CNC_Grinder_SOW_(8.29.16).pdf

Statement of Work - CNC Cylindrical Grinder SECTION 1.0: Background

The Bureau of Engraving and Printing (BEP) is a component of the Department of the Treasury that designs, engraves, and prints U.S. banknote currency and other U.S. security products.

Banknote currency manufacturing occurs at BEP’s Office of Currency Manufacturing (DCF) located in Washington, DC and Office of Currency Manufacturing WCF located in Fort Worth, TX. BEP’s primary customer is the Federal Reserve Board (FRB).

DCF uses a computer numerical control (CNC) Cylindrical Grinder to support the manufacturing process in providing high quality print products. The primary product is United States currency.

SECTION 2.0: Purpose

2.1 Product, Service or Outcome Needed:

The objective of this requirement is to acquire a new CNC Cylindrical Grinder. This grinder will ensure the maintenance of operations and crucial grinding tolerances for currency plates that satisfy quality objectives and ISO 9001 requirements. Adequate operations will ensure maximum machine life. The BEP, Plate Making Division has a requirement to grind electroformed nickel currency plates to within thickness specifications of .0287 - .0297 inches, and maintain a Surface Grinding finish of no less than 32 root means squared (rms). The plates vary in size from 3 feet square to 4 feet square by .042 to .045 inches thick; the plates are bent to fit on a cylinder and then ground to the required thickness.

2.2 Scope of the Product, Service, or Outcome:

The Government will host an initial site visit. Contractor shall complete a pre-installation survey to determine the appropriate dimensions to complete installation no later than six months after award. The contractor shall provide all labor, travel, parts, materials, transportation, equipment, tools, supplies, management and supervision and all other items and services necessary to supply, deliver, rig and install new CNC Cylindrical Grinder. Contractor shall complete installation of the CNC Cylindrical Grinder in accordance to the following specifications in Section 3.0, within one year after contract award. Contractor shall also provide the following: commensurate training to the appropriate BEP employees on machine usage and troubleshooting; three (3) hardcopy manuals and one (1) searchable electronic manual, detailing common errors and troubleshooting techniques; one-year warranty; inspection and acceptance testing; and one year of consumables with list of item and part numbers and the accompanying description of each. Contractor shall perform preventive and emergency maintenance on the grinding machine located at the DCF as needed. Repairs shall be initiated by phone or email and contractor shall respond within 24 hours of the emergency contact.

SECTION 3.0: Technical Requirements/Tasks/Outcomes

3.1 The following represent the minimum features and benefits for the Cylindrical Grinder:

• Machine shall include CNC and an environmental enclosed control system

• CNC Cylindrical Grinder capability machine is intended for use in operations where multiple work pieces are ground and turned from programs with closed tolerances.

• CNC shall include transformer.

• Connectivity to existing BEP power disconnect box (480v, 3 Phase, 40 Amp)

• Delivery time of one year (12 months)

Work Envelope & Work Holding:

• CNC Cylindrical Grinder with a generic control

• Conversational type (CNC programming system)

• Accommodate various cylinder diameters of up to a maximum of sixteen inches (16”) and a working length of seven feet (7’)

• Work unit will be contained within a headstock and a tailstock.

Capacity:

• Maximum work swing- no more than 16 inches (16”)

• Maximum distance between centers- no more than 60 inches (60”) or 5 feet (5’)

• Worktable travel- no more than 84 inches (84”) or 7 feet (7’)

• Center height- no more than 16 inches (16”)

• Grinding wheel size- commercially available standard sized wheel with capability to grind nickel plates to specified tolerances

• Number of revolutions- no more than 1,650 rotations per minute (rpm)

Axis performance:

• CNC single axis wheel head infeed system driven by servo motor and precision ball screw using touch screen conversational program

• Y- axes with Fanuc AC digital servo drives

• X- axis precision ball screw assembly

• X-axis- minimum of one inch (1”) travel

• X-axis- Auto Feed (variable speed between 2 to 160 IPM [inches per minute])

• Y-axis- ± 0.0002 inch (.0002”) Positioning accuracy

• Y-axis- minimum of 4.0 inch (4”) travel ±2.0 inches (2”) from centerline

• Y-axis- Auto Feed (variable speed between 2 to 160 IPM)

Spindle Motor & Performance:

• Minimum of 25 horsepower (HP) spindle motor

• Minimum 2-speed Gearbox that can accept 1000 foot pound (ft.- lb. torque at 150 rpm)

High Intensity Lighting System for Work Area:

• Door switch activated & manual override

• Self-contained Flood Coolant System

• Coolant tank

• With grinder grit extraction system

• Able to sustain at minimum 10 gallons per minute GPM at 30 PSI

Compressed Air Blast System:

• Clears work piece and work area of debris

Automatic Lubrication System:

• Steel enclosure around work envelope

• Sliding double wall safety door for access

• Cast iron or comparable machine framework for rigidity/dampening

• Machine framework to be cast iron or comparable for rigidity/dampening

Machine Control Panel & Interface:

Hardware

• Minimum of USB & RS-232 file transfer

• Minimum 15 inch color LCD monitor

• Minimum 750 MB Solid State program memory

• Easy to read LCD display for machine positional and running program information

Software

• Inch Measurement units

• ISO standard G-code compatible

• Comprehensive conversational programming system

• Graphic Program Review

• Triple checking functions (machining program, grinding path, and wheel motor overload detection).

• All Axes control

• Cycle Start & Cycle Stop Control

3.2 Contractor Responsibilities: At minimum, the Contractor shall be responsible for the following:

3.2.1 General: Furnishing, delivering, rigging, installing and conducting the commissioning of a CNC Cylindrical Grinder.

3.2.1.1 Pre-installation Survey: Contractor shall complete a pre-installation survey to determine the appropriate dimensions to complete installation no later than six (6) months after award.

3.2.1.2 Installation: Installation shall be completed no later than one (1) year after award.

Installation shall include, at minimum, assembling, setting-up, conducting start-up and making adjustments as necessary to the equipment. Riggers will be required to make a site visit to determine path of movement machine through the BEP prior to delivery. In general, the Contractor shall ensure the CNC Cylindrical Grinder is operational in accordance with the original equipment manufacturer (OEM) requirements (e.g. factory system start-up, run tests, etc.) so as to prepare for the performance of the acceptance test.

3.2.2 Commissioning: The Contractor shall start the CNC Cylindrical Grinder, operate it, make adjustments and verify that it is operating within the original equipment manufacturers’ (OEM) requirements. Once the equipment is operating properly and is stable, the Contractor shall commission the equipment. The Contractor shall document the results of commissioning in a written report as outlined in Section 5.0 below.

3.2.3 Consumables: The Contractor shall provide one year of necessary consumables upon installation.

3.2.4 Preventive and Emergency Maintenance: Contractor shall perform preventive and emergency maintenance on the grinding machine located at the DCF as needed. Repairs shall be initiated by phone or email and contractor shall respond within 24 hours of the emergency contact.

3.2.5 Deliverables: Providing the Deliverables specified in Section 5.0 below.

3.2.6 Regulations/Publications/Codes: Complying with and performing all services associated with this effort in accordance with any and all applicable Regulations/Publications/Codes. Regulations/Publications/Codes means any and all applicable Federal, State, City, Local and Organizational laws, regulations, codes, ordinances standards, and conditions (e.g. Department of Transportation (DOT), Environmental Protection Agency (EPA), and NFPA 70), public and occupational health, safety, and environmental, etc.), original equipment manufacturer specifications, requirements and standards as well as any and all BEP policies, procedures, guidelines and requirements that govern the performance of the services as prescribed by the contract. The Contractor is solely responsible for ensuring it is complying with and performing in accordance with any such amendments, supplements to such Regulations/Publications/Codes as well as any and all superseding documents issued or enacted during the period of performance of the work. The Government reserves the right to request copies of the company license(s) and other certification documentation that demonstrates their company and personnel have the ability to perform the services at any time during performance.

The Contractor shall provide the requested information within five (5) business days of the request.

3.2.7 Schedule and Coordination: Scheduling and coordinating with the Contracting Officer’s Representative (COR) the specific dates and times for delivery and installation of the racks. Altogether, it is critical that the COR is kept abreast of the on-going status of project and is notified of any concerns or issues that may arise and can result in delay.

3.2.8 Training: Performing training at time of installation for up to two (2) Electromachinists.

3.2.8.1 Training: Performing four week (4) training for up to twelve (12) BEP designated individuals in regards to the operation of the CNC Cylindrical Grinder. To include operator maintenance procedures

SECTION 4.0: Inspection and Acceptance:

4.1 Acceptance Testing: Acceptance testing will be scheduled no later than two weeks after the completion of commissioning of the CNC Cylindrical Grinder, at a time mutually agreed upon by both parties.

• Test Plan: The test plan shall encompass the grinding of a blank nickel plate to a nominal thickness of 0.0292” +/- 0.0005” and maintain less than 0.0002” deviation across the entire plate of the final nominal thickness reached within that tolerance. It is also required that the plate surface finish of less than 32 RMS.

4.2 Visual Inspection: The CNC Cylindrical Grinder shall be visually inspected by BEP personnel at a minimum for possible damage as well as to ensure that all parts have been provided and properly installed, covers and shrouding are in place, doors and hatch ways move freely, all lights work and monitor is clear and legible.

4.3 Operation Inspection: The CNC Cylindrical Grinder shall at a minimum be inspected for operational soundness, workstation(monitor) swings freely, remote control works grit extraction and coolant systems perform as intended, spindle speeds will operated through full range

4.4 Defects: If the above inspections find damage or defective workmanship or materials, issues with system operability or missing parts, the Contractor shall be responsible for replacing and/or correcting the damaged, defective part(s), and/or providing the missing parts and making adjustments.

4.5 Acceptance: Acceptance for the CNC Cylindrical Grinder will be considered complete when all the requirements described in the test plan have been completed and signed off by the COR, as having met the established acceptance criteria. The COR will provide the Contractor, writing a document stating BEP’s acceptance of the CNC Cylindrical Grinder.

SECTION 5.0: Deliverables

5.1 Commissioning Report: Contractor shall provide a written report describing the commissioning process to be performed, along with the resources involved. This deliverable is to be submitted to the COR for review and approval at the time of proposal submission.

5.2 Consumables List: Contractor shall provide a consumable list and recommended replacement intervals for the grinder at the time of installation.

5.3 Insurance Certificate: Contractor shall provide a certificate of insurance reflecting the coverage description and amounts. This Deliverable is to be provided to the Contracting Officer (CO) within thirty (30) business days after award.

5.4 Operation and Maintenance Manuals: Contractor shall provide three (3) hardcopies of manuals and one (1) searchable electronic manual detailing Operation and Maintenance requirements and troubleshooting guide to be delivered to the COR by date of installation of the CNC Cylindrical Grinder. These manuals shall provide at a minimum a discussion and description of the operation and preventative maintenance tasks required to operate and maintain the CNC Cylindrical Grinder and associated equipment. These will also include electrical, pneumatic, hydraulic schematics.

5.5 Preventative Maintenance Schedule: Contractor shall provide a recommended five (5) year Preventative Maintenance Schedule.

5.6 Primary Personnel Point of Contact Information: The Contractor shall provide the name of an individual(s) along with their corresponding contact information (e.g. telephone number, fax number, address and cell number) who will perform as the Contractor’s primary point of contact in support of this effort, along with a back-up point of contact as well. This Deliverable is to be provided within five (5) business days after award and within five (5) business days after any changes.

5.7 Warranty Information: Information or documentation regarding the warranty of the new CNC Cylindrical Grinder. Contractor shall provide a point of contact for any warranty issues or concerns. This deliverable shall be provided to the COR within fifteen (15) business days after delivery. Warranty shall begin at the completion of BEP testing and acceptance of the equipment.

5.8 Work Plan: Contractor shall provide a detailed work plan that describes, but is not limited to the following:

5.8.1 The anticipated date of delivery of the CNC Cylindrical Grinder.

5.8.2 The approach and associated requirements for the installation of the CNC Cylindrical Grinder, inclusive of at a minimum dates and times, tasks to be performed, the resources (e.g.

labor, equipment, etc.

SECTION 6.0: Government Responsibilities

6.1 Access: BEP shall provide access to areas necessary for installation to be performed by the Contractor.

6.2 Service Connections: BEP shall provide normal service connections.

6.2.1 Main power source disconnect switch (480 or 240v 3 phase)

6.2.2 Pneumatic connection to house air.as needed.

# Deliverable Due Date Deliverable Recipient (include contact information)

Deliverable Format

1 (Para. 4.1) Test Plan At time of installation

COR (3) Hardcopies and (1) Electronic

2 (Para. 5.1) Commissioning Report

At time of proposal submission

COR (3) Hardcopies and (1) Electronic

3 (Para. 5.2) Consumables List

At time of installation

COR (2) Hardcopies and (1) Electronic

4 (Para 5.3) Insurance Certificate

30 business days after award

COR (1) Hardcopy and (1) electronic

5 (Para 5.4) Operation and Maintenance Manuals with troubleshooting guides (Section II, para. 2)

At time of installation

COR (3) hardcopy manuals & (1) searchable electronic copy

6 (Para. 5.5) Preventive Maintenance Schedule

At time of installation

COR (1) Hardcopies and (1) Electronic

7 (Para. 5.6) Primary Personnel Point of Contact Information

Within 5 business days after award

COR (2) Hardcopies and (1) electronic

8 (Para. 5.7) One year warranty information

Within 15 business days after delivery

COR (1) Hardcopy and (1) electronic

9 (Para. 5.8) Work Plan Within 15 business days after award

COR (1) Hardcopy and (1) Electronic

SECTION 7.0 Terms and Conditions

7.1 Place of Installation: The CNC Cylindrical Grinder shall be installed in the D100M space in the BEP’s DCF. It must meet all of the DCF EMS requirements as stipulated in Section

7.10 Attachment A).

7.2 Place of Delivery: Final delivery location will be made to the BEP Washington, DC facility.

7.2.1 BEP Washington, DC facility:

Bureau of Engraving and Printing Attn: To-be-completed upon award

BM-5

D Street, Between 13th & 14th Streets, S.W.

Washington, DC 20228

7.3 Delivery Instructions:

7.3.1 BEP’s DCF : Receiving hours for BEP’s DCF deliveries are 8:00 a.m. to 2:15 p.m., local time, Monday through Friday, excluding U.S. Government holidays and BEP year-end shutdown (which normally occurs between December 24 and January 1). The Contractor shall call the BEP appointment line at (202) 874-2333 at least twenty-four (24) hours in advance to schedule approximate delivery times. The appointment line is staffed from 8:30 am. to 2:30 pm. Monday through Friday. A voice mail message maybe left after normal working hours. The following information should be provided:

• Name of supplier/manufacturer

• Contact Person with phone number

• Contract/Purchase Order Number

• Total number of cartons or pallets

• Total weight

• Date and Time of Delivery

7.4 Performance under this Contract:

7.4.1 Performance of work under this contract is subject to the technical direction of the COR identified above, or a representative designated in writing. The term “technical direction” includes, without limitation, direction to the contractor that directs or redirects the labor effort, shifts the work between work areas or locations, and/or fills in details and otherwise serves to ensure that tasks outlined in the work statement are accomplished satisfactorily.

7.4.2 Technical direction must be within the scope of the contract specification(s)/work statement. The COR does not have authority to issue technical direction that:

(a) Constitutes a change of assignment or additional work outside the contract specification(s)/work statement;

(b) Constitutes a change as defined in the clause entitled “Changes”;

(c) In any manner causes an increase or decrease in the contract price, or the time required for contract performance;

(d) Changes any of the terms, conditions, or specification(s)/work statement of the contract;

(e) Interferes with the contractor's right to perform under the terms and conditions of the contract; or

(f) Directs, supervises or otherwise controls the actions of the contractor's employees.

Technical direction may be oral or in writing. The COR must confirm oral direction in writing within five workdays, with a copy to the Contracting Officer.

7.4.3 The Contractor shall proceed promptly with performance resulting from the technical direction issued by the COR. If, in the opinion of the contractor, any direction of the COR or the designated representative falls within the limitations of 7.4.2 above, the contractor shall immediately notify the Contracting Officer no later than the beginning of the next Government work day.

7.5 On-site Work Restrictions: When performing services at the place of installation such work must be performed without:

• Interfering with Government business;

• Unduly restricting traffic;

• Causing unsafe conditions for employees and visitors; and

• Adversely affecting the operation of BEP Facility.

• Non-compliance with security regulations.

Failure to adhere to this requirement can be considered grounds for termination. In addition, if the CO determines that the Contractor is performing work in violation of any of the above. The Contractor shall be required to perform the work at such time and under such conditions as are in the best interest of the BEP.

7.6 Dates, Times and Hours: BEP anticipates that the work performed at the place of performance can be performed Monday through Friday during the following Hours of Operation;

7:30AM to 4:00 PM local time. However, the exact dates and times are to be appropriately scheduled and coordinated with the COR prior to the execution of work on-site. If work, needs to occur during weekends and or Federal Holidays the Contractor is responsible for notifying the COR and scheduling and coordinating the work. A current listing of Federal Holidays can be located via the following website; https://www.opm.gov/fedhol/. BEP normally shuts down production during the week between December 25th and January 1st. If applicable, the COR will notify the Contractor concerning the specific dates Year-End Shutdown.

7.7 Personnel Qualifications: Contractor personnel shall be competent, dependable, knowledgeable, trained, inclusive of any necessary or applicable certification and/or license and experience, thereby qualifying them to perform their specific duties in supporting this effort.

7.8 Security: While on-site at BEP DCF Contractor personnel will be given a visitors security badge and escorted by Government authorized personnel. Visitor security badges shall be worn above the waist, clearly visible, with picture or front side front forward at all times.

Visitor security badges are to be returned upon leaving the site.

7.9 Parking: The Government will not be responsible for providing on-site parking at BEP DCF for Contractor personnel performing under this effort.

7.10 Attachments: Attachment A- OEHS 75D-07.0-06 Rev.#1 dated 04/18/14Requirements

SECTION 8.0: Performance/ Delivery Period:

8.1 The Period of Performance under this contract is 30 September 2016- 30 September 2017

SECTION 9.0: Quality Assurance Surveillance Plan (QASP)

Acceptable Quality Levels: (in accordance to Section II, paragraph 2)

− Accuracy Rates- 100% passage of Inspection and Acceptance testing − Completion of Milestone Rates- 90% on time completion of milestones

Evaluation/Surveillance Method(s):

– Observation- May be performed periodically or through 100% surveillance

Incentives and Awards:

ATTACHMENT 1: PERFORMANCE REQUIREMENTS SUMMARY

Required Services (Tasks)

Performance Standards

Acceptable Quality Levels

Methods of Surveillance

EXAMPLES:

Machine accuracy rate (C.2.2 and C.3)

Milestone completion

100% machine accuracy

100% on time completion

95%

90%

100% surveillance

100% surveillance

The COR shall use the surveillance methods listed below in the administration of this Contract.

The COR shall always contact the Contractor when a defect is identified and inform the Contractor of the specifics of the problem. The COR, with assistance from the Contract

Specialist, shall be responsible for monitoring the Contractor’s performance in meeting a specific performance standard/AQL.

ATTACHMENT 1: PERFORMANCE REQUIREMENTS SUMMARY