Attachment G - Manufacturing Requirements.doc

Attachment G

BEP-10-0001

BUREAU OF ENGRAVING AND PRINTING

MANUFACTURING REQUIREMENTS

FOR DISTINCTIVE CURRENCY PAPER

May 19, 2009 The following provides the requirements for manufacturing currency paper for the Bureau of Engraving and Printing (BEP). These requirements apply to all “prime” and “sub” contractors to the BEP.

1. PRODUCTION CAPACITY

The contractor shall have production capacity sufficient to provide an uninterrupted supply of currency paper to the Bureau of Engraving and Printing (BEP) as required by the contract. The contractor shall ensure that the quality of the paper is maintained and meets the requirements of the currency paper specification. The contractor shall maintain an adequate number of personnel and equipment to meet production requirements.

2. RAW MATERIALS

The contractor shall have reliable sources of supply of raw materials to support the manufacture of currency paper. The reliability of the sources of supply includes the dependable delivery and quality of the raw material supplied. The contractor shall have a system for assuring the quality of the raw materials including recyclable materials through quality control inspection and testing of raw materials when received and during the manufacturing process. The contractor shall have a system for identifying materials meeting quality requirements and for nonconforming materials. The contractor shall provide adequate warehouse storage and management of inventory to maintain the quality and quantity of the raw materials.

3. MANUFACTURING PROCESS

A. PAPER MAKING

The contractor shall have the systems to monitor and control the cleaning and conditioning of the raw materials during the stock preparation, metering, and blending processes. The contractor shall have an appropriate control system for the addition of materials to the furnish. The contractor shall have an in-line process control system for formation, grammage, caliper, and moisture starting at the head-box and throughout the manufacturing process. The contractor shall also have a process control system for the white water recycling, pressing, sizing, drying, and reel operations.

In addition to the current 32-subject sheet, the BEP is planning to produce currency using a larger 50-subject sheet. The offeror should have the capability to manufacture 50-subject sheets of currency paper. Therefore, the Manufacturing Plan shall address the offeror’s capability to manufacture a 50-subject sheet consisting of 5 columns of notes in the cross direction with each column containing 10 rows of notes.

B. THREAD AND/OR WATERMARK

During the manufacture of currency paper, the contractor shall have a real-time automated control system for maintaining the quality and location of the thread(s) and/or watermark. This system shall ensure compliance with the BEP currency paper specification.

C. FINISHING

The contractor shall have a system for the control of all finishing operations with special attention given to roll splitting, rewinding, notching, sheeting, counting, stacking, packaging, and labeling. Due to the security and accountability requirements, the contractor shall ensure sheet count accuracy from load to load. The notch in the sheets shall meet the location and size requirements of the BEP currency paper specification.

D. INSPECTION

The contractor shall have in-line inspection systems and procedures for quality control of the currency paper, the thread(s), E-material, and/or the watermark. The systems shall assure the detection and elimination of flaws and defects in the currency paper.

E. STORAGE

The contractor shall have adequate storage and management of inventory to maintain the quality and quantity of the finished currency paper. The location of the storage facility and the storage conditions shall not compromise the quality of the currency paper. The contractor should have a system for monitoring, recording, and retrieving historical data on relative humidity and temperature in all currency paper post-manufacture storage and transportation areas.

4. ANCILLARY PROCESS

The contractor shall have the systems to control critical ancillary processes for manufacturing currency paper. Ancillary processes are defined as processes which support but are not directly a part of the paper manufacturing process. For example, the contractor shall have a system for ensuring the quality of the watermark screens and threads.

5. PERSONNEL

The contractor shall have personnel with the experience and expertise to manufacture currency paper. Additionally, the contractor shall have technical personnel who have expertise in paper-making. The contractor shall maintain, at all times, an adequate number of employees in the paper making operations and quality assurance functions.

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