Brand Name Justification H0WP52 Shot Peen Components_Redacted.pdf

Sole Source (Including Brand Name) Justification - Simplified Procedures for Certain Commercial Items

FOR OFFICIAL USE ONLY

18 Jun 2019 FOR OFFICIAL USE ONLY Page 1 of 7

NOTE: If a Justification was approved for the preceding acquisition, a copy of the approved Justification for the predecessor action must be included in the staff package for approval of the instant Justification. This applies to Justification staff packages that are submitted for review and approval at a level above the contracting officer. The predecessor Justification will be used as a reference document by the approving official.

Is this a new or amended J&A Document? New Amended ( Prior to Award Only! )

Is this a Bridge Action as defined in the AF Bridge Action Reduction Plan? Yes No

Funding level for this acquisition: >SAT and < $700K > $700K and < $13.5M

Contracting Activity: AFSC/PZIMC

Purchase Request / Local ID Number: H0WP52

Program / Project (and PE, if applicable): Dual Media Shot Peen Machine

Program Type (PEO or Other Contracting): Other Contracting

Authority: AFFARS 5313.501 - 10 U.S.C. 2302b, Implementation of Simplified Acquisition Procedures (41 U.S.C. 1901)

AFFARS 5313.501 - 10 U.S.C. 2304a, Special Emergency Procurement Authority (41 U.S.C. 1903)

Estimated Contract Cost (including options): Justification Type: Class Individual

COORDINATION (AFFARS 5306.304(a))

Date

22 Apr 2020

Date

22 Apr 2020

Date

22 Apr 2020

APPROVAL (AFFARS 5306.304(a) )

Date

23 Apr 2020

Contracting Officer

GRAHAM CHAPMAN

AFSC/PZIMC; 405-739-5197

Signature

Sole Source (Including Brand Name) Justification - Simplified Procedures for Certain Commercial Items

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I. Contracting Activity.

This justification is for other than full and open competition is to support 76th Propulsion Maintenance Group (PMXG), Oklahoma City Air Logistics Complex (OC-ALC), Tinker AFB, OK. The contracting office to support this procurement is AFSC/PZIMC and the Contracting Officer is Graham Chapman.

II. Nature and/or description of the action being processed.

This requirement will result in a firm-fixed-price contract totaling approximately . This requirement will provide for a CNC-based shot peen machine with several, specific brand name parts for PMXG. The estimated award date for this requirement is 30 Aug 2020.

III. Description of supplies/services required to meet agency needs.

This justification is for the requirement of brand name and brand name or equal equipment related to critical systems used in this Dual-Media Shot Peen Machine - to include (but not limited to) the following:

- Blade Peening System:

- Proportion Air Regulator Systems - Brand Name Only; NO SUBSTITUTIONS

- EI Magna Valves and Flow Controllers - Brand Name Only; NO SUBSTITUTIONS

- Goodyear Plicord 4-Ply Pressure Blast Hose - Brand Name or Equal

- Media Recovery System

- SWECO Screens - Brand Name Only; NO SUBSTITUTIONS

- CNC System:

- Fanuc 31i CNC Controller and Fanuc motors - Brand Name only; NO SUBSTITUTIONS

- Gantry Robot - variable speed & frequency for all axes

- Media Cabinet, Base, Operator Platform, and Machine Specific Construction

- PC Operator Interface

Full details of this machine can be found in the Statement of Work.

IV. Statutory authority permitting other than full and open competition.

AFFARS 5313.501 - 10 U.S.C. 2302b, Implementation of Simplified Acquisition Procedures (41 U.S.C. 1901)

V. Demonstration that the contractor's unique qualifications or nature of the acquisition requires the use of the authority cited above (applicability of authority).

Shot peening is used on Aerospace Engine applications, and is typically performed on critical rotating parts in the engine. PMXG must have reliable shot peen machines that are capable of peening according to specific technical data requirements as established by the OEM. The complex nature and critical application of these shot peen machines require precision to effectively accomplish PMXG's mission. Extensive calibration and testing is required to ensure that all key components are working together perfectly.

PMXG currently uses 10 shot peen machines that contain key components from at least 13 different manufacturers. Key shot peen machine components include a computer numerical control (CNC) controller, air regulator, media flow control valves, media classifiers, and pressure blast hoses. Each of these components greatly affects a shot peen machine's reliability. Further, these components are not standardized across all

Sole Source (Including Brand Name) Justification - Simplified Procedures for Certain Commercial Items

18 Jun 2019 FOR OFFICIAL USE ONLY Page 3 of 7 machines, thus, configuration and operational control is largely different from one machine to the next. This leads to increased repair costs, longer lead times, scrap rates, additional training, and downtime for operators, programmers, shop support, and maintenance ultimately affecting PMXG's mission to support the warfighter.

Requiring these brand name only (BNO) and brand name or equal (BNOE) components will establish equipment standardization for PMXG's shot peen machines. Therefore, it is in the best interest of the Government to standardize these key components to avoid substantial cost duplication for the Government by ensuring machine availability, parts supportability, and maintenance support. Substantial duplication of cost can be avoided by leveraging the common physical, functional, theory of operation, and hardware/ software through the acquisition of these BNO and BNOE components.

Fanuc 31i CNC Controller and Associated Motors (BNO) - CNC controllers and their associated motors are used to move the gantry robot and peening nozzle. CNC controllers are complex equipment critical to the performance of a shot peen machine, and the quality of the controller greatly affects the reliability of the shot peen machine. A poorly-functioning or non-standard CNC controller results in significant duplication of costs and delays for the Government. It is in the Government's best interest to standardize CNC controllers used in shot peen machines to the Fanuc 31i because of its parts supportability, lower maintenance costs, and reduced downtime.

PMXG has 5 different CNC controllers in its shot peen machines from three different manufacturers: Siemens, Allen Bradley, and Fanuc. The Siemens and Allen Bradley controllers result in longer lead times and duplication of costs for the Government because they are obsolete, unreliable, or they are no longer suitable for PMXG's workload. In particular, the average cost to maintain these systems over the past 10 years is approximately $227,500 per year, which includes labor costs associated with repair, troubleshooting, training, and reprogramming. For example, Siemens and Allen Bradley CNC controllers take roughly twice the amount of time to troubleshoot issues and repair than Fanuc controllers. Lastly, the machines that use these other controllers condemn about $100,000 worth of parts each year because of an old, outdated interface that also requires additional training and programming to use.

Replacements parts are both expensive and have long lead times of 4 weeks or more. For example, the shot peen machine equipped with a Siemens controller has been down for 2 months due to an inoperable, obsolete CNC controller computer. Controller computers are specifically made to function with a particular brand of controller, and in this case, there is a significant lead time for the replacement computer because it must communicate with an older, unsupported version of Microsoft Windows.

Another example is the Allen Bradley controller. A motor drive failed on one of these controllers, and it took 6 weeks to find, order, and receive the replacement part. For both of these controllers, the market for new and unused parts is limited, and most replacement parts are used or secondhand. This greatly affects the ability to find replacement parts, generally. For those that are available, their condition is often unknown, varied, or in some cases, broken when delivered. This has led to twice the amount of downtime for shot peen machines that utilize CNC controllers other than Fanuc.

The Fanuc 31i exceeds the accuracy and backlash specification in technical data 2-1-111, GE P11TF8, and AMS 2432. Further, Fanuc controllers are robust and often outlive multiple machines, and multiple process changes. MXSG has extensive experience working on Fanuc CNC controllers, and most issues can be solved in under two hours. Further, Maintenance Group (MXSG) mechanics, PMXG engineers, and PMXG machine operators have extensive experience working on, troubleshooting, and calibrating the 31i series controllers.

The price to upgrade to a Fanuc CNC controller $300,000 per machine, which is nearly half the purchase price of a new machine.

Sole Source (Including Brand Name) Justification - Simplified Procedures for Certain Commercial Items

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Proportion Air Regulator System (BNO) - Air regulation systems control air pressure in the peening process and contain pressure transducers that must be calibrated yearly to stay compliant with OEM specifications and AMS 2432. The reliability of this system is important because it is critical to ensure uniform peening in accordance with applicable technical data. Currently, there are 4 different types of air regulation systems from two different manufacturers used in PMXG's shot peen machines. It is in the best interest of the Government to standardize air regulators in all shot peen machines to the Proportion Air Regulator System for lower downtime, lower maintenance costs, and better quality control.

While other air regulation systems are cheaper than the Proportion Air - $800 versus $1,400 for the Proportion Air - the lead time to procure replacement parts for these systems is significantly longer and the maintenance costs are higher. It is estimated that maintenance of these other systems and associated downtime cost the Government $57,000 per year over a 10-year period. Worse, condemned parts attributable to these non-standard air regulation systems cost the Government $100,000 per year, on average.

The Proportion Air Regulator System includes a Proportion Air R000 pilot operated regulator, a DSY100 or DSY110 pressure transducer, and a QBX2 electronic air pressure regulator. This system delivers the correct airflow and pressure for shot peening applications within ±0.2% accuracy across a full scale calibration of 0-100 psig. The cost of upgrading to a Proportion Air is approximately $10,000, primarily due to installation and configuration of the part. Standardizing PMXG's shot peen machine air regulation systems to Proportion Air would allow for replacement parts to be on hand for quicker replacement and calibration, and would ensure the quality of service PMXG is able to provide to its customers. It is in the Government's best interest to make Proportion Air the standard because of better parts supportability, more reliability, less maintenance, and - most importantly - they do not condemn engine blades.

578-24 EI Magna Valve and FC-24 Flow Controller (BNO) - Media flow valves control the media flow through the nozzle during the peening process. These are yet another component crucial to shot peening because they ensure the machine is not over-peening or under-peening parts. Due to the nature of shot peening, parts may not show signs of over-peening, so it is even more important for the machine operator to know how much media is flowing through the peening nozzle. PMXG currently uses Electronic Inc. (EI) Magna Valves and Flow Controllers on all of its machines. It is in the Government's best interest to ensure that EI Magna Valves and Flow Controllers continue to be the standard because of their reliability, parts supportability, low maintenance cost, and low engineering cost.

The only other known method of controlling media flow to accomplish peening to specification is to use orifice plates. Orifice plates are made to connect to the blast hose on the machine. These plates regularly wear out so repeatability is not possible. Further, these orifice plates must be manufactured which makes replacement parts not readily available. While orifice plates may work for some applications, they are not accurate to the point of being usable for F119 and F135 engine lines. To use any method or component other than an EI Magna Valve and Flow Controller would jeopardize PMXG's ability to accomplish F119 and F135 engine workloads in the future. Because workload must be transferred in the event of a shot peen machine being down, all shot peen machines must be capable of performing any of PMXG's workload.

The 578-24 EI Magna Valve (PN999020) media control valve paired with an EI FC-24 Flow Controller is capable of an accuracy of ±3% across the full scale range of 3-30lb/min. These two BNO components are robust and do not need to be regularly changed. In addition, parts are readily available which further reduces downtime.

MXSG and PMXG are both familiar with this particular brand of BNO components, which further reduces maintenance costs, machine downtime, and engineering time needed for calibration. In particular, newer generations of this valve and controller combination take less than half the time to calibrate, which has to occur at least once or twice a year as required by PMXG's customers. As such, it is in the Government's best interest to establish a standard for shot peen machines to use the 578-24 EI Magna Valve and EI FC-24 Flow Controller (and subsequent generations) to ensure quality shot peening, reduce maintenance costs, and lower

Sole Source (Including Brand Name) Justification - Simplified Procedures for Certain Commercial Items

18 Jun 2019 FOR OFFICIAL USE ONLY Page 5 of 7 engineering costs.

SWECO Round Vibro-Energy Separators (BNO) - Media separators are used to separate useable media from non-conforming media according to AMS 2431. PMXG uses media separators from two different manufacturers: Midwest Industries and SWECO. Midwest Industries' separators fail and lead to work stoppages. When these separators fail, there are additional costs for cleanup and repair, and there is additional downtime due to part lead times. Further, these separators pose a safety hazard due to their poor design and construction. It is in the Government's best interest to standardize media separators used on shot peen machines to SWECO Vibro-Energy Separators (BNO).

Classifiers other than SWECO have cost the Government, on average, $32,000 per year over a 10-year period.

This past year alone, there were 3 work stoppages resulting from a spring failure in the classifiers made by Midwest Industries. These separators have a design flaw where the external spring falls off of the separator causing media to back up in the shot peen machine. As a result, media collects on the screens within the separator, and eventually break due to excess weight. Extensive effort is required to entirely clean out the separator system, inspect or replace the screens, and reinstall the exterior spring. In some cases, the spring is either broken or not found, an additional 1 or 2 weeks of downtime occurs until the replacement part is delivered. Lastly, these failures can be incredibly dangerous in the event that multiple springs fail because the separator is often elevated and pose a serious risk to personnel.

SWECO Round Vibro-Energy Separators are reliable, well-designed, and well supported by their manufacturer.

For example, the design of their separators utilize internal springs which prevents them from falling out of place and prevents internal components of the separator from becoming damaged. As such, SWECO Separators have not failed or required replacement parts. It is in the best interest of the Government to standardize shot peen machines to use BNO SWECO Round Vibro-Energy Separators because of their reliability, lower maintenance costs, and safer construction.

Goodyear Plicord 4-Ply Pressure Blast Hose (BNOE) - A pressure blast hose connects the supply air pressure to the peening nozzles, providing air flow for shot peening. PMXG uses various pressure blast hoses on many different types of machines, including shot peen machines. Less durable hoses require additional preventive maintenance and repair, they fail more often which leads to more machine downtime, and in some instances, are attributed to the condemnation of parts. In particular, pressure blast hoses cost the Government approximately $20,000 per year.

Goodyear Plicord 4-Ply Blast Hoses are heavy duty and specifically made for applications like steel shot or sand blasting. These hoses use special construction for additional reinforcement, easy to manipulate, and easy to repair. Goodyear Plicord 4-Ply Blast Hoses result in less machine downtime and repair costs. It is in the best interest of the Government to standardize pressure blast hoses used on shot peen machines to Goodyear Plicord 4-ply Blast Hoses (BNOE).

PMXG currently has four machines with all of the BNO or BNOE components listed within this justification.

These machines have significantly less downtime and are far more efficient than the machines that only have some of these components installed. The machines equipped with these components increases PMXG's capability to support the warfighter, despite increases in workload. PMXG estimates that shot peen machines using Siemens and Allen Bradley CNC controllers, Wilkerson Air Regulation Systems, Midwestern Media Separators, and less durable pressure blast hoses have cost the Federal Government over $4,000,000 due to downtime, repair costs, programming costs, and the cost of condemned parts over a 10-year period. If all shot peen machines came equipped with these components, PMXG estimates that the associated costs mentioned above could be reduced as much as 90%.

Sole Source (Including Brand Name) Justification - Simplified Procedures for Certain Commercial Items

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Shot peening machines are complex in nature and require an acute level of precision to process parts correctly; therefore, it is in the best interest of the Complex - as well as the AFSC - to establish equipment standardization for its shot peen machines for the reasons mentioned in this justification. Therefore, continuing full and open competition with regard to the acquisition of components other than the BNO and BNOE components listed in this justification will continue to adversely affect PMXG's ability to support the war fighter.

VI. Description of efforts made to ensure that offers are solicited from as many potential sources as practicable.

All the items in this BNJ are commercial off the shelve items available to all manufacturers of shot peen machines.

VII. Determination by the Contracting Officer that the anticipated cost to the Government will be fair and reasonable.

The contracting officer will ensure that the items described here in will be purchased at fair and reasonable prices, through price analysis. The contracting officer expects price competition.

VIII. Description of the market research conducted and the results, or a statement of the reasons market research was not conducted.

The original market research was conducted IAW FAR Part 10, using previous similar contracts for these products, GSA Advantage, and Internet searches of the proposed acquisition.

IX. Any other facts supporting the use of Other Than Full and Open Competition.

None

X. List of any sources that expressed, in writing, an interest in the acquisition.

5 businesses were contacted, 4 of which were small businesses. Only 3 small businesses responded and expressed interest:

Please see attached Market Research Report for further details.

XI. A statement of the actions, if any, the agency may take to remove or overcome any barriers to competition before making subsequent acquisitions for the supplies or services required.

The Government will continue to monitor the market place for other brand items that may be a suitable replacement.

As for now the Government will follow the direction of the T.O. and Tinker engineering to procure brands listed in the T.O. For future acquisitions that do not require training, brand name will be used which will eliminate the need for limited sources acquisition.

Sole Source (Including Brand Name) Justification - Simplified Procedures for Certain Commercial Items

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XII. Certification by the Contracting Officer.

As evidenced by our signatures above, we have determined this document to be both accurate and complete to the best of our knowledge and belief.

XIII. Certification by the technical/requirements personnel.

As evidenced by my (our) signature(s) above, I (we) certify that any supporting data contained herein, which is my (our) responsibility, is both accurate and complete.