DRAFT_SNI_PreSolicitation_Statement_of_Work.pdf

Single Note Inspection System Upgrades

SECTION C – DESCRIPTION/SPECIFICATIONS/STATEMENT OF WORK

C.1 BACKGROUND

The Bureau of Engraving and Printing (BEP) is seeking to modify existing Single Note Inspection (SNI) equipment and integrate a packaging system onto the SNI systems located at the BEP Washington, D.C. Facility (DCF) and the BEP Fort Worth, TX. Facility (WCF). The existing Single Note Inspection (SNI) systems are Giesecke & Devrient (G&D) Banknote Processing Systems (BPS) 2000.

The packaging system delivered with the current SNIs do not track, verify the product by serial numbers, or package finished products that meet the BEP’s requirements. The BEP must manually package notes from the SNI for shipment to the Federal Reserve. With this requirement, the contractor shall enable the BEP to automate the packaging process to significantly improve accountability and address issues with product packaging.

Under this requirement, the contractor shall be responsible for designing, fabricating, assembling, integrating, and installing a packaging system on the current SNI equipment.

Contractor shall also train BEP personnel on the operations of the updated SNI systems.

As an option, the BEP may also require installation of a cutting system on the front end of the SNI units at each facility.

C.2 STATEMENT OF WORK

This Statement of Work (SOW) defines the requirements of the Bureau of Engraving and Printing (hereafter referred to as the BEP or Bureau) to modify existing SNI equipment and integrate a packaging system for the BEP SNI systems at each of the BEP facilities.

The contractor shall provide all labor and materials to integrate their inspection software and hardware onto the BEP’s existing machinery. The contractor shall be responsible for the performance of all activities and materials to install and make the system ready for operation.

The contractor shall provide the design, fabrication, assembly, testing, shipment, delivery, startup and acceptance of the system machinery and performance of all services, as well as provide the BEP with information on the status of the work being performed for this requirement herein.

The modifications are to be performed in sequence; the contractor will not be allowed to modify a second system until the first has been fully validated, formally accepted by the BEP, and returned to operation through the Bureau Acceptance Test (BAT).

The contractor shall perform all work to assess the capabilities of the SNI BPS 2000 machines and determine what changes to propose as part of the required modification to integrate a packaging system.

C.3 DOCUMENTS

C.3.1 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) shall be signed and notarized as part of the submission package for consideration, S N I P a c k a g i n g S O W P a g e 1 | of 40

Attachment 18.

The notarized agreement shall be returned to:

Bureau of Engraving and Printing Office of Acquisitions, Room 705-A 14th and C St, SW Washington, DC 20228 Attn: Millie Cortes, Contract Specialist

C.3.2 REFERENCED DOCUMENTS

Equipment to be delivered under this contract shall meet all current U.S. commercial codes and industrial standards, or equally stringent international standards, for manufacturing of high quality industrial equipment, commercial printing presses and finishing equipment to be utilized within an industry environment. At a minimum, all equipment shall conform to National Electric Code, NEC, standards.

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

All applicable sections of 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) or at (https://www.archives.gov/federal-register/executive-orders/1999.html)

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) or at (https://www.epa.gov/laws-regulations/laws-and-executive-orders) and District of Columbia (DC) government (www.doee.dc.gov) and State of Texas (TX) government (www.tceq.texas.gov).

C.3.3 ATTACHED DOCUMENTS

The following lists the documents attached to this SOW. NOTE – Attachments identified with an asterisk (*) require a Non-Disclosure Agreement (NDA). All NDA documents provided under this contract shall be considered proprietary and sensitive to the government. NDA documents shall not be copied, scanned or reproduced without written approval by the U.S.

Government, such as a BEP Contracting Officer (CO). All NDA documents shall be returned to the BEP when no longer required or upon request by the CO.

Some documents will only be made available in redacted versions. Request to have copies of the original versions must be made to the Contracting Officer (CO) with information on why the information is required.

Identifier Title/Description 1 Paper Band Specifications 2 Shrink-wrap Films Specifications 3 BEP Label Specifications Specification

S N I P a c k a g i n g S O W P a g e 2 | of 40 http://www.acgih.org/ http://www.omb.gov/ https://www.archives.gov/federal-register/executive-orders/1999.html https://www.archives.gov/federal-register/executive-orders/1999.html http://www.osha.gov/ http://www.epa.gov/ https://www.epa.gov/laws-regulations/laws-and-executive-orders https://www.epa.gov/laws-regulations/laws-and-executive-orders

Drawing 30084 rev 1: Cash-pak Shipping Label Drawing 30085: Cash-pak BEP-FRB Label 4 Drawing 30101: Currency Bundle Drawings* 5 Drawing 30102: Currency Brick Drawing* 6 Drawing 30083: Cash-pak Drawing* 7 Cash-pak Drop Test Requirements 8 Currency Skid Stacking Drawing* 9 BEP-FRB Currency Skid 10 Site Drawing 11 IT Computer Attachments 11 Federal Information Processing Standards 11A NIST Special Publication 800-53 11B US Government Security Baseline (USGCB) 11C Department of Justice Reference 12 75.00-ENV-005-FW: EH&S Boilerplate Requirements for Construction and

Service Contractors 12A 75D-07.0-04 EHS Contractor Requirements 13 SNI Automated Packaging Preliminary Test Plan 14 Prohibited Materials 75D-07.0-07 Restricted Materials at DCF

C. 4 REQUIREMENTS

Under this contract, the contractor shall accomplish at a minimum the following:

A. DATABASE

(1) Amend SNI (BPS 2000) data output to provide the serial numbers of the top note of each strap for tracking through the packaging operation

(2) Integrate data from packaging system with SNI database of Serial Numbers of acceptable notes within each unique Bundle and Cash-Pak. Each bundle and Cash-Pak shall have a unique identifier in the form of a “3 of 9” bar code.

B. PACKAGING SYSTEM

(1) Modify the existing SNI (BPS 2000) machines so that the current output (½ bundles) works with the packaging system to produce packages meeting the BEP requirements and utilizing BEP materials. Packages shall be identical to those presently produced by the BEP Large Examining Printing Equipment (LEPE) and Currency Overprinting Processing Equipment (COPE) machines. Specifications for current packages are included in this document as text or Attachments.

(2) Remove the existing bundle packaging system.

(3) Fabricate, install, integrate, startup, test and turn-over an automated packaging system to produce Bundles, Bricks, Cash-Paks and Skids similar to those produced by KBA-Notasys’ LEPE press; that uses BEP materials and resulting

S N I P a c k a g i n g S O W P a g e 3 | of 40 product that matches the appearance and performance of existing packages produced by the BEP. The packaging system must have an integrated serial number tracking system to verify the packaging of the product and ensure that the serial numbers of the notes being packaged are known and are recorded.

The packaging system shall accept notes from one (1) or two (2) SNI machines. The contractor shall integrate the packaging system onto one (1) SNI and demonstrate compliance with the Government’s specification, Attachment 10. After acceptance by the BEP, the contractor shall integrate the second SNI with the packaging system and demonstrate the complete system for final acceptance. When running at full capacity, there are two (2) SNI machines running simultaneously with both machines outputting product into the single packaging system.

However, the packaging system shall be capable of packaging notes with just one SNI running as well. Either SNI machine shall be capable of running in single SNI operation. This flexibility is intended to provide the ability to still obtain production when maintenance is being performed on an SNI machine. The system shall be able to track the serial numbers of all notes whether one (1) SNI is running or both.

C.4.1 TASK 1 – SNI DATA REQUIREMENT

The contractor shall perform all software code generation, testing and debugging to perform the following:

A. Amend SNI (BPS 2000) data output to provide the serial numbers of the top note of each strap for tracking thru the packaging operation.

The data shall be digitally outputted with the physical output of the ½ bundles from the SNI machine for packaging. System shall verify receipt of the data transfer to the packaging system prior to proceeding.

B. Integrate data from packaging system with SNI database of Serial Numbers of acceptable notes within each unique Bundle, Brick, Cash-pak and Skid.

Data is to be uploaded into the BEP database. System shall verify receipts of data transfer and redundantly maintain backup copies of the data to ensure against loss. Refer to section C.4.7(N)

C. Data integrity is to be maintained at all times and all stages of the process. Data integrity shall be such that the BEP can maintain product tracking as described on page 12, section C.4.7 (N) of this SOW.

C.4.2 TASK 2 – PACKAGING SYSTEM REQUIREMENT

The contractor shall:

A. Modify the existing SNI (BPS 2000) machines so that the current output (½ bundles) works with the packaging system to produce packages meeting the BEP requirements utilizing BEP materials.

B. Remove the existing bundle packaging system.

C. Fabricate, install, integrate, startup, test and turn-over an automated packaging system to produce Bundles, Bricks, Cash-Paks and Skids similar to those produced by KBA-

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Notasys’ LEPE press. Resulting product shall match the appearance and performance of existing packages produced by the BEP. The packaging system must have an integrated serial number tracking system to verify the packaging of the product and ensure that the serial numbers of the notes being packaged are known and recorded.

C. 4.3 MATERIALS REQUIREMENT

The system shall utilize the following materials.

A. SKIDS

The system shall use the BEP’s skids for the stacking of the finished product for shipment. The drawing of the skids and lids are at Attachment 9.

B. SNI STRAPS

The system shall accept the straps produced by the SNI . A strap is 100 notes, bound together face up, and held together with a paper band. The paper band around the straps and positioning on the strap shall remain the same.

C. BAND SPOOLS (Bundle) The system shall use the BEP’s spools of paper bands for application around the 10 straps to produce a Bundle. Bundle bands are plain unprinted bands. The specifications for the paper bands are Attachment 1.

D. PACKAGING FILMS (Bundle, Brick, Cash-pak and Skids) The system shall use the BEP’s Bundle, Brick and Cash-pak shrink-wrap films for the packaging of the notes. The Bundle film is alinear low-density polyethylene ( LLD-PE) material. The Brick film is apolyvinyl chloride (PVC) material. The Cash-pak film is a LLD-PE material that has been printed and laminated. The specifications for the stretch-wrap film are Attachment 2.

The system shall use the BEP’s stretch-wrap film for the wrapping of the skids of cash-paks after palletizing. The BEP’s stretch-wrap film specification is included in Attachment 2.

E. LABELS (Bundle and Cash-pak) The system shall use the BEP’s Labels for the Bundles and Cash-paks. One (1) label is applied to each bundle that contains bar-coded information applied over the face of the bundle. Each Cash-pak has two (2) labels applied, a shipping label that contains bar-coded information applied over the face and a BEP-Federal Reserve Board (FRB) label that covers the window on the back of the Cash-pak. The specifications and drawings of the labels are Attachment 3.

F. CONTRACTOR FURNISHED MATERIALS

Any other materials required for successful utilization of the system shall be specified and an initial batch of the materials shall be provided by the contractor for BEP review and approval.

The specification shall be complete to allow the BEP to competitively procure the materials in the future. An initial batch shall be sufficient for one year (240 working days) at three (3) shifts per day, eight (8) hours operation per day. The initial batch shall be in addition to that supplied by the contractor for startup and testing of the system prior to final acceptance.

Any contractor supplied materials shall have a shelf life of not less than one (1) year. Materials with specific storage requirements to maintain their shelf life shall be identified or shall be furnished in batches to minimize the time in stock.

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An initial batch of material(s) shall be supplied prior to the performance of the Bureau Acceptance Test (BAT) by the contractor. The remaining supply of material(s) shall be scheduled in accordance with the anticipated usage rate of the system with the final material(s) being supplied no later than 9 months after completion of the BAT.

A specification and Safety Data Sheet (SDS) shall be provided for each contractor proposed material no later than 90 days prior to Bureau Acceptance Test (BAT). Materials shall be reviewed and approved by the BEP Office of Environmental, Health and Safety prior to the contractor bringing the material on site. Materials not approved shall not be brought on to the site and consequently not used on the system. In this case, alternative materials shall be proposed.

C.4.4 PRODUCT REQUIREMENTS

Product from the system shall meet the following requirements.

A. BUNDLES

A bundle is 10 straps, one thousand (1000) notes, bound together face up, held together with a paper band, shrink-wrapped and labeled. All straps within a bundle shall be face up with every other strap rotated 180°. A bundle with paper band is shown in the attached drawing, Attachment 4. The paper band shall be tight enough to hold the straps together. Position of the band on the bundle shall be within ± 4 mm of the location set by the operator.

The bundle shall be shrink-wrapped as a total enclosure package with plastic film and have a unique label applied to the top. The film shall be shrink-wrapped tight around the bundle without wrinkles. All edges of the film shall be sealed together. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The appearance, strength and durability of the bundles produced on the system shall be identical to the existing bundles produced by the BEP.

The wrapped package shall be labeled with a unique label designating the bundle. The labels shall be applied over the top note. The label font shall be “Impact” and the bar code shall be code 39.

B. BRICKS

A brick is four (4) bundles, four thousand (4000) notes, shrink-wrapped together. A brick is shown in the attached drawing, Attachment 5. Only the two (2) ends of the film need be heat sealed, the overlap of the film does not require sealing.

The package shall have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. All bundles shall be face up within the brick. The brick wrapping film over the bundle label shall not prevent scanning of the bar code on the bundle label or reading of the information printed on the label.

The brick film shall not fuse to the bundle film. The appearance, strength and durability of the bricks produced on the system shall be identical to the existing bricks produced by the BEP.

C. CASH-PAK

A cash-pak is four (4) bricks, sixteen thousand (16,000) notes, shrink-wrapped together using a polyethylene laminated film as a total enclosure package. The attached drawings show the cash-

S N I P a c k a g i n g S O W P a g e 6 | of 40 pak, including placement of the labels, Attachment 6. The system shall have the ability to handle up to 24 ½” long cash-paks.

All edges of the film shall be heat sealed together. The film shall be shrink-wrapped around the cash-pak tight without wrinkles. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The clear windows along the top and bottom of the cash-pak shall allow counting of the straps’ paper bands contained within the cash-pak.

Labels shall be placed over the clear windows at both ends of the package covering the currency within. The cash-pak film shall not fuse to the brick film nor cause the brick film to fuse to the bundle film. The appearance, strength and durability of the cash-paks produced on the system shall be identical to the existing cash-paks produced by the BEP. The performance requirement for cash-paks, drop test, is Attachment 7.

D. SKIDS

A skid is forty (40) cash-paks, six hundred forty thousand (640,000) notes, stacked and stretch-wrapped on a BEP provided currency skid. The cash-paks shall be stacked as shown in the attached drawing, Attachment 8. The appearance, strength and durability of the skids produced on the system shall be identical to the existing skids produced by the BEP.

C.4.5 FUNCTIONAL REQUIREMENTS

The system shall perform the following functions utilizing the materials specified in Section C.4.3 and producing product meeting the requirements in Section C.4.4.

A. MACHINE STAGES

1. Accept data from each SNI (Serial Number of top note of each strap in each bundle)

2. Remove product from each SNI (Either straps or ½ bundles)

3. Separate product into straps

4. Verify serial number of each strap by means of optical character recognition (OCR) to verify order matches with data output from SNI

5. Re-assemble straps to produce bundle per product requirements (rotating every other strap)

6. Track assembly of straps into bundles

7. Apply paper band around bundle

8. Verify quantity of notes in bundle (1000 note counter). For further details, refer to Section

C.4.4.A .

9. Shrink-wrap bundle

10. Print and apply bundle label

11. Verify label and OCR top note

12. Track bundles into bricks (Bricks may contain bundles from either SNI machine)

13. Accumulate bundles to produce bricks per product requirements

14. Shrink-wrap bundles into brick

15. Track bricks into cash-paks

16. Accumulate bricks to produce cash-paks per product requirements

17. Shrink-wrap bricks into cash-paks

18. Apply BEP-FRB Eagle label

19. Print and apply Shipping Label

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20. Verify Labels

21. Track cash-paks onto skid

22. Palletize onto skid per product requirements

23. Offload full skids, hold up to four (4) finished skids while continuing operation

24. Operator to

a. Manually remove skid from offload conveyor

b. Stretch-wrap Skid

25. Merge data with SNI system – Serial Numbers of notes in each of the straps Bundles, Bricks, Cash-pak and Skid

B. OTHER FUNCTIONAL REQUIREMENTS

(1) PRODUCT TRACKING

The system shall track the movement of product (straps, bundle, bricks and cash-paks) through the production process and ensure that no product is missing or out of order. At strategic locations, the system shall verify the product order (via optical character recognition( OCR)) of the top serial number of straps and bundles. A strategic location is where the cameras will have a clear view of the serial numbers of the straps and bundles. If the system detects that any product is missing or out of order, the system shall stop and signal the operator for corrective action and not allow continued operation until corrective action is complete.

Product tracking shall be redundant, robust and shall account for all possible jams or errors that could impact the product movement or potential loss of product tracking information. The system shall know at all times the serial numbers of the straps being packaged into Bundles and Cash-paks.

(2) FAULT RECOVERY

The system shall have detection components to detect whenever a fault, i.e. jam or error, occurs that would result in a disruption to the sequence of the finished product, cause damage to the equipment, produce unsatisfactory product or operation, or would pose a safety hazard to operational or maintenance personnel. The system shall take appropriate actions when a fault is detected to stop and notify the operators. The system shall display specific detailed information such as 3-digit fault codes on operator stations for trained operators to locate and take corrective actions to correct the fault.

The system shall have provision to recover from all faults. No faults shall negatively impact the sequence of the notes within the straps, bundles, bricks, cash-paks or skids; create a hazard to operational or maintenance personnel; or cause the system to lose tracking of the product so that the straps within a package would be unknown.

If the operator determines that the product was damaged or unacceptable for further processing from an error/jam, the operator shall be able to remove product from the system and OCR enter by the top note of straps removed.

The contractor shall provide detailed plans on each operator station detailing the step-by-step activities for the corrective actions required to correct the fault condition and return to production.

(3) REPACKAGING OF PRODUCT

If the operator determines that any package does not meet the quality level for shipment, the

S N I P a c k a g i n g S O W P a g e 8 | of 40 system shall allow for the operator to manually remove the product, re-package the product, and return the product to its correct position within the system. Repackaging shall be able to be performed without emptying the system. Repackaged product will be counted as spoilage from the system.

(4) SINGLE SNI OPERATION

The system shall be able to operate with only one (1) SNI in operation. This is to allow for continued operation when issues/maintenance is being performed on an SNI or if special testing is being performed on an SNI to minimize the impact on operation.

(5) BUNDLE COUNTER

The packaging system shall redundantly verify the count of all bundles produced. If the first counter fails to obtain a correct count, the count shall be re-verified by a second counter on the oppose corner of the bundle.

If both counters fail to verify that the bundle contains 1000 notes, the bundle shall be diverted for operator intervention. An audible and visual signal shall alert the operators to the diverted bundle. The operator shall have a separate counter for manual verification of the bundle count.

The manual counter shall be the same make and model as the counters utilized to count every bundle in the automated system. Manual counting of a bundle shall not cause the packaging system to lose the continuous numerical sequence of the product. After verifying the count, the operator shall place the bundle in a staging area for automatic re-insertion back into the production process in compliance with the product sequence. If the operator takes longer than the system allows verifying the bundle count, the system shall stop and wait on the placement of the bundle in the re-insertion position.

If after manual counting, the operator still fails to verify that the bundle contains 1000 notes, the bundle shall be removed. The straps shall be removed and assuming the notes are not damaged, will be reprocessed by SNI. The system shall account for the removal of any product, and shall not cause the packing system to lose tracking of the final product so that the straps within a package would be unknown. The contractor shall provide detailed plans on each operator station detailing the step-by-step activities the corrective actions required to correct the fault condition and return to production.

Bundle counters shall have a false acceptance rate of not greater than 1 out of 10,000 and a false rejection rate of not greater than 1 out of 2,500.

C.4.6 PERFORMANCE REQUIREMENTS

The system shall meet the following performance requirements, utilizing the materials specified in Section C.4.3 and producing product meeting the requirements in Section C.4.4.

A. PROCESSING RATE

The system shall be able to support the full operation of two (2) SNI machines at each BEP location. The theoretical maximum output from two (2) SNI is 80 notes per second or 48 straps per minute. The system shall be capable of buffering up to twenty (20) cash paks in order that SNI product level will not be impacted.

B. MANNING

The system shall be fully automated and not require the oversight or direct labor of more than

S N I P a c k a g i n g S O W P a g e 9 | of 40 one (1) employee. The system shall be designed such that replacement of materials can be performed once per shift. The system shall accumulate finished skids to allow removal once per shift.

Operators of the SNI machinery shall be able to support any stoppages or replacement of materials on the packaging machine without impacting their duties on the SNI machinery.

C. SYSTEM YIELD (SPOILAGE)

The system shall yield at least 99.99% acceptable work, no more than 0.01% spoilage.

D. STOPPAGES

The system shall operate reliably and independently to produce high quality product without the direct oversight or intervention of BEP personnel. The system shall not require the direct intervention of personnel more than fifteen (15) minutes every three (3) hours of operation.

E. SET-UP TIME

Set-up time is defined as the time it takes from when a crew begins working on the system until the system is in production, operating at full speed and meeting the quality requirements for the product.

The total time to set up the system, without changing the denomination or configuration of the system, shall be less than ten (10) minutes.

The total time to set up the system to process a new job shall require no more than one (1) hour.

F. UNSCHEDULED CORRECTIVE MAINTENANCE

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 functional or performance requirements for more than fifteen (15) minutes.

The mean time between unscheduled corrective maintenance is defined as the Mean-Time- Between-Failure (MTBF). The MTBF will be measured during the extended operation of the system after the Bureau Acceptance Test (BAT) and Training. If during the extended operation of the system, the system fails to successfully demonstrate the required MTBF, the contractor shall make any and all corrective actions necessary to increase the robustness and reliability of the system.

The overall MTBF shall be greater than 1000 hours.

The mean time required to perform corrective maintenance on the system is defined as the Mean- Time-To-Repair (MTTR). The system shall have a MTTR less than two (2) hours. The MTTR will be measured during the extended operation of the system after BAT and Training. If during the extended operation of the system, the system fails to successfully demonstrate the required MTTR, the contractor shall make any and all corrective actions necessary to decrease the time required to perform maintenance or repair activities.

G. PREVENTATIVE MAINTENANCE

The yearly average for time utilized for preventative maintenance on the system shall not exceed 0.5% of the operational time. Major components shall have a Mean Time Between Maintenance (MTBM) of no less than 2000 hours.

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All Preventative Maintenance work shall be detailed within the Maintenance Manual, including all check-lists, procedures and recommended schedules for the time to perform.

C.4.7 DESIGN REQUIREMENTS

A. CONTROL STATIONS

Control stations shall be provided at all strategic locations to maximize safe and efficient operation. All controls shall be clearly and permanently marked in English. Each control station shall include emergency stop, stop-and-lock, and inch buttons.

An audible warning device shall sound for at least three (3) seconds prior to the operation of the machine in both “inch” and “run” modes.

B. CENTRAL OPERATION STATION (COS)

The contractor shall provide a free standing Central Operation Station (COS) to the government.

The station design shall be approved by the government before the contractor provides the station The COS shall be equipped with a computerized graphical operational interface, which will display all machine status and operational information, and allow adjustment of all parameters and settings for the machine operation. The interface shall utilize windows and drop-down menus. Additional displays shall be strategically located to facilitate operation of the equipment and to minimize the time required for operators to determine the cause of a stoppage and take corrective actions.

When not in use with one of the subsystems, the COS shall display the: Total number of sheets processed during the shift, Total number of sheets remaining to be processed within a batch (decreasing), Total number of sheets processed within a batch “Process”, Time, Date, Process number being processed, Denomination being processed, and any active error or fault codes.

The COS shall include a bar code reader(s) and standard computer 101 key keyboard to input data. The bar code reader shall read BEP operator and maintenance personnel badges, order number, job suffix load number, and seal numbers. Up to four (4) operating personnel and two

(2) maintenance personnel shall be able to be logged onto the machine simultaneously.

The bar code readers shall be capable of reading a character string of up to fifteen (15) digits printed in a medium density “3 of 9” code (10 characters/inch). This may include ID card sets, which will have a “3 of 9” bar code heat encapsulated in a polyester pouch or between PVC sheets. Card thickness will be between 0.030 and 0.035 inch (0.75 - 0.90 mm).

Access to the system, all set points, settings, and data shall be performed through the interface.

Levels of password protection shall provide protection to critical information and settings, and for different job classifications and work to be performed. The operators shall have the ability to save the configuration settings and set points, by file name. The system shall enable the operators to recall previously saved settings to minimize the time to set up the system to process similar work.

Controls for the palletizer are desired to be connected into the COS but may be separate. If separate, the palletizer control system shall provide detailed descriptions for corrective actions and meet the other requirements for control stations. If separate, the COS shall display the status (idle, busy or error) and error code information of the palletizer.

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C. OPERATIONAL PROCESS

The system shall have the following operational processes.

(1) SHIFT START

The system shall require the operators to log into the system that will be operating the equipment during the shift. The system shall not allow operation until at least one (1) operator is logged into the system.

(2) SHIFT END

At the selection by the operators or at fixed times, the system shall end a shift. The operators shall be automatically logged off the system. The system shall generate a shift operational report and/or daily operational report. The supervisor shall be able to turn on or off the automatic ability of the system to log the operators off for an end of shift.

(3) CREW CHANGE

At the selection of the operators, the system shall log the operators off the system and not allow processing until an operator logs into the system.

(4) INTERRUPTION OF PRODUCTION

At the selection of the operator, the system shall generate a partial load report for the load interrupted.

(5) PROCESS START

At the initiation of the operator, the system shall allow for the beginning of processing a new process. The system shall be empty to initiate a process start.

(6) CYCLE EMPLY (PROCESS PAUSE)

At the initiation of the operator, the system shall proceed to package all products into cash-paks.

Any extra bundles or bricks that cannot become cash-paks shall be manually removed, OCR verified, and re-fed into the SNI for repackaging. The skid, partial or complete, shall be pushed out of the palletizer. The system shall generate a partial process report.

(7) PROCESS RESTART

At the initiation of the operator, the system shall allow for reloading of a partially completed skid and continuation of the processing of work from a Process that was interrupted and the system was cycled empty.

(8) PROCESS END

At the initiation of the operator, the system shall proceed to package all products into cash-paks.

Any extra bundles or bricks that cannot become cash-paks shall be manually removed, OCR verified, and re-fed into the SNI for repackaging. The skid, partial or complete, shall be pushed out of the palletizer. The system shall generate a final process report.

D. DATA COLLECTION SYSTEM (DCS)

The equipment shall have an automated Data Collection System (DCS) with the following subsystems. All DCS database records shall be captured at the date and time of any changes within a given record.

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(1) ACCOUNTABILITY SUBSYSTEM

The DCS shall include a subsystem to record and track all products passing through the equipment. Electronic files of all counters, exchanges and all other accountability data shall be recorded.

(2) ERROR CODE SUBSYSTEM

The DCS shall include a subsystem, which will be capable of storing error codes, machine status conditions and associated data. It is required that fault analysis be extended to all components that are monitored by the machine controller.

The system shall include the time and date of each error occurrence.

(3) OPERATOR'S DAILY LOG SUBSYSTEM

The DCS shall include a subsystem that allows for the entry of operational information by the operators. The equipment shall have provisions for manual entry of data for purposes of allocation of labor to various downtime conditions. The BEP currently maintains a log of downtime labor by manually recording the date, time, duration, and description for each occurrence. To facilitate record keeping, numerical codes have been assigned for the more frequent conditions. One approach is to establish "look up tables", in which the more frequent downtime conditions could be entered into on screen menus. Operating personnel could then quickly log the occurrence without entering a written description. The precise format will be determined during the course of the design review meetings.

Shift Log visibility from Managers desks will require equipment data to be replicated to an existing replication database in the BEP infrastructure. The contractor will need to configure the replication.

(4) MACHINERY DATA LOGGING SUBSYSTEM

The DCS shall include a performance monitoring subsystem which will provide a display of current values and conditions and the ability to electronically record those values according to a variable, operator selected scheme. The subsystem shall monitor all specified values and conditions whenever the equipment is running.

The DCS display shall be able to present all electro-mechanical variables, such as sensor inputs that are captured by the logfiles that the controller regulates or monitors. Any operating parameter, which may result in a fault trip or error code condition, shall be included. Each display value shall be appended with its set point, alarm and trip limits, and its units of measurement. Values displayed shall be current with the control system logic.

Any variable machinery information available on the DCS shall be recordable. Each data element shall be tagged with its units of measurement, year, month, day, shift, and time.

(5) MANAGEMENT INFORMATION SYSTEM (MIS)

The DCS shall include the ability for the BEP to connect to the system to retrieve all data temporarily stored on the DCS. The configuration, layout, and data type shall be specified as where the access points to the data will be located.

The system shall have provisions for authorized BEP personnel to override any or all capabilities/systems. When the override function is exercised by authorized personnel, the badge

S N I P a c k a g i n g S O W P a g e 13 | of 40 number, time, date, system number, and all current counters shall be recorded. When reconnection occurs, the system shall record the time, data, machine number, and current counters, and prompt for entry as to why the system was disconnected.

(6) BEP DATABASE INTERFACE SUBSYSTEM (DIS)

The contractor shall configure the BEP provided hardware and software infrastructure necessary for interconnecting the equipment’s control system to the BEP's database. The BEP will use a database as the primary information storage layer between machine control system and other BEP information systems. The database will also serve specialized and localized information processing needs, such as maintenance management and historical process data retrieval.

The DIS will perform the actual exchange of digital information between the machine control system and the BEP's database. The information exchanged will take many forms, including temperature, distance, time, load size, etc.. This specification identifies the control system data that will serve as the BEP’s default configuration.

DIS should deliver “Bi-Directional Ready” data with the existing equipment event telegraphs and infrastructure. The BEP anticipates additional event telegraphs over the life cycle of the system.

The contractor is required to provide the DIS so that the control system can be designed to accommodate information exchange with a database, and so that contractor engineers, most familiar with the specific control system used on the equipment, can provide the best communications devices between the control system and the DIS computer.

To meet the BEP's changing information demands, the contractor shall design a fully open system using commercial-off-the-shelf (COTS) U.S. software products, which maximize BEP configuration. The DIS shall be designed such that a programmer familiar with common programming languages and with the machine control system will be able to make operationally needed configuration changes without the assistance of the contractor; for example, add storage capacity to the database.

The DIS and the control system shall be designed with reasonably sufficient expansion capability to meet the BEP's communication needs over the life of the equipment.

The contractor must provide and support a bi-directional flow solution which will enable the Bureau’s Manufacturing Execution Console (MEC) and the DIS to communicate across the BEP network using an Enterprise Service Bus (ESB). The key tasks that are currently enabled for bi-directional communication are Load Start, Load Stop, Assignments, and Consumable data. The contractor shall be able to provide time stamps and error codes for these tasks. The Bureau foresees additional bi-directional flows in the future. The purpose of the ESB is to enable all of the various applications within the BEP enterprise (BEN) Architectural framework to communicate with one another via web services. The ESB provides system transparency across the BEN architecture and ensures minimal message loss. The ESB solution at BEP leverages Oracle Fusion Middleware with a small amount of custom Java code. The architecture is loosely coupled. If a consumer system is unavailable the producer will not be directly affected.

Likewise, if a producer is offline the consuming systems will have nothing to run, but they will not directly generate errors. This modularization allows producer and consumer to interact with ESB independent of the other and creates more ease in scaling the solution.

The contractor shall support at least four (4) messages where DIS is the consumer of the message

S N I P a c k a g i n g S O W P a g e 14 | of 40 payload and two (2) messages where DIS is the producer of the message payload. If any additional messages are envisioned, the contractor shall develop the message payload. The payload will contain at the minimum information such as facility, equipment name, date and time, operation, load type, jobname, denomination/series, badge name, load size and action.

The contractor shall provide an accept acknowledgement where the response includes the original message (full payload) and the transaction return status code.

Contractor shall provide error checking for transport when a table insert fails, parsing errors while parsing the XML content, syntax errors for invalid format for data element and semantic errors when items cannot be processed by the application. The contractor shall create before insert triggers to validate header and payload header information, update columns and transform data.

The contractor shall create after insert triggers to insert a job into a queue that starts JAVA.

JAVA will read the table records for records with a new status. The JAVA job will validate the elements, extract a CLOB XML elements into columns and insert the record into the database.

E. SYSTEM LIFE

The system shall be designed for a service life of no less than twenty (20) years of operation at three (3) shifts per day, five (5) days per week. Generally, “day” shift runs from 7:00 AM to 3:00 PM, “evening” shift from 3:00 PM to 11:00 PM, and “midnight” shift from 11:00 PM to 7:00 AM. To the extent possible, means shall be provided to restore all worn surfaces by the simple replacement of individual elements.

F. COMPONENT ACCESS

Components that require regular service, such as motors, pumps, etc., shall be located to facilitate maintenance and repair. Access to these parts shall not take more than fifteen (15) minutes by no more than two (2) persons. All enclosures, which conceal gears, shafts, bearings, etc., shall be accessible without the requirement of dismantling or removing of sub-units or components.

Sub-assemblies that require frequent adjustment, maintenance, replacement and repair, such as main motor, banding units, numbering blocks, note counters, sealing bars, etc., shall be of modular design to facilitate easy and quick replacement.

G. 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 system, 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.

H. UTILITIES

The equipment shall operate with the following BEP provided utilities:

Electrical power: 480 volts, 3 phase, 60 hertz, four wire alternating current

Compressed Air: up to 80 psig, not oil free and at ambient humidity

Vacuum: up to 18 inches Hg.

S N I P a c k a g i n g S O W P a g e 15 | of 40

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 equipment. 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 equipment. The utilities shall be connected overhead.

I. ON-GRADE INSTALLATION

The equipment shall be installed on a flat slab. It shall be designed to use no trenches, pits, floor covers or decking. Floor recesses may be approved by the assigned Contracting Officer Representative (COR) to facilitate material handling if they are between the internal supporting structures. Floor recesses shall be no deeper than one (1) inch (25 mm). Piping and wiring shall be connected internally, and as necessary, routed via overhead troughs.

J. FLOOR LOADING/VIBRATION

The vibration produced by the operation of the equipment at any speed within the specified limits and its impact to the building shall be minimized. Vibration isolation devices shall be provided to prevent vibrations from entering the facility. The maximum floor loading shall not exceed 200 pounds per square foot.

K. PRODUCTION AREA

The system shall meet the following requirements:

(1) SIZE – The system shall be designed to fit within the area shown on Attachment 10. It is desired that system fit within a 120’-0” x 26’-6” area. The area shall be sufficient for the operation and maintenance of the equipment and for material handling around the system, based upon maximum production rates.

(2) AMBIENT CONDITIONS - The equipment shall be designed for normal operations under the following ambient conditions at the installation site:

• Temperature: 73 ± 2oF (22.8 ± 1.1oC)

• Relative Humidity: 45 ± 5%

L. 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 equipment. 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 equipment shall be performed via Programmable Logic Controllers (PLC) or industrial rated PCs. The model of PLC used on the equipment 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 equipment shall be included with the proposal such that the BEP can select the most advantageous.

The power supply(s) shall contain circuitry for the orderly shutdown of the machine in the event

S N I P a c k a g i n g S O W P a g e 16 | of 40 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 equipment 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 diagnostics on the operating software shall be furnished with the equipment. All software documentation comments shall be in English.

Configurations settings, randomly determined sampling plans, counters and other operational variables shall not be lost when the equipment is shut down, rebooted or a general reset of the electronics occurs. The system shall retain knowledge of the configuration settings, sampling, counters and other variables to enable a return to operation in the quickest possible time.

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 equipment.

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.