Attachment_R_-_Preliminary_Test_Plan.pdf

FIT/BAT TEST PLAN

WCF INTAGLIO PRESSES

I – Introduction

This document specifies the testing procedures for the Factory Inspection Test (FIT) and the Bureau Acceptance Test (BAT) for the WCF Intaglio Presses.

The FIT will occur at the contractor’s facility. The objective of the FIT is to verify that all design, development, and manufacturing has been completed and to ensure that only minor adjustments and /or changes will be required upon installation at the Bureau of Engraving and Printing (BEP).

The Bureau Acceptance Test (BAT) will occur following installation and start up of the machinery within the Bureau of Engraving and Printing’s Western Currency facility (WCF). The objective of the BAT is to verify that the equipment satisfies all contract requirements. The BAT is a much more exhaustive test than the FIT.

Both the FIT and BAT are divided into four phases. These phases include: Certification, Visual Inspections, Demonstration and Production Run. Certifications are used for any item not possible to be demonstrated or tested within a short time period. Certifications are typically design criteria items that relate to the life of the machinery. All Certifications shall be provided on Company letterhead stating compliance with the requirements.

Inspections are visual checks of contract requirements which can either be witnessed during the production run or when the machinery is not in operation. Inspection items which are not witnessed during the production run and are not possible without the machine running, shall be included as part of the demonstration items.

Demonstrations are items which typically cannot be witnessed during the production run or which would cause disruptions during the operation of the equipment. Demonstrations include causing faults and emergency stops of the equipment, and electronic testing.

The Production Run on the presses requires the production of a specified quantity of sheets within a specific time period. During the Production Run, the spoilage and printing registration will be tracked for analysis.

Each machine will be tested independently and acceptability (FIT OR BAT) will be solely based upon the performance of the individual press to meet the requirements specified in the contract.

Prior to the FIT and BAT, the offeror will process sheets to ensure the machine is ready for the performance of the test. The BEP shall be notified by the Contractor in writing, fifteen (15) days prior to the start of the FIT that the equipment is ready for testing to be performed.

For reasons beyond the control of the BEP or the offeror any testing that cannot occur on a given day, testing will be arranged to be performed on the next available day.

This test plan is an anticipation of how testing will be performed. The test plan can be changed by mutual agreement between the BEP and the offeror.

II – Materials for FIT/BAT

A) Government Furnished Materials:

The following is a listing of the materials and /or services that the BEP will provide during the performance of the FITs and BATs on each of the presses. Any items not listed as to be provided by the BEP shall be furnished by the offeror.

1) FIT:

• U.S. Currency Paper

a. ______ Sheets Non-Distinctive Banknote, Type I

b. ______ Sheets Currency, Type IV

c. ______ Sheets Currency, Type V

• U.S. Currency Ink

a. _____ Pounds Magnetic Black

b. _____ Pounds Regular Green Ink

c. _____ Pounds Non-Magnetic Black Ink

d. _____ Pounds Metallic Ink

e. _____ Pounds IR Green Ink

f. _____ Pounds Optically Variable Ink

2) BAT:

During the BAT, the machine will be operated as if in normal production.

The presses will be provided working materials from the normal BEP production stream. Any notes printed during the BAT meeting the BEP’s Quality Standards shall be usable as normal work. Using these notes does not constitute passing or acceptance of the equipment.

The following materials will be furnished by the BEP for the performance of the Bureau Acceptance Test on each press:

Materials:

• 32 and/or 50 subject offset printed currency sheets

• Green intaglio currency ink

• Black intaglio currency ink

• OVI intaglio ink

• 32 and/or 50 subject printing plates

Personnel:

• Intaglio Printers (to assist contractor personnel)

• Printing Plant Workers (PPW)

B) Contractor Furnished Materials:

The following materials shall be furnished by the Offeror for the performance of the FIT and BAT.

1) FIT Materials:

During the Factory Inspection Test, the Offeror will furnish all manpower, utilities and any other materials and services necessary to demonstrate the compliance of the machinery not provided by the BEP.

2) BAT Materials:

During the Bureau Acceptance Test, the Offeror will furnish two Intaglio Printers to operate the machinery and be responsible for insuring compliance.

The BEP’s Intaglio Printers will be provided to assist the Offeror’ s personnel and to ensure that the quality of the material is sufficient to ensure use of the finished notes.

III – Test Plan

The performance of the Factory Inspection Test (FIT) and Bureau Acceptance Test (BAT) will be divided into four phases. These phases include Certifications, Visual Inspections, Demonstrations and Production Run. It is the responsibility of the Offeror to ensure demonstration of all items to the BEP.

A) FIT LOCATION

The FIT will be performed at Offeror’ s facility.

B) FIT Duration:

The FIT is expected to require a total of five (5) days for each press. Prior to commencing the FIT, the Offeror will provide the Certification Document to the COR as specified in the Certification section of the Test Plan.

C) Proposed FIT Schedule:

Day1 Day 2 Day 3 Day 4 Day 5 Make Ready, tuning and demo of inspection system

Large format Production Run

Large format Production Run

Job Change, Certifications, Visual Inspections, Demonstration of press, IT/

DCS and Accountability

Small format Production Run

D) BAT:

The Bureau Acceptance Test will be performed at the BEP after installation and start-up of the equipment. The Offeror will inform the BEP in advance of when the necessary materials will need to be present during the installation and set up phases.

The printed notes produced during the BAT shall remain the property of the BEP and the BEP shall have the right to use the printed notes as normal work without effect on the outcome of the BAT.

E) BAT Duration:

The BAT is expected to require five (5) days. One day for the Visual Inspection and Demonstrations and four (4) day Production Run. During the Production Run the presses shall print at least 60,000 acceptable quality sheets within the 6 ½ hour Production Run each day.

In addition to the BAT of the press, a BAT of the Data Collection System (DCS) is expected to take an additional two days of testing on the first press and one additional day on subsequent presses.

The BAT will not be complete until system accuracy and robustness is demonstrated over a thirty (30) day period under actual production conditions. If the test is deemed unacceptable, the BEP reserves the right to require a full test or a partial retest of the equipment and the Offeror will provide the BEP with all of the following: (1) Causative factors for the nonconformance; (2) A written explanation on how the Offeror proposes to correct the nonconformance; (3) The estimated time that will be necessary to correct the nonconformance; and (4) How the Offeror intends to demonstrate compliance. Once a BAT is in progress, if there are extenuating circumstances or equipment-caused delays, the BEP as agreed to by the offeror, may exercise one of the following options: (1) Extend the test accordingly;

(2) Restart the test from the beginning; or (3) Abort the test. Any equipment fault/incident that occurs during the BAT that results in a 15-minute or longer press stoppage is considered a failure. There will be no failures during the 4-day production run portion of the BAT. If a failure occurs, resolution will proceed as described above in Section C E.4 of the contract.

F) Proposed BAT Schedule:

Day1 Day 2 Day 3 Day 4 Day 5 Enviromental and Safety inspection,Visual

Inspection and Demonstrations, Make Ready, tuning and demo of inspection system

Production Run and , IT/ DCS and Accountability

Production Run and , IT/ DCS and Accountability

Production Run Production Run

IV- Guidelines

The following are the guidelines for the performance of the FIT/BAT. Some of the guidelines apply to only the FIT or BAT, or specific parts of the testing.

1. BEP personnel will witness the performance of the FIT/BAT. The Offeror is responsible for the performance of the testing to demonstrate compliance.

2. Other than that which is stipulated in the operations and maintenance manuals, maintenance shall not be performed during the FIT/BAT, unless to correct defective or damaged parts. In the event an incident occurs that can be attributed to defective or damaged parts, the Offeror will provide an explanation in writing. The incident will also be considered a “failure”, and will be used to determine MTBF.

3. Normal operator adjustments can occur during the FIT/BAT as necessary.

4. No transferring of parts or components shall occur between machinery during the BAT.

5. A daily listing of the Offeror’s personnel whom will be working in the test area shall be provided to the COR. The listing shall include the name of the Offeror’s personnel and the specific purpose for their access.

6. All data collected from the machines during the FIT/BAT, regardless of who collected the data, shall become the property of the BEP. The Offeror will be furnished a complete copy of all data collected.

7. During the Production Run, the machinery will be operated as if in production. Any items, components, software, etc., used on the machinery during the FIT/BAT to ensure compliance will remain as part of the machine upon acceptance.

8. All machines will be identical. If any item, component or software is changed on one machine to comply with the requirements, then all other machines will have the identical change performed.

9. The schedule for each days events will be mutually agreed to by the Offeror’s representative and the BEP’s COR.

10. Certification will specifically address each item required.

11. Certifications will be on Company Letterhead with the name and title of the companies authorized representative.

12. If the machine is stopped during the production run for a lunch break, the production timer will stop when the machine stops feeding sheets and restart when the first sheet is fed. No work will be performed on the machinery during the lunch break.

13. It is the responsibility of the Offeror’s representative to coordinate all demonstrations and work with the BEP’s COR.

14. A decision by the BEP to proceed with further processing and /or shipment of “Live” work produced during the BAT production run, will not be considered formal acceptance of the SOI presses.

V- Procedures

The following are testing procedures for the presses during the Factory Inspection Test and Bureau Acceptance Test.

A) Certifications:

Certifications are used whenever inspection, demonstration, or witnessing the production run will not result in insurance of compliance with contract requirements.

Certification items are typically items related to the life and design of the machine and cannot be tested within the time frame of the FIT/BAT. For each machine, a certification document will be provided prior to the start of the test.

All certifications will be furnished on Company Letterhead with a signature of responsible party that all items have been met. It is expected that the Certification document will not require any time during the performance of the testing.

The listing of items that require Certifications are shown on the attached Check Listing as items with a “C” on how the requirement will be verified.

B) Visual Inspections:

Visual Inspection are used to ensure compliance on items which can be visually witnessed either during operation of the machine or while the machine is not in operation. Visual Inspection is expected to require two (2) to three (3) hours on the machine.

The listing of items that require Visual Inspections are shown on the attached Check Listing as items with a “V” on how the requirement will be verified.

C) Demonstrations:

Demonstrations are used whenever the verification of an item would cause disruptions to a timed production run. Demonstrations are typically items related to fault detection, diagnostic capabilities, etc.

The listing of items which require Demonstrations are shown on the attached Check Listing as items with a “D” on how the requirement will be verified. Special Demonstrations are as follow:

1) Feeder Fault Detection:

Special sheets consisting of full-size FIT sheets will be prepared by the Offeror for the demonstration of the Feeder Fault Detection for both the FIT and BAT on all machines. The sheets will be marked to allow for easy identification of the sheets. The sheets will be used to demonstrate the ability of the feeding mechanism to detect and stop when the following types of faults occur:

Double Sheets (Mechanical and Electronic Two-Sheet Detectors) Side Lay Misalignment Front Lay Misalignment Missing Sheets Jammed Sheet Foreign Material Detector

During the demonstration, the machine will be set up as if in normal production. At least 2,000 sheets will be placed into the feeder with the prepared sheets for the feeder demonstration inserted randomly into the stack.

The sheets will be spaced sufficiently to allow the machine to obtain full operational speed between stops.

2) Feeder Lifting Mechanism:

The lifting mechanism on the feeder will be tested to ensure that the required safety features exist to prevent jams and possible damage to the feeder. The pre-piling device will also be checked to ensure that it is working properly.

Testing of the feeding lifting device will occur via engaging the machine and manually initiating the emergency stops at the top of the feeder. The machine will stop lifting the pile and go into a safe position.

3) Control Stations:

The Emergency Stop, Stop and Lock, and interlocks fore each control station will be checked for compliance. The BEP personnel will randomly select Emergency Stop buttons to be tripped and ensure the system shuts off and is unable to be restarted without resetting.

The Stop-n-Lock buttons will be checked to ensure that once a button is depressed, the machine cannot be restarted from any other station until the button depressed is released

The Interlocking Safety Features of the control stations will be checked to ensure compliance. Once an inch button is depressed at a station, no other stations will initiate operation of the machine until the control of the machine is released from the station where the inch is initiated.

4) Safety Covers/Interlocks:

Covers and the related interlocks will be tested to ensure that they are present and are in working order. BEP personnel will randomly select covers to be opened to demonstrate the ability of the machine to stop and prevent operation. With a cover open, only a slow inch shall occur.

5) PLC Programmer/Interrogator:

The full range of function for the PLC Programmer/Interrogator (P/I) unit will be demonstrated for the first press and a demonstration of connectability and start-up for all subsequent presses.

6) Noise Rating:

The noise produced by the machine in operation will be measured as specified in the contract. A preliminary noise analysis will be provided with the first machine during the FIT. This analysis will demonstrate the general noise rating for the machine.

A certified firm will be employed to perform a noise rating and analysis as part of the BAT on the first machine. The analysis results will be provided to the BEP. All measurements of the noise produced will be taken while the machine is in normal operation.

D) Production Run:

During the performance of the Factory Inspection Test and the Bureau Acceptance Test, the presses will be placed into production for a specific amount of time. During this time frame, the press shall print the required number of sheets as if in normal operation.

The equipment will be operated by no more than the required number of personnel and will be operated as if in normal operation.

1) FIT Run:

During the FIT on two consecutive days the press will perform production runs to demonstrate productivity at a sustained production speed of up to 10,500 sheets/hr. Accordingly, the Offeror will print between 20,000 and 25,000 sheets within a 2 – 2 ½ hour time frame.

When the COR and the Offeror agree to begin the FIT production run, a minimum production press speed of 10,000 sheets per hour will be demonstrated when the press is in full production mode. If the press experiences an error that prevents resuming production within fifteen minutes, then the error will be considered a failure.

Sample sheets from these production runs will be inspected for print quality as well as sheets extracted from the loads to be used for registration measurements.

During both days of the production run portion of the FIT, “print density variation” and “print recovery time” will be closely monitored whenever press stops occur. No intentional press stops will be requested during this portion of the FIT. The In-line sheet inspection system shall be in full operation mode for the entire duration of the production run. An appropriate reference image will be generated, stored and used for inspection. The number of sheets printed, following a press stop, before the In-line sheet inspection system determines acceptable quality has resumed shall be counted and documented.

BEP’s desired target for print recovery time is less than 12 sheets.

After the required two consecutive production days are completed, the following test designed to evaluate print density variation and print recovery time shall be conducted. The presses will be setup for a normal BEP production run utilizing BEP’s supplied materials as listed in this document.

The presses shall be operated at a production press speed of 10,000 sheets per hour. The Presses shall be operated in accordance to a randomly generated series of press on (in production) and press stop cycles. Duration of the test will be approximately 4 ½ hours with approximately 20,000sheets being printed. The series of cycles has the following limits: a maximum allowable press on-time of 15 minutes; a maximum allowable stop time of 20 minutes; a minimum press stop-time of 30 seconds. Changes to the cycles may be determined necessary due press operating characteristics and/or press conditions witnessed by the BEP team and the offeror during FIT production runs. Two candidate run-stop/idle cycles (times in minutes) are presented in the attached Appendix.

2) BAT Run:

During the performance of the BAT, the Press will be operated for four (4) days in normal production. During the BAT Production Run, the press will print at least 60,000 sheets everyday within the 6 ½ hours of operation.

During the operation of the BAT, the Press will be used to produce normal product. The use of the printed sheets after the BAT is at the sole discretion of the BEP. The acceptability of the machine will not decide the use of the printed sheets by the BEP.

The production timer will begin when the first sheet is fed into the machine on each day of operation and will stop when the feeder stops at the end of each day.

Time stoppages at the end of each load to adhere to the BEP’s accountability reporting requirements will not be considered part of the 6 ½ hour production run. All time stoppages other than end of load accountability activities will be documented and used to assess BAT failure in the event 60,000 sheets are not produced in the specified 6 ½ hour period.

During the BAT print density variation and press recovery time will be closely monitored whenever press stops occur. No intentional press stops will be requested during BAT.

VI – Analysis

This section of the Test Plan specifies how analysis of the test data will occur. Analysis will occur, on the Printing Registration, Spoilage Rate, and Production Run.

A) Printing Registration:

Analysis of the Printing Registration will occur by comparing the results of the data to the requirements in the contract. Measurements will be taken for the Front-Left, Front-Right and Side Lay Registrations. The location of the Front Lay registration measurements will be taken from the leading edge of the paper to the top of the printing at the approximate location of the right and left front lays.

The location of the Side Lay registration measurements will be taken from the respective side of the sheet, at approximately the third note position. This position approximates the location of the Side Lay registration.

Fifty sheets will be selected from the machine for all measurements. These sheets will come from an individual plate segment.

From the measurements, the mean, range, maximum, minimum and standard deviation will be determined for the measurements for each of the registrations. The acceptance criteria will be determined by 2.379 times thee standard deviation being less than or equal to the specification limit in the contract.

B) Spoilage Rate:

The Spoilage Rate of the machine will be determined by the following manners:

FIT Spoilage Rate:

During the FIT, the printing will be periodically inspected by the Requesting Office Representative (ROR) to ensure the machine is printing correctly at an acceptable quality level. As the press is equipped with a In-line Sheet Inspection System, the sheets deposited in the reject piles will be manually inspected to assess the reason for their rejection. The setup of In-line Sheet Inspection System and establishment of acceptance/reject criteria will be evaluated by the BEP’s ROR. The ROR will mark a known printing flaw size on sheets and ensure that In-line Sheet Inspection System rejects all flaws larger and accepts all smaller. Spoilage attributable to the press operation, such as print-to-print and print-to edge mis-registrations, improper feeding and/or transfer of sheets, improper ink application including smearing of the printed images, excessive set off, stains, line breaks, etc. will be less than 1.5% of the number of sheets fed per shift. In general, spoilage is considered any equipment related error or fault that results in printing of sheets including startup sheets that do not meet the existing BEP print quality standards.

BAT Spoilage Rate:

During the BAT, the spoilage rate will be determined by the number of defective sheets diverted from the production pile to the rejection pile. Once the 60,000 sheets have been printed, the sheets on the reject pile will be manually examined. Those sheets found to be acceptable will be returned to the good pile and only those sheets found to be unacceptable due to the performance of the press will be used to calculate the spoilage rate.

C) Production Run:

The production rate of the Equipment will be determined by the ability of the printers to produce at least 60,000 acceptable sheets within the 6 ½ hour production run.

The clock will start with the feeding of the first sheet and will stop upon the printing of the 60,000th sheet. Time associated with “end-of-load” accountability requirements will be added to the clock.

The productivity requirements for the press will include the following: Print quality, print registration and spoilage will be consistent over the entire press operating speed range. The system will be available for operation no less than 95% of the time with no more than 5% downtime for maintenance or repairs.

ELECTRONIC TESTING PROCEDURES FOR THE BAT

Upon installation of the presses in the BEP’s facility, inspection and testing of the various electronic systems will be done for hardware, software and data collection. A summary of the testing to be done is given below.

1.) Hardware:

A visual inspection of the hardware and associated connections will be done. Cabling will be inspected for overall workmanship and for obvious problem areas. Major components such as servers and the Ethernet will also be inspected.

A “cold start” or reboot of the system will be done during the hardware inspection. The BEP will verify that all components operate properly after the reboot.

Disconnects may be performed on some major components such as servers, in order to verify operation after reconnection. If a “hard” disconnect is inadvisable, a shutdown of the software and component can be done.

2.) Software:

A visual inspection of the software components will be done. The BEP will verify that all programs are written in standard programming language. Operation of the bar code reader and keypad will be verified.

(a) Bidirectional communication with the BEP ORACLE database.

(b) Storage of digital values through both time driven and event driven data logging.

(c) Ability of BEP to independently make software configuration changes.

3.) Data:

The ability of the database to collect, store and replicate information will be verified.

The BEP will verify that database outputs such as report generation of error codes, daily logs, and maintenance management reports are generated. The accuracy of the database reports will be verified. Verification of information as described above shall apply to the ORACLE Server, the BEP ORACLE Server, and the BEPMIS Server.

Appendix 1 – Print Density Variation and Print Recovery Testing Sample

Duration Work out Print Stop Idle 1 13:00 Print X 2 03:30 Stop X 3 12:30 Print X 4 18:00 Idle X 5 11:00 Print X 6 04:00 Stop X 7 01:30 Print X 8 11:30 Idle X 9 09:00 Print X 10 04:30 Stop X 11 03:30 Print X 12 10:00 Stop X 13 04:30 Print X 14 13:30 Stop X 15 08:00 Print X 16 19:30 Idle X 17 14:30 Print X 18 08:00 Stop X 19 11:30 Print X 20 06:00 Idle X 21 02:00 Print X 22 14:00 Stop X 23 08:30 Print X 24 07:30 Stop X 25 05:00 Print X 26 10:30 Stop X 27 05:30 Print X 28 13:30 Idle X 29 06:00 Print X 30 01:00 Stop X 31 07:00 Print X 32 11:00 Idle X

Cycle Testing #1

Appendix 1 – Print Density Variation and Print Recovery Testing Sample

Duration Work out Print Stop Idle 1 11:30 Print X 2 06:00 Stop X 3 11:00 Print X 4 16:30 Idle X 5 04:30 Print X 6 05:00 Stop X 7 12:00 Print X 8 04:00 Idle X 9 05:00 Print X 10 07:00 Stop X 11 06:30 Print X 12 13:30 Stop X 13 14:00 Print X 14 02:30 Idle X 15 14:30 Print X 16 16:00 Idle X 17 09:30 Print X 18 19:30 Idle X 19 13:00 Print X 20 14:30 Stop X 21 03:30 Print X 22 02:00 Stop X 23 04:00 Print X 24 14:00 Idle X 25 05:30 Print X 26 01:00 Stop X 27 08:30 Print X 28 20:00 Idle X

Cycle Testing #2