BEP-RFP-16-0433.pdf

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, & 30

1. REQUISITION NUMBER PAGE 1 OF

2. CONTRACT NO. 3. AWARD/EFFECTIVE

DATE

4. ORDER NUMBER 5. SOLICITATION NUMBER 6. SOLICITATION ISSUE

DATE

7. FOR SOLICITATION

INFORMATION CALL:

a. NAME b. TELEPHONE NUMBER (No collect calls)

8. OFFER DUE DATE/

LOCAL TIME

9. ISSUED BY

13b. RATING

14. METHOD OF SOLICITATION

CODE

15. DELIVER TO 16. ADMINISTERED BY CODE

18a. PAYMENT WILL BE MADE BY CODE17a. CONTRACTOR/

OFFEROR

CODE

FACILITY

CODE

CODE

TELEPHONE NO.

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT SUCH ADDRESS IN

OFFER

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a UNLESS BLOCK

BELOW IS CHECKED

RFQ IFB RFP

SEE ADDENDUM

19.

ITEM NO.

20.

SCHEDULE OF SUPPLIES/SERVICES

21.

QUANTITY

22.

UNIT

23.

UNIT PRICE

24.

AMOUNT

(Use Reverse and/or Attach Additional Sheets as Necessary)

25. ACCOUNTING AND APPROPRIATION DATA 26. TOTAL AWARD AMOUNT (For Govt. Use Only)

28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN

COPIES TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH AND

DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY

ADDITIONAL SHEETS SUBJECT TO THE TERMS AND CONDITIONS SPECIFIED

29. AWARD OF CONTRACT: REF. OFFER

DATED . . YOUR OFFER ON SOLICITATION

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

30a. SIGNATURE OF OFFEROR/CONTRACTOR

30b. NAME AND TITLE OF SIGNER (Type or print) 30c. DATE SIGNED

31a. UNITED STATES OF AMERICA (SIGNATURE OF CONTRACTING OFFICER)

31b. NAME OF CONTRACTING OFFICER (Type or print) 31c. DATE SIGNED

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV. 2/2012)

Prescribed by GSA - FAR (48 CFR) 53.212

10. THIS ACQUISITION IS UNRESTRICTED OR

NAICS:

SIZE STANDARD:

13a. THIS CONTRACT IS A

RATED ORDER UNDER

DPAS (15 CFR 700)

SET ASIDE: % FOR:

11. DELIVERY FOR FOB DESTINA-

TION UNLESS BLOCK IS

MARKED

SEE SCHEDULE

12. DISCOUNT TERMS

ARE ARE NOT ATTACHED

ARE ARE NOT ATTACHED

27a. SOLICITATION INCORPORATES BY REFERENCE FAR 52.212-1, 52.212-4. FAR 52.212-3 AND 52.212-5 ARE ATTACHED. ADDENDA

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA

8 (A)

EDWOSB

WOMEN-OWNED SMALL BUSINESS

(WOSB) ELIGIBLE UNDER THE WOMEN-OWNED

SMALL BUSINESS PROGRAM

SERVICE-DISABLED

VETERAN-OWNED

SMALL BUSINESS

HUBZONE SMALL

BUSINESS

SMALL BUSINESS

2 BEP-RFP-16-0433 Bureau of Engraving and Printing

SECTION B - SUPPLIES OR SERVICES AND PRICES/COSTS

B.1 SCHEDULE OF ITEMS AND PRICES

Contractor shall provide a firm fixed price for automated palletizer systems for use in the Cash Pack Section. The project will provide for the automated loading and transportation of pallets loaded with “currency bricks”. This contract will include each of the items listed below.

Proposed pricing shall be inclusive of all labor, materials, tools, equipment, and training.

Offerors are required to submit, at a minimum, an offer that conforms to the solicitation specifications with pricing for all Contract Line Item Numbers (CLINs). Offerors shall price each individual CLIN on a firm fixed price basis. The Government will provide a firm fixed price not to exceed amount for travel and spares, and will only pay for actual incurred costs for travel and spare parts. An Offeror’s failure to submit an offer which conforms to the solicitation specifications may render the proposal unacceptable. The Government will negotiate payments based on the deliverable schedule submitted by the Offeror and agreed to by the Government.

BASE YEAR: 29 September 2016 – 28 September 2017

ITEM

NO

SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 COPE Palletizer#1 1 EA $___________ $__________

ITEM

0002 Factory Inspection Test (FIT) Labor, Materials, & Supplies

1 EA $___________ $__________

0003 Installation/Bureau Acceptance Test

(BAT)#1

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0004 Travel 1 NTE $5,000.00 $5,000.00

The Government will only pay actual costs for travel. All travel shall be in accordance with Federal Acquisition Regulations. (See H.17 for more details)

0005 Training Session #1 1 LOT $___________ $__________

0006 COPE Palletizer#2 1 EA $___________ $__________

0007 Installation/Bureau

(BAT)#2

4 BEP-RFP-16-0433 Bureau of Engraving and Printing

0008 Travel 1 NTE $5,000.00 $5,000.00

The Government will only pay actual costs for travel. All travel shall be in accordance with Federal Travel Regulations. (See H.17 for more details)

0090 Training Session #2 1 LOT $___________ $__________

0010 COPE Palletizer#3 1 EA $___________ $__________

0011 Installation/Bureau

(BAT)#3

5 BEP-RFP-16-0433 Bureau of Engraving and Printing

0012 Travel 1 NTE $5,000.00 $5,000.00

The Government will only pay actual costs for travel. All travel shall be in accordance with Federal

0013 Training Session #3 1 LOT $___________ $__________

0014 Spare Parts (OPTION) 1 NTE $20,000.00 $20,000.00

Offeror shall provide a listing of spare parts. The listing shall include the manufacturer’s part number, detail description of the parts, function, lead time for delivery, estimated mean time for failure/maintenance, recommended quantity and unit price. Proprietary spare parts shall be identified on the spare parts listing. Proprietary spare parts are defined as parts not available from a source other than the original manufacturer.

OPTION 1: 29 September 2017 – 28 September 2018

ITEM

1001 COPE Palletizer #4 1 EA $___________ $__________

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1002 Installation/Bureau

(BAT)#4

1003 Travel 1 EA $5,000.00 $5,000.00

The Government will only pay actual costs for travel. All travel shall be in accordance with Federal

1004 Training Session #4 1 LOT $___________ $__________

1005 COPE Palletizer #5 1 EA $___________ $__________

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1006 Installation/Bureau

(BAT)#5

1007 Travel 1 EA $5,000.00 $5,000.00

The Government will only pay actual costs for travel. All travel shall be in accordance with Federal

1008 Training Session #5 1 LOT $___________ $__________

TOTAL AMOUNT OF CONTRACT: $__________________

8 BEP-RFP-16-0433 Bureau of Engraving and Printing

SECTION C - DESCRIPTION/SPECIFICATION(S)/STATEMENT OF WORK

AUTOMATED PALLET HANDLING SYSTEM AT THE DCF

C.1 Background The Bureau of Engraving and Printing Washington, DC Currency Facility (DCF) has a requirement for an automated pallet handling system. This system may include three (3) to five

(5) commercially available turnkey automated palletizers to stack the output from the Currency Overprinting and Packaging Equipment (COPE) presses operating at the DCF.

Currently, COPE workers manually transfer currency bricks from the discharge end of the COPE presses and stack them on BEP skids in a specific order to maintain the proper numerical sequence for shipping in the Cash Pack section.

C.2 Purpose The automated palletizers shall automatically transfer currency bricks from the discharge end of the COPE and stack them in the proper numerical sequence for packaging and shipping in the Cash Pack section. The automated palletizers shall be designed and fabricated to meet the specifications and functionalities described within this SOW. The automated palletizers shall also be configurable to adjust the stacking sequence.

C.3 Scope Contractor shall provide up to five (5) automated palletizer systems to include all labor, materials, tools, equipment, and training.

C.4 DOCUMENTS

C.4.1 Non-disclosure Agreement

During the course of this contract, the contractor will require sensitive but unclassified information that is proprietary to the United States Government. A Non-Disclosure Agreement (NDA), Attachment 1, shall be signed and notarized as part of the submission package for consideration.

The notarized agreement shall be returned to:

Bureau of Engraving and Printing Office of Procurement, Room 705-A 14th and C Streets, SW Washington, DC 20228 Attn: Gladys Wilks, Contracting Officer

C.4.2 Referenced Documents Equipment delivered under this contract shall meet all current U.S. commercial codes and industrial standards.

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The following is a listing of specific standards that the system shall meet:

American Conference of Government Industrial Hygienists (ACGIH) (www.acgih.org) All applicable documents related to Energy Policy Act of 1992 with specific reference to

Executive Order 13123 (www.omb.gov) All applicable Occupational Safety and Health Administration (OSHA) standards with specific references to OSHA standards 29 CFR 1910 (www.osha.gov) All applicable codes and standards and environmental permitting of U.S. Environmental

Protection Agency (EPA) (www.epa.gov) and District of Columbia (DC) government (www.doee.dc.gov) o Federal Regulation: Environmental Protection Agency, EPA Clean Air Act Amendments of 1990, Section 112-Air Toxics (www.epa.gov/air/oaq_caa.html) o 40 CFR 403-General Pretreatment Regulations for Existing and New Sources of Pollution (www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm)

NIST Special Publication 800-53 (current version) (http://nvlpubs.nist.gov/nistpubs/SpecialPublications/NIST.SP.800-53r4.pdf )

NIST US Government Security Baseline (USGCB) (available at http://usgcb.nist.gov/) Windows 2012/2012R2 Member Server (MS) DISA STIG

(http://iase.disa.mil/stigs/os/windows/Pages/index.aspx) 75D-07.0-06 Environmental Health and Safety (EHS) Requirements for Large Equipment

Purchases (Attachment 2)

C.4.3 Attached Documents The following lists the documents attached to this SOW:

Attachment 1: NDA Document Attachment 2: 75D-07.0-06 Environmental Health and Safety (EHS) Requirements for Large Equipment Purchases Attachment 3: Skid Drawing Attachment 4: Brick Drawing Attachment 5: COPE-Pak Discharge Conveyor Drawing Attachment 6: Brick Stacking Sequence Attachment 7: The United States Government Configuration Baseline (USGCB) Attachment 8: Federal Information Processing Standards (FIPS) Publication 199:

Standards for Security Categorization of Federal Information and Information Systems

Attachment 9: NIST Special Publication 800-53 (current version) Attachment 10: Department of Justice: Mapping PIV Card Certificates to a Privileged

Account

C.5 GOVERNMENT FURNISHED MATERIALS

The items listed in this section will be supplied by the BEP for utilization with the automated palletizers. Any additional materials required for successful utilization of the automated palletizers shall be specified in the Offerors’ proposal. The contractor shall provide the initial batch of additional materials when the equipment is delivered. The initial batch of additional materials shall be sufficient for the successful utilization of all purchased automated palletizers for one year (240 working days) at three (3) shifts per day, eight (8) hours operation per day.

10 BEP-RFP-16-0433 Bureau of Engraving and Printing

The contractor shall supply any items specified for all startup and testing on the automated palletizers prior to final acceptance. The materials utilized during startup and testing shall not be considered part of the initial batch to be supplied to the BEP for the first year’s operation of the automated palletizers.

The contractor shall provide a specification and SDS (Safety Data Sheet) for all contractor proposed materials no later than 90 days prior to Factory Inspection Test (FIT). The contractor shall arrange for their materials to be reviewed and approved by the Office of Environmental, Health and Safety prior to their bringing the materials on site. Materials not approved shall not be brought on to the site and consequently these materials shall not be used by the automated palletizers. In this case, the contractor shall propose alternative materials. The contractor shall remove all unused chemicals from BEP.

C.5.1 Skids The automated palletizers shall utilize the existing BEP Currency Skids for the stacking of the bricks. The drawing of the skid is Attachment 3.

C.5.2 Bricks A brick is four (4) bundles, four thousand (4000) notes, shrink-wrapped together with serial numbers on the notes in a continuous numeric sequence. A brick is shown in the attached drawing, Attachment 4.

C.6 TECHNICAL REQUIREMENTS/TASKS/OUTCOMES

The automated palletizers shall automatically transfer currency bricks from the existing discharge end of a COPE-Pak machine and stack them in the proper numerical sequence onto BEP provided skids. The automated palletizers shall meet the following Functional, Performance and Design requirements.

C.6.1 Functional Requirements

C.6.1.1 Discharge Conveyor The automated palletizers shall pick up individual bricks from the discharge conveyor of the COPE-Pak machine. The discharge conveyor shall not be required to be modified. Attachment 5 details the COPE-Pak discharge conveyor.

C.6.1.2 Stacking Order The automated palletizers shall stack the bricks in the BEP designated order onto the skid.

Attachment 6 details the stacking sequence of the bricks on the skids.

C.6.1.3 Stacking Configuration The palletizer shall stack bricks into the required configuration without impacting the stability of those bricks already stacked on the skid. The palletizer shall produce a skid with the bricks in the required configuration 999 out of 1000 times.

11 BEP-RFP-16-0433 Bureau of Engraving and Printing

C.6.1.4 Pertinent Specifications and Dimensions The following specifications and dimensions are pertinent to the operation of the automated palletizers:

(a) Pallet dimensions: Maximum size of 48” x 36” x 5.5”

(b) Product: Currency Bricks

(c) Brick Product Size:

i. Length: 18 inches

ii. Width: 6.25 inches

iii. Height: 2.75 inches

iv. Weight: 9.5 pounds

(d) The Contractor shall specify and provide a repeatable means for placement of two BEP provided skids for system operation. BEP personnel will manually remove the complete skids and place empty skids into position for continued operation. The automated palletizers shall have means for the operator to signal completion of the replacement process to continue operation.

(e) The proposed automated palletizers shall not block forklift access to skids through the sliding doors.

(f) Maximum Equipment Foot Print: 71” x 128” x 20’ (See figure below, reference hatched area)

(g) Proposed equipment shall be located in a manner that maintains OSHA-required egress width of 32 inches at all egress routes.

C.6.1.5 Loading Head The head used for picking up and placing the bricks shall have the following:

(a) Capability of both single and multiple product(s) pickup with loading head.

(b) Capability of 360 degree placement of products onto pallet.

Skid Part A

Skid Part B

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(c) Four (4) axis rotation capability; x, y, z and a (rotation around z-axis) axes

(d) Capability of loading products based upon operator-selected pattern.

(e) Loading head with mechanical and/or vacuum pickup utilizing gripper or fork system.

C.6.1.6 Processes United States currency is printed in units known to the BEP as “processes.” Two (2) distinct types of processes currently exist; process size for the lower denominations of bills, namely $1 through $20 bills and process size for higher denominations which include $50 and $100 bills.

The process size for the lower denomination of bills consists of 6,400,000 notes producing 1600 “bricks” (4,000 notes each) of currency after printing and packaging. A total of ten (10) skids, part A and B, will be produced per process.

The process size for the higher denominations consists of 3,200,000 notes and produces eight hundred (800) bricks when printed and packaged in COPE. A total of five (5) skids, part A and B, will be produced per process.

C.6.1.7 Stacking Sequence Stability The automated palletizers shall ensure that the stacked currency bricks are stable during the stacking sequence. Maximum permissible overhang of currency bricks is +/- 2.5mm.

C.6.1.8 Bar Code Verification The automated palletizers shall verify the bar code on the bricks to ensure that the numerical sequence of the product is maintained. Error rate for reading bar codes shall be less than 1 per

250. The automated palletizers shall alert the operator if the bricks are not in the correct numerical sequence.

C.6.1.9 Skid Sequencing and Alerting Process The automated palletizer shall indicate, visually and audibly, when the skids are 80% and 100% full. The palletizer’s audible alarm shall be a series of beeps/horns that sounds for a definable sequence at a fixed time increment until addressed by the operator. The system shall have a silencing button for the operator to signal acknowledgment of the status.

The sequence and alerting process shall be agreed upon between the BEP and contractor during the design review meeting on the system after award (see Section C.7.1). BEP personnel will remove the skids from the palletizer and signal the system when a new skid is in place for continued stacking.

C.6.1.10 COPE-Pak Controls Interface The contractor shall integrate the automated palletizers through an interface with the COPE- Paks’ electronic controls. Prior to integrating the automated palletizers with the COPE-Paks’ electronic controls, the contractor shall develop and submit to the BEP an Interface Control Document explaining how the interface will work. After award, BEP will provide the contractor with access to the facility and the BEP’s COPE-Paks’ control systems enabling contractor to ensure the Interface Control Document is 100% compliant with the existing COPE-Paks.

The contractor shall include the following in the COPE-Pak Controls interfaces:

(a) Indication that the palletizer is ready; if not the COPE-Pak shall not operate

13 BEP-RFP-16-0433 Bureau of Engraving and Printing

(b) E-Stop: when activated on either the palletizer or COPE-Pak, both systems are shut down

The contractor shall develop the interfaces so they are readily accessible within a junction box equipped with terminal strips. The contractor shall coordinate with BEP to facilitate installation.

C.6.1.11 User Interface The following are the requirements for the user interface.

(a) Touch screen interface

(b) On-line diagnostics

(c) Ability to store stacking patterns for specific products

C.6.1.12 Job Setup The job setup shall be 100k and 200k process sizes (5 skids or 10 skids respectively)

C.6.1.13 Restarts/Interruptions The automated palletizers shall have the ability to restart an existing job after the stacking sequence has been interrupted. The BEP may pause production of a process for downtime over weekends or other events. The automated palletizers shall have the ability to restart and know which bricks already have been stacked onto skids to continue the operation.

C.6.1.14 Uninterruptible Power Supply (UPS) The automated palletizers shall be protected by an Uninterruptible Power Supply (UPS). The UPS shall prevent damage to the system’s PCs and/or loss of data in case of power instability or power loss.

C.6.2 Performance Requirements The following specify the performance requirements of the system.

C.6.2.1 Processing Rate The automated palletizers shall be capable of operating at normal and high speed processing speed as specified below:

(a) Normal Operation: 6 bricks/minute

(b) High Speed Operation: 8 bricks/minute

C.6.2.2 Staffing The automated palletizers shall operate at full production rate without the direct supervision of an operator being required to perform any function other than remove full skids and place empty skids into position.

C.6.2.3 Yield The automated palletizers shall yield at least 99.9% acceptable work, no more than 0.1% spoilage (failure/false rejects of acceptable work) per shift.

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C.6.2.4 Set-Up Time The total time to set up the automated palletizers to stack and scan currency bricks shall require no more than 5 minutes for a job change.

C.6.2.5 Unscheduled Corrective Maintenance The Mean Time Between Failure (MTBF) for any unscheduled corrective maintenance required by the system shall average less than one (1) event per 300 hours of operation. An unscheduled corrective maintenance event is considered any time maintenance personnel must be called by the operators or when the system is unable to operate within conformance to the product, functional or performance requirements for more than fifteen (15) minutes.

The Mean Time to Repair (MTTR) for any unscheduled corrective maintenance event shall average less than 2 hours for corrective actions to be made and the automated palletizers returned to production.

C.6.2.6 Preventative Maintenance The yearly average for time utilized for preventative maintenance on the automated palletizers shall not exceed 3% of the operational time for the system. Major components shall have a mean Time Between Maintenance (MTBM) of no less than 3% of the operational time. Major components shall include any component(s) that require the palletizers to be down for more than two hours to remove a component for maintenance and replace with a spare. All preventative maintenance work shall be detailed within the maintenance manual, including all check-lists, procedures and recommendation for the time to perform.

The BEP may elect to purchase spare parts from the contractor (see options) to have on hand as a preventative measure. No later than sixty (60) days after the contract award, the contractor shall provide a listing of all parts that the contractor recommends BEP carry in stock to support the twenty-four (24) hour operation of the automated palletizers. The listing shall be provided in MS-Excel format. The listing shall include the manufacturer’s part number, detail description of the part, function, lead time for delivery, estimated mean time for failure/maintenance, recommended quantity and unit price. Proprietary spare parts shall be identified on the spare parts listing. Proprietary spare parts are defined as parts not available from a source other than the original manufacturer.

C.6.3 Design Requirements The following are specific requirements for the design and fabrication of major production machinery for the BEP.

C.6.3.1 Production Machinery Life The automated palletizers shall be designed for utilization by the BEP for three (3) shifts per day, five (5) days per week operation for ten (10) years. To the extent possible, the contractor shall provide means for restoring all worn surfaces by the simple replacement of individual elements.

C.6.3.2 Uniformity All equipment delivered to the BEP under the terms of this contract shall be of the same type, model, software version etc. Any changes that are made to the later palletizers or support

15 BEP-RFP-16-0433 Bureau of Engraving and Printing systems, including software, shall be retrofitted onto any previously accepted system(s). The installation of changes on a system previously accepted shall not occur until after the change has been proven during a Bureau Acceptance Test (BAT). The contractor shall perform a test to validate that the upgrade does not negatively impact performance of the previously accepted system and that all functionality of the previously accepted system remains.

C.6.3.3 Utilities

(a) The equipment shall operate with the following BEP provided utilities:

Electrical power: 480 volts, 3 phase, 60 hertz, four wire alternating current or standard single phase 110-120 V AC power Compressed Air: up to 80 psig, not oil free and at ambient humidity Vacuum: up to 18 inches mercury (Hg)

(b) The contractor shall provide and install devices such as transformers, filters, dryers, surge suppressors, etc., to make these BEP provided utilities compatible with proper functioning and operation of the system.

(c) The contractor shall be responsible for utilities connections from disconnect points. The BEP will furnish all utilities to within 6 meters (20 feet) of the installation site for the system. The utilities shall be connected overhead.

C.6.3.4 Jam & Error Recovery The automated palletizers shall have detection components to detect whenever a fault, i.e. jam or error, occurs that would result in a disruption to the continuous numerical stacking sequence of the finished product, cause damage to the equipment, produce unsatisfactory product or operation would pose a safety hazard to operational or maintenance personnel. The automated palletizers shall take appropriate actions to stop and notify the operators when a fault is detected.

The automated palletizers shall display specific detailed information on operator stations for trained operators to locate and take corrective actions to correct the fault.

The automated palletizers shall have provision to recover from all faults. No faults shall negatively impact the continuous numerical stacking sequence or create a hazard to operational or maintenance personnel.

C.6.3.5 General Electronic & Electrical Requirements All electronic and electrical components, especially Programmable Logic Controllers (PLCs), network communications hardware and any embedded computers, shall be of the latest version available on date of fabrication of the automated palletizers. All components shall be commercially available within the United States. All motors shall be of Alternating Current (AC) design unless individually approved by the Contracting Officer’s Representative (COR).

Control of the automated palletizers shall be performed via Programmable Logic Controllers (PLC) or industrial rated PCs. The model of PLC used on the COPE Robotic Automation Device shall be uniform. The PLC shall be commercially available and supported within the United States. Communication ports shall allow access of a programming panel and peripheral devices such as modem, printer, and Programmer Interrogator (PI). The makes and models of PLCs that can be incorporated into the automated palletizers shall be included with the proposal such that the BEP can select the most advantageous.

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The power supply(s) shall contain circuitry for the orderly shutdown of the machine in the event that the incoming power does not meet the requirements. The power supply shall be capable of operation with voltages +15% of the normal supply. The machine shall be capable of restarting following return of the power to normal supply without problems or resetting. An Uninterrupted Power Supply (UPS) shall be provided on the system for all computers and control systems to ensure against the loss of data or operational setting during power variations.

All electrical and electronic components shall be designed to operate in an industrial environment without the use of external fans, air conditioning, or electrical filtering. All electronics shall be free from undue electromagnetic radiation and shall be unaffected by normal emissions. The electrical system shall be capable of handling Radio Frequency Interference (RFI) surges of one (1) KV peak to peak with a pulse frequency of less than 10 KHz.

PLC Programs shall be stored in non-volatile memory. All program memory of the machine shall be protected from loss during power interruption. All data shall be retained during loss, spikes or dips in power supply. Data retention shall be provided for a minimum of 14 calendar days. Key type protection or software password protection shall be provided to ensure software memory protection from unauthorized changes, access, or deletion.

All controllers shall perform internal error checking to ensure reliable data transfer. Detection of internal communication faults shall occur via watchdog timers. In the event that a communication fault is detected, then controllers shall turn off all outputs (i.e., fail-safe).

Indication lights shall be provided at all diagnostic points. All Input/Output modules shall have lighted status indicators.

To the maximum extent possible, all software programs shall be commercially available. All programs shall include sufficient documentation to allow maintenance personnel to debug the program. All software to modify, install, or perform diagnostic on the operating software shall be furnished with the system. All software comments shall be in English language.

Fluorescent lighting shall be from commercially acceptable fixtures for their intended locations.

Lighting shall be provided at all points where fine adjustments are to be performed. A minimum lighting of 1076.4 lumens per square meter (100 foot-candles) on these working areas shall be provided. Individual switches to control these lamps shall be provided. The lights shall be operable without powering on the automated palletizers.

Lighting provided for the purpose of manual inspection of product shall be in accordance with Commission International de l’Eclairage (CIE) Standard D65 for daylight as specified in American Society for Testing and Materials (ASTM) Standard D1729. All light fixtures and bulbs shall be in standard sizes available in the United States

All components such as power rectification equipment, control components, etc., shall be mounted on the back panel of the electrical cabinet and not on the sides or the doors of the electrical cabinet for easy access and safety. Mounting of power supplies on the bottom of cabinets is allowable.

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C.6.3.6 Programming Interrogation (PI) A Programming-Interrogation (PI) unit shall be provided with the automated palletizers to allow trained maintenance personnel to perform diagnostic, maintenance and support services with all embedded electronics; PLCs, PCs, Linear Drives, etc. The PI shall be capable of accessing all programs in use on the automated palletizers, and enable cloning hard drives, making back-up copies, modifying programs, and interrogation of control functions. The PI shall be software password locked to ensure against unauthorized access.

C.6.3.7 Safety Requirements The following safety requirements shall be met:

(a) Noise Level: The noise produced by the operation of the automated palletizers at maximum production speed shall not exceed 85 Decibels A-weighted Sound Level (dBA) when measured at 914 mm (3 feet) distance along the plan view of the equipment and at an elevation of 1,524 mm (5 feet).

(b) General Safety: The automated palletizers shall be designed to prevent injury to operation and maintenance personnel at all times.

(c) Sharp Edges: All sharp edges and corners, which present personnel hazards, shall be guarded or padded. All covers and safety guards shall be interlocked with the press control to prevent its normal operation while any cover or guard is open or absent. The location of opened switches shall be displayed on the Master Control Station. Covers and guards shall be manufactured for easy removal by Bureau personnel with tools to facilitate removing mechanical and electrical parts for repair. All rotating and reciprocating parts shall be guarded as specified by OSHA regulation 29 CFR 1910.212.

(d) Heated Surfaces: The contractor shall ensure that the automated palletizers provide the means to prevent heated surfaces on the palletizers from causing burns to personnel during operation.

(e) Asbestos: Materials containing asbestos shall not be used.

(f) Airborne Contaminants Employee Exposure: Operation of the automated palletizers shall not result in worker exposure to airborne contaminations exceeding current maximum allowable concentrations established by Occupational Safety and Health Administration

(OSHA) (29 CFR 1910.1000)

(g) System Locking Arrangement: The automated palletizers shall be equipped with a locking arrangement that will prevent unauthorized manual or power operation of the system. An electrical interlock shall be provided to prevent accidental starting with the mechanical lock engaged.

(h) Safety Data Sheets: Safety Data Sheets (SDS) for all contractor-supplied and specified chemicals that are part of the process must be approved by the Office of Environment, Health and Safety (OEHS) and prior to bringing on site. The SDS shall comply with OSHA, as listed in standard 29 CFR 1910.1200, with particular emphasis on paragraphs

(g) and (i).

(i) Overload Protection: The system shall be equipped with overload protection and power factor correction devices to prevent damage to its components and operating personnel.

(j) Safe-Ready: All control stations shall include a "safe-ready" collar or equivalent. Upon turning the collar to the safe position, it shall be impossible to start the press from any

18 BEP-RFP-16-0433 Bureau of Engraving and Printing other station. Console shall indicate that the particular interlock including emergency stop buttons causes the press to start or not.

(k) Emergency Stop: Emergency stop buttons shall be provided at all operator stations.

Emergency stop buttons shall stop the equipment within one (1) second so as to reduce damage to the equipment and injury to personnel. Emergency stop buttons shall be of the pronounced mushroom type, red in color, with no raised guards to prevent accidental depression. Emergency stop buttons shall remain activated with blinking red light once depressed until manually reset.

(l) Energy Isolation: Disconnect or lockout devices shall be provided and identified with signage for all sources of energy on the presses. This includes electrical, hydraulic, pneumatic, and kinetic sources of energy. All isolating devices (levers, breakers, valves, etc.) for all associated energy sources (electrical, hydraulics, pneumatics, gravity, etc.)

shall be identified by a color coded tag which indicates the type of energy source, the magnitude of the energy and an ID number. All isolating devices shall be capable of being locked out with a standard locking device and/or padlock. Stored sources of energy such as pneumatic and hydraulic forces shall be automatically bled and returned to a zero energy state when an interlocked device (i.e. a guard or a door) is opened.

(m) Guidelines for robotics safety: The system shall adhere to the OSHA STD 01-12-002 Guidelines for Robotics Safety. The automated palletizers shall have safeguards to prevent any operation whenever an individual enters the assigned area. Safety monitors shall trigger upon entry and not allow operation until reset by the operator.

C.6.3.8 Environmental Protection Requirements All equipment installed at BEP shall meet all local, state, and federal environmental regulations, including but not limited to air quality, industrial solid waste, hazardous waste, and wastewater.

The equipment installed at BEP shall comply with the following regulations:

Federal Regulation: Environmental Protection Agency, EPA Clean Air Act Amendments of

1990, Section 112-Air Toxics (www.epa.gov/air/oaq_caa.html) 40 CFR 403-General Pretreatment Regulations for Existing and New Sources of Pollution

(www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm) 75D-07.0-06 Environmental Health and Safety (EHS) Requirements for Large Equipment

Purchases (Attachment 2)

C.6.3.9 IT Components, Configurations and Control Requirements The contractor shall ensure IT components shall be maintained and updated such that over the system lifecycle hardware, operating systems, and software updates or replacements are completed at least 6 months prior to the expected end of useful life or support.

As of the writing of this SOW, the BEP IT hardware, software, configurations and controls are modern and up-to-date with what is currently available in the marketplace or what is required by current federal regulations. (See Attachment 7, United States Government Configuration Baseline.) Depending on when the automated palletizers are delivered to BEP, many of these may be out of date with what is standard at BEP or allowed by regulation or supported by the contractor.

In general software has a 10-year support life. For example, Windows 7 goes out of support in January of 2020; Win Server 2012 goes out of support in January of 2023, and Oracle 12.x goes

19 BEP-RFP-16-0433 Bureau of Engraving and Printing out of support in July 2021. Hardware components have an even shorter lifespan generally 5-7 years before their ability to run newer software becomes difficult or impossible and parts become difficult to obtain. Also older hardware and software increases the risk of system failure due to their age and they are usually more vulnerable to security breaches for the same reason.

Upgradeability is of the upmost importance in the IT components, configurations, and controls section of this document. This will allow for the modernization of the IT components during the 20 year expected life of the equipment, which in turn maintains the usability of the equipment in a safe and secure manner.

As stated, BEP is required by Federal Law to ensure all computer systems are in compliant with Federal Information Systems Management Act (FISMA) security requirements and are consistent with BEP enterprise architecture. To this end, the contractor shall assume that the computer components are categorized as a Federal Information Processing Standards (FIPS) LOW system and that NIST Publication 199 (Attachment 8) controls for a LOW information system are required to be addressed as either inherited, hybrid, or system specific security controls and that hybrid and system specific controls shall undergo a security assessment during the deployment phase and prior to the authority to operate being issued. The contractor shall ensure IT Security Controls are updated as new regulatory requirements are received over the systems life expectancy and allow for periodic updates as threats and vulnerabilities that affect the stability or security of the equipment are identified.

For reference, the previous equipment implemented the following controls as defined in NIST 800-53 Rev 4 (Attachment 9) as inherited, hybrid, and system specific. BEP cannot provide the System Security Plan (SSP) or specific implementation details due to the security sensitivity of the system. The contractor shall assume that they will work with the BEP IT Security team to coordinate cybersecurity control implementation post award.

Inherited Controls:

CA-1, CA-2, CA-3, CA-5, CA-6, CA-7, PL-1, PL-4, RA-1, RA-5, SA-1, SA-2, SA-3, SA-4, SA- 9, PM-1, PM-2, PM-3, PM-4, PM-5, PM-6, PM-7, PM-8, PM-9, PM-10, PM-11, AT-1, AT-2, AT-3, AT-4, AT-5, CM-1, CM-6, CP-1, CP-6, CP-7, CP-8, CP-9, CP-10, IR-1, IR-2, IR-3, IR-4, IR-5, IR-6, IR-7, IR-8, MA-1, MA-2, MA-5, MP-1, PE-1, PE-2, PE-3, PE-4, PE-6, PE-7, PE-8, PE-9, PE-10, PE-11, PE-12, PE-13, PE-14, PE-15, PE-16, PE-17, PE-18, PS-1, PS-2, PS-3, PS- 4, PS-5, PS-6, PS-7, PS-8, SI-1, SI-2, AC-1, AC-2, AC-3 AC-19, AU-1, AU-8, AU-9, IA-1, SC-

1, SC-7

Hybrid Controls:

CA-3, CM-6, MA-2

System Specific Controls:

PL-5, RA-3, CM-2, CM-4, CM-7, CM-8, CP-2, CP-3, CP-4, MA-4, MP-2, MP-6, AC-7, AC-8, AC-14, AC-17, AC-18, AC-20, AC-22, AU-2, AU-3, AU-4, AU-5, AU-6, AU-11, AU-12, IA-4, IA-5, IA-6, IA-7, IA-8

Note: For inherited and hybrid controls to be utilized, the contractor must plan for the following control integration points with enterprise processes and services. Any controls that cannot be

20 BEP-RFP-16-0433 Bureau of Engraving and Printing integrated with enterprise controls must be implemented as system specific controls.

There must be a bridge or network component connected to the BEP internal network to facilitate data collection and monitoring.

If the component is a workstation or server, the component must utilize the enterprise Anti-virus solution to monitor for and protect both the equipment and the BEP infrastructure from malicious code infections. BEP has successfully deployed this solution on other industrial control systems using a modified configuration that allows for real-time protection without impacting real-time data processing. BEP will work with the contractor to test and tune these control settings as part of this effort.

A minimum of two service account for BEP IT Operations and IT Security use is required to be added to the bridge component.

The following sections provide additional details for specific cybersecurity control implementation details for implementation:

(1) Access Control

a. Systems shall include a mechanism to require users to uniquely identify and authenticate themselves to the equipment before beginning to perform any actions.

b. The contractor shall provide the capability to logout users after a period of either system or user inactivity to prevent user logins from persisting past the user being present at the press.

c. System operational settings shall not be changed remotely nor shall operation of the equipment occur over the BEP Manufacturing Local Area Network (LAN) connection; but shall remain under the control of the equipment operators.

d. Authentication shall utilize Personal Identity Verification (PIV) smartcards;

e. Passwords may only be used as a temporary (30 day) authentication for users who have damaged or lost smartcards; or for service/machine accounts. Password rules shall be consistent with the rules documented in NIST US Government Security Baseline (USGCB) (available at http://usgcb.nist.gov/) with the following enterprise approved exception: service/machine accounts must have random complex passwords with a minimum length of 16 characters that may be set to not expire. The contractor shall provide a mechanism to allow BEP to change passwords for events including, but not limited to, suspicion of an account compromise, departure of a privileged user who may have had access to the password(s).

f. Access to the equipment must be limited based on user identification, role within the organization, or context of a particular request; or any combination of the above.

g. System or application administrative privileges must be required to change the access control configuration on equipment.

h. Administrator shall be able to aggregate users (for example, by assigning them to groups or roles) to simplify administration.

i. Users with both non-privileged and privileged (Administrator) roles shall use a different authentication token to elevate their access rights. For reference: BEP utilizes ActivClient to allow Privileged users to use a Digital Signature certificate to be used for elevating accounts to a privileged level. (See Attachment 10 for

21 BEP-RFP-16-0433 Bureau of Engraving and Printing additional details).

j. The equipment shall maintain and protect authentication data, which contains information for verifying the identity of individual users (e.g., passwords) so that an unauthorized user cannot access it. Specifically, authentication information (e.g., passwords) shall be stored as “salted hashes” in accordance with NIST FIPS guidance and industry best practices to protect authentication information from being compromised due to unauthorized access to the system. Note: For additional information on this topic, please search the NIST site (http://csrc.nist.gov/). There are multiple guides, papers, and recommendations available.

k. Passwords stored for scripting or task automation shall leverage operating system security controls (e.g., encrypted password storage vault built into the Microsoft Operating system). Passwords shall not be stored in clear text.

l. BEP utilizes Computer Associates (CA) Identity Manager (IDM) for facilitating account access management controls. The contractor shall provide the necessary capability and support to integrate the user access management capability for the equipment to allow the CA IDM to automate updating user access rights, provisioning, and de-provisioning users.

m. The system shall use identification and authorization data to determine user access to information.

1. The system shall be able to define and control access between subjects and objects in the computer system.

2. Access permission to an object by users not already possessing access permission shall be assigned only by authorized administrators.

3. Access controls shall be implemented to enforce “Least Privilege”, access to the information providing only the required access for an individual to perform their job specific duties.

4. Access controls shall also enforce separation of duties.

(2) Audit Log and Monitoring

a. In accordance with NIST SP 800-53 (current version, available at http://nvlpubs.nist.gov/nistpubs/SpecialPublications/NIST.SP.800-53r4.pdf) control objectives, the contractor shall document the IT Security Specific events that represent normal, suspicious, and cybersecurity incident states for the system and system component including, but not limited to: activities, including administrative actions, that might modify, bypass, or negate security controls. Logged events shall include the following minimum information: time/date of the event, identity of the user or system performing the event, actions taken (e.g., software changes, add or delete accounts, system time clock changes, etc.), whether the action completed successfully or not including any associated system event id.

b. The contractor shall document the location of the logs where the security events are captured

c. The contractor shall provide an automated mechanism to search, extract, and aggregate the logs for alerting and analysis.

d. The contractor shall provide the ability to forward events to a centralized enterprise event log management system.

22 BEP-RFP-16-0433 Bureau of Engraving and Printing

e. The contractor shall ensure safeguards are in place to detect and minimize the inadvertent modification or destruction of data, and to detect and prevent the malicious destruction or modification of data.

f. The mechanisms that enforce access control and other security functions shall be continuously protected against tampering and/or unauthorized changes.

g. The audit trail shall be of sufficient detail to reconstruct events in determining the cause or magnitude of compromise should a security violation or malfunctions occur.

As a minimum, the log files shall show the identity of each person and device, successful and unsuccessful logon attempts, applications and files accessed and time/date stamps.

(3) Data Storage Applications that require large storage systems or have unpredictable storage growth rates shall use the BEP Enterprise Storage Area Network (SAN) technology. BEP SAN’s utilize Dell PowerVault systems and be configured with Redundant Array of Independent Disks (RAID) controllers, redundant fiber channel or Internet Small Computer System Interface (ISCSI) host bus adapters and switches, and reside in the BEP computer facility.

The system shall have capabilities to collect and store all information while processing sheets.

Storage capacity shall be for at least 4 days of continuous operation of the system. When the data storage system is reaching max capacity, an alarm shall be initiated to provide sufficient time to archive data and prevent overwriting of the data (e.g., 70% capacity allows for sufficient time to archive data and prevent data overwriting).

(4) Network Connection All BEP network attached systems shall support Gigabit Ethernet (10/100/1000Mb/sec) and TCP/IP protocols. Network interface cards (NIC) shall support 10/100/1000Base-Tx/RJ-45 connections. All Simple Network Management Protocol (SNMP) enabled equipment shall support SNMP v.3. All physical network connections and addressing shall be initiated and maintained by the Office of Information Technology (IT) Operations. The contractor may assume that they will be provided IP addresses within the same class C network for connectivity to the BEP Network. If a secondary, internal network is used, the contractor shall not utilize addresses in the 10.0.0.0/8 range but shall use IP addresses that are compliant with RFC 1918 for IPv4 addresses. The contractor will coordinate with OITO on this address space assignment to verify that the addresses and networking configuration do not conflict with existing network configurations. In accordance with BEP Directives, this acquisition requires all functionality, capabilities and features to be supported and operational in both a dual-stack IPv4/IPv6 environment and an IPv6 only environment.

(5) Database Connection Database management systems shall be compatible to current BEP Oracle version (Oracle 12.1 as of this writing) or later. Client-server applications shall be Open Database Connectivity (ODBC) compliant.

(6) Computer Software Requirements: (Application Development Environment) Development shall be subject to Software Development Life Cycle best practices of

23 BEP-RFP-16-0433 Bureau of Engraving and Printing configuration management procedures. Specifically, for BEP, Changes shall be submitted as Requests for Changes for review and approval by the BEP Change Control Board. Approved changes shall be coordinated under a project management plan that shall include development and testing in a non-production environment prior to user acceptance, functional, and security testing prior to deployment to production.

(7) Computer Hardware Requirements All BEP network attached workstation and desktop computers on the production floor shall be Dell Optiplex 7020 series or newer and be configured with a minimum of 8 GB of RAM, 500GB or more Ultra SATA Disk storage, minimum of Quad Core, 3MB, 3.6GHz i7 processor, be equipped with optical DVD +/-RW, USB ports, serial ports, auto switching power supply, minimum of a 19” flat screen monitor, accommodate duel NIC cards and Arcnet card if needed.

Any dual network computers shall be configured to block routing between the connected networks. These computers shall alert operators if they are configured in a bridged or router mode.

All BEP network server computers shall be Dell PowerEdge models, configured with RAID controller and Internet Small Computer System Interface (ISCSI) storage devices, redundant power supplies, and CD/DVD-ROM drives. They shall have storage, RAM and processor configurations to meet proposed application needs. All servers shall reside in the BEP computer facility and be rack mountable.

Computer systems located in production areas shall be housed in NEMA-12 rated enclosures to protect equipment from dust (and splashing liquid).

All computer systems whether…