4 days)

· Simulated 32-subject Sheet Production (1 days)

· Note Production (1 day) In addition, the vendor shall demonstrate the capabilities of the system to:

· UV cure

· Change Note Sizes

· Change Formats

· Jam and Error Recovery; Product Tracking

· IT and Data Capture

IV – Bureau Acceptance Test (BAT)

The purpose of the BAT is for complete demonstration of all requirements by the vendor for acceptance by the BEP. The system shall be configured for regular production. The BEP will coordinate with the vendor on the denomination and format for the production of the BAT. The BEP will provide a collection of blank sheets, sheets containing defects (MUTs) and regular production sheets for the setup and preparation for the BAT.

Pre-BAT Demo: Since the system will require the use of “live” product during the BAT and that the materials produced during the BAT may be utilized by the BEP, the contractor shall successfully demonstrate the system readiness to begin the BAT while ensuring the product quality and appearance. Prior to being authorized to begin the BAT, the contractor shall demonstrate system functionality, product accountability, product quality and product appearance in full compliance with the contract during the production of 1 complete process of test or MUT work and startup quantities of Star Sheets and Star Notes. If during these demonstrations any issues or problems are noted, the contractor will not be authorized to begin the BAT but must make corrective actions prior to repeating the demonstration.

Materials: The BEP will provide those materials listed within the contract as Government Furnished Materials (GFM) for the performance of the BAT. The contractor shall provide any other materials required for the performance of the FIT.

Duration: The BAT is anticipated to require ten (10) days for the vendor to successfully demonstrate all requirements. Four (4) of the days will require the operation of the system in production mode. The daily plan for the BAT is attached.

Tests: During the performance of the BAT, the vendor will be required to demonstrate the following in addition to the production running of the system for four (4) days:

· Jam and Error Recovery; Product Tracking

· IT and Data Capture

The BEP will not require demonstrations of the capabilities of the system to change formats or note sizes during the BAT.

V – Final Acceptance

Final acceptance of the Hot Foil Machine will occur after the following:

1. Successful completion of the BAT

2. Successful Training of all BEP personnel

3. Successful Production Validation (PV) by the BEP

4. Successful operation by BEP personnel of the equipment in production for at least twenty (20) days on three (3) shifts or 480 hours without any problems or failures in full compliance with the requirements within this contract.

During the Extended Run, the BEP will operate the system as instructed. The BEP will monitor and report on the compliance of the system with the specified performance requirements. The BEP will adjust performance data to compensate for any non-machinery impacts or influences outside of the control of the contractor.

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