CNC Controller PWS 17 Sept.pdf

PERFORMANCE-BASED WORK STATEMENT (PWS)

GIDDINGS & LEWIS (G&L) PC-50X HORIZONTAL BORING MACHINE

(HBM) MODIFICATION

U.S AIR FORCE

309 COMMODITIES MAINTENANCE GROUP (CMXG)

9/17/2020

GIDDINGS & LEWIS (G&L) PC-50X HORIZONTAL BORING MACHINE (HBM) MODIFICATION

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TABLE OF CONTENTS

1 DESCRIPTION OF SERVICES

2 BASIC SERVICES

3 ADDITIONAL REQUIREMENTS

4 SERVICE SUMMARY

5 CONTRACT DATA REQUIREMENTS LIST (CDRL)

6 GENERAL INFORMATION

APPENDIX A – ACRONYMS AND ABBREVIATIONS

APPENDIX B – SAFETY, FIRE PROTECTION AND HEALTH SPECIFICATION

INDUSTRIAL SAFETY REQUIREMENTS

1 DESCRIPTION OF SERVICES

This requirement is to provide all management, tools, supplies, equipment, labor, and travel necessary to install one Fanuc 0i-MF Computer Numerical Control (CNC) Control Kit on one

G&L PC-50X HBM located in building 511 at Hill Air Force Base (AFB), Utah. The contractor shall remove the current CNC control system and shall install the Fanuc 0i-MF CNC Control kit, to be provided by the Government. Upon work completion, the G&L PC-50X HBM shall be inspected and tested to determine functionality and serviceability In Accordance With (IAW) the latest Original Equipment Manufacturer (OEM) configuration, as required. The contractor shall notify the Point of Contact (POC), Engineering Technician, at a minimum of two (2) weeks prior to the on-site work start date.

2 BASIC SERVICES

2.1 Fanuc 0i-MF CNC Control Kit Installation

2.1.1 The contractor shall conduct an on-site visit to remove the current CNC controller. After removal, the contractor shall install, calibrate, and certify one

Fanuc 0i-MF CNC Control Kit on one G&L PC-50X HBM located at Hill AFB, Utah.

2.1.1.1 Equipment Removal: The contractor shall dis-assemble and remove the

OEM CNC control system. The following items shall be reused:

2.1.1.1.1 Existing Spindle Motor and Drive

2.1.1.1.2 Magnetic panel

2.1.1.1.3 Main disconnect

2.1.1.1.4 Motor starters

2.1.1.1.5 Limit switches

2.1.1.1.6 Pressure switches

2.1.1.1.7 Home switches

2.1.1.2 Equipment Installation: The contractor shall mount and integrate the

Faunc 0i-MF CNC Control Kit to the G&L PC-50X HBM. The

Government shall provide the Faunc 0i-M CNC controller.

2.1.1.2.1 The Faunc 0i-M CNC Control Kit shall include the following:

2.1.1.2.1.1 Fanuc 0i-MF CNC

2.1.1.2.1.2 Fanuc servo motors, cables, and drives for X, Y, Z, W, & B axes and adaptor plates

2.1.1.2.1.3 Fanuc Handy Machine Operator’s Pendant (HMOP)

2.1.1.2.1.4 Renishaw RMP60 compact spindle probe with RMI-Q

radio machine interface

2.1.1.2.1.5 General electrical supplies required to complete the

CNC controller installation onsite

2.1.1.2.2 Contractor shall provide motor mounts that are manufactured to match existing motor configuration

2.1.1.2.3 Equipment installation must meet the minimum specifications for grounding and surge suppression as recommended by

Fanuc.

2.1.1.3 Equipment Inspection: All Alternating Current (AC) motors shall be inspected for operation and performance. Any motor not performing to

OEM specifications will be identified and brought to the immediate attention of the Government POC.

2.1.1.4 Equipment Acceptance: Upon completion of work and prior to acceptance by the Government, the contractor shall ensure the following actions are completed:

2.1.1.4.1 The machine shall be powered up, debugged, and operated under power

2.1.1.4.2 Hydraulic pressures adjusted to OEM specifications

2.1.1.4.3 Lubrication system performs IAW OEM specifications

2.1.1.4.4 Confirm all spindle and axis feeds and speeds are within OEM specifications

2.1.1.4.5 Perform Fives Machine Tool Services & Solutions (MTSS) standard test cuts

3 ADDITIONAL REQUIREMENTS

3.1 Familiarization

3.1.1 Upon completion of the control/machine tool set-up, the contractor shall provide operator and maintenance familiarity training for up to three people. Training shall cover basic machine operations and CNC controller maintenance familiarization. Training shall be for a period of no less than 2 days.

3.2 Documentation

3.2.1 Contractor shall provide documentation of the areas of the machine that were modified by Fives MTSS during the installation of the Faunc 0i-MF CNC

Control Kit. Documentation shall be delivered No Later Than (NLT) 5 days after completion of installation. Documentation shall include the following:

3.2.1.1 Electrical wiring diagrams of affected areas (CDRL A001)

3.2.1.2 Final inspection reports (CDRL A002):

3.2.1.2.1 Fives MTSS Preventative Maintenance (PM) forms, if PM actions are performed

3.2.1.2.2 Final OEM geometry sheets, if inspected

3.2.1.2.3 Final laser results, if performed

3.2.1.3 Manuals (CDRL A003):

3.2.1.3.1 Fanuc Operators Manual

3.2.1.3.2 Fanuc Programming Manual

3.2.1.3.3 Fanuc Maintenance Manual

3.2.1.4 Machine specific programing codes

3.3 Proprietary Information

3.3.1 Contractor shall have access to any proprietary information required to complete the installation. Proprietary information may include machine specific drawings, test procedures, and proprietary ladder logic cods to ensure that parameters and setting are set up correctly for proper function, movement and precision.

4 SERVICE SUMMARY

Performance Objective PWS

Paragraph

Performance Threshold

On-Site Work Notification 1 The contractor shall notify the Government POC at a minimum of two (2) weeks prior to the on-site work start date.

Document Delivery 3.2.1 The contractor shall delivery all required documentation to the

Government POC NLT 5 days after completion of installation.

5 CONTRACT DATA REQUIREMENTS LIST (CDRL)

Data

Item

Title PWS

Paragraph

Delivery Threshold

A001 Electrical Diagrams 3.2.1.1 The contractor shall provide inspection report within five (5) days of completion.

A002 Final Inspection Reports 3.2.1.2 The contractor shall provide inspection report within five (5) days of completion.

A003 Operating/Program Manuals 3.2.1.3 The contractor shall provide inspection report within five (5) days of completion.

A004 Accident/Incident Report 6.7.3 &

Appendix

B Sec B

A written or email copy of the mishap/incident notification shall be sent within three calendar days.

For information not available at the time of initial notification, the contractor shall provide the remaining information no later than 20 calendar days after the mishap, unless extended by the ACO.

6 GENERAL INFORMATION

6.1 Security Requirements

6.1.1 Government POC or designee will be responsible and ensure that the contractor is given clearance at the South Gate by escorting the individual or by phone clearance, and will escort contractor to Government facilities.

6.1.2 The contractor shall comply with all clearance and access requirements throughout the period of performance. Contractor shall provide the POC proper identification of all employees that will require access to installation no later than

14 days before work begins. The contractor shall provide government issued identification for all employees that require access to Hill AFB.

6.2 Foreign Object Damage (FOD) and Tool Control

6.2.1 The contractor shall follow the applicable guidance in chapters/paragraphs/ sections of AFI 21-102, AFMC Supplement to 21-102, AFSCMAN 21-102, Chapter 10, OO-ALC supplements to the AFI 21-102 concerning base tool

(chapter 10), and FOD control policies (chapter 14, and sub paragraphs designated as 41), daily. Cloth rags are considered tools and will follow the same regulations and procedures as tools.

6.2.2 If tools, and/or equipment are lost, the contractor will report the loss to the

Government POC no later than two (2) hours after discovery. If tools are lost or not accounted for, then the contractor shall implement the lost tool procedures of

AFMC supplement to AFSCMAN 21-102, Chapter 10, section B.

6.2.3 Contractors performing functions in industrial areas on the center shall have a method for controlling and accounting for all tools used. All contractors working on the center shall inventory their tools at the beginning and end of each shift and at the end of each task to check for any lost or missing tools.

6.2.4 The contractor shall follow control/restrictions of cell phones and personal electronic devices within designated high potential FOD areas (reference chapter

1 sub paragraph 35, Communication) of AFI 21-102 and HQ AFMC, Hill AFB, and OO-ALC supplements.

6.3 Quality Control Standards

6.3.1 The Government may inspect each task as completed or increase the number of quality control inspections if deemed appropriate because of repeated failures discovered during quality control inspections or because of repeated customer complaints.

6.3.2 Any matter concerning a change to the scope, prices, terms or conditions of this contract shall be referred to the Contracting Officer (CO). At no time will contract work or requirement be changed by anyone other than the CO.

6.4 Environmental Controls

6.4.1 The contractor shall ensure their employees are made aware that the performance of these services will occur in industrial areas. The industrial complex at Hill

AFB has the potential to expose workers to hazardous materials, which may include, but are not limited to, hexavalent chrome, cadmium, beryllium, lead, etc.

While the contractor will not perform duties in a marked and signed regulated area, (where exposures are expected to exceed the permissible exposure limits set by Occupational Safety and Health Administration (OSHA), there may be contact hazards with these materials during cleanup of dust, metal shavings, etc.

The contractor shall ensure proper protective measures and training is taken to ensure contracted employees are protected from these hazards.

6.4.2 Compliance with Laws and Regulations. The contractor shall be knowledgeable of and comply with all applicable Interstate, Federal, State, and Local laws, regulations, and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor is required to comply as such laws come into effect. If there is an increase or decrease in cost as a result of the change, the contractor shall inform the CO pursuant to notice requirements and negotiate a modification to the contract.

6.4.3 Notification of Environmental Spills. If the contractor spills or releases any substance contained in 40 CFR 302, including hazardous materials, into the environment, the contractor or its agent shall immediately call 911. If the call is made from an on base phone, it will go directly to Hill AFB dispatch. If using a cell phone it will go off base, ask the 911 dispatcher to be transferred to Hill

AFB. The liability for the spill or release of such substances rests solely with the contractor and its agent.

6.4.4 The contractor shall maintain current Material Safety Data Sheet (MSDS) documents for all chemicals used in maintaining and operating the system, and shall provide copies to upon request IAW Appendix B of this PWS.

6.5 Hours of Operation

6.5.1 The contractor shall perform services during normal working hours of Monday through Friday, 0600 through 1530, excluding federal holidays.

6.5.2 Federal Holidays: Unless otherwise required by the Government, the contractor shall not have access to Government facilities on the following federal holidays:

New Year’s Day, Martin Luther King’s Birthday, Washington’s Birthday, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans’ Day, Thanksgiving Day, and Christmas Day. If a holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

Any other circumstances that may prompt base closure, such as Days of National

Mourning, may also restrict opportunity access to the installation. There may also be up to six AFMC Goal Days and four Wingman Days per year awarded to

Government civilian employees, as well as possible weather related days and

Government directed holidays. On these days, the contractor shall not generally be required to work and the Government shall not be billed for work not performed.

NOTE: Good Friday is regarded as a holiday by the Utah Wage Determination;

however, Good Friday is not a Federal Holiday so the Government facilities will be open for work that day. The contractor shall plan on employees working business as usual on that day, unless the Government supervisor or section chief determines that such services are either unnecessary or will be less than a full normal workday.

6.6 Annual Manpower Report

6.6.1 The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via a secure data collection site. The contractor is required to input all data into the System for Award Management (SAM) at https://www.sam.gov.

6.6.1.1 Reporting Period: Contractors are required to input data for the labor executed during the Period of Performance (POP) for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be recorded anytime during the FY, all data shall be reported no later than 31 October of each calendar year.

6.6.1.2 Uses and Safeguarding Information: Information from the secure web site is considered proprietary in nature when the contract number and contractor identity are associated with direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.

6.7 Safety and Health Standards

6.7.1 The contractor shall follow Appendix B and adhere to the Air Force is part of the

OSHA.

6.7.2 Hill AFB has adopted the Voluntary Protection Program (VPP) as recognized by

OSHA. Consequently, VPP impacts all “applicable contractors” operating on Air

Force Installations. It is the contractor’s responsibility to ensure its employees and managers have a comprehensive understanding of VPP as well as full compliance with OSHA requirements. Detailed information on VPP is available on the OSHA website (http://www.osha.gov/dcsp/vpp/index.html). Contractors, whether regularly involved in routine site operations or engaged in temporary projects such as construction or repair, must follow the safety and health rules of the installation or VPP site.

6.7.3 In the event of an accident/mishap, the contractor shall take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence. A written or email copy of the mishap/incident notification shall be sent within three (3) calendar days to the CO. (CDRL A004) https://www.sam.gov/

6.7.4 3.2.2 When Air Force and contractor personnel conducting joint lockout/tagout operations the contractor shall use requirements in AFMAN91-203 para. 21.8.

6.7.5 A government representative and an authorized worker most familiar with the equipment or machinery being serviced by the contractor will ensure the contractor is provided specific information related to the known hazards of the work to be conducted, e.g., type and magnitude of energy sources. All affected workers shall be made aware of the contractors work and the need to follow prescribed related safety procedures.

6.8 Warranty

6.8.1 The contractor shall provide a standard twelve (12) month warranty on all mechanical and electrical work performed. The contractor shall repair or replace without charge, any defective part or parts for this period.

APPENDIX A – ACRONYMS AND ABBREVIATIONS

Acronym/Abbreviations Definition

AC Alternating Current

AFI Air Force Instruction

AFB Air Force Base

AFMAN Air Force Manual

AFMC Air Force Material Command

AFSCMAN Air Force Sustainment Center Manual

CFR Code of Federal Regulation

CMRA Contractor Manpower Reporting Application

CMXG Commodities Maintenance Group

CNC Computer Numerical Control

CO Contract Officer

FOD Foreign Object Damage

FY Fiscal Year

G&L Giddings & Lewis

HBM Horizontal Boring Machine

IAW In Accordance With

MSDS Material Safety Data Sheet

MTSS Machine Tool Services & Solutions

OEM Original Equipment Manufacturer

OO-ALC Ogden Air Logistics Complex

OSHA Occupational Safety and Health Act

POC Point of Contact

PM Preventative Maintenance

PWS Performance Work Statement

SS Service Summary

TCIR/DART Total Case Incident Rate/Days Away Restricted Transfer

TO Technical Order

VPP Voluntary Protection Program

APPENDIX B – SAFETY, FIRE PROTECTION AND HEALTH

SPECIFICATION INDUSTRIAL SAFETY REQUIREMENTS

OGDEN AIR LOGISTICS COMPLEX

UNITED STATES AIR FORCE

HILL AIR FORCE BASE, UTAH 84056

CNC CONTROLLER UPGRADE

6 Aug 2020

OO-ALC/SE

Control Number: TH200802

SECTION I - GENERAL REQUIREMENTS

A. Safety Program Requirements.

The contractor will implement a safety program that ensures protection of

Government personnel and property. The program will consist of, as a minimum:

1. Mishap reporting, as defined in paragraph B1 below.

2. Routine and recurring surveillance to ensure the safety requirements of this contract are enforced.

3. Identification of segregated work site locations for operations that cannot be co-mingled with general industrial operations and the process for ACO approval of operations and changes at these specific sites.

4. All contractor personnel shall be trained and qualified to perform their duties safely.

5. The contractor shall include a clause in all subcontracts requiring the subcontractors to comply with the safety provisions of this contract, as applicable.

B. Mishap Notification

1. The contractor shall notify OO-ALC/SE (801-586-6038) or the Hill AFB Command Post

(801-777-3007) after normal duty hours, and the designated Government Representative

(GR), i.e., the ACO, PCO, or DCMA COR (Contracting Officer's Representative) within one (1) hour of all mishaps or incidents at or exceeding $2,000 (material + labor) in damage to DOD property entrusted by this contract, even if the government is wholly or partially reimbursed. This notification requirement shall also include physiological mishaps/incidents. A written or email copy of the mishap/incident notification shall be sent within three calendar days to the GR, who will forward it to OO-ALC/SE. For information not available at the time of initial notification, the contractor shall provide the remaining information no later than 20 calendar days after the mishap, unless extended by the ACO. (CDRL A004)

Mishap notifications shall contain, as a minimum, the following information:

(a) Contract, Contract Number, Name and Title of Person(s) Reporting

(b) Date, Time and exact location of accident/incident

(c) Brief Narrative of accident/incident (Events leading to accident/incident)

(d) Cause of accident/incident, if known

(e) Estimated cost of accident/incident (material and labor to repair/replace)

(f) Nomenclature of equipment and personnel involved in accident/incident

(g) Corrective actions (taken or proposed)

(h) Other pertinent information

2. The contractor shall cooperate with any and all government mishap investigations.

Additionally if requested by government personnel or designated government representative (GR), i.e., the ACO, PCO, or DCMA COR (Contract Officers

Representative), the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by safety investigators.

3. The contractor shall provide copies of contractor data related to mishaps, such as contractor analyses, test reports, summaries of investigations, etc. as necessary to support the government investigation.

4. The contractor shall support and comply with the safety investigation and reporting requirements of AFI 91-204, Chapters 1 – 5.

C. General Safety Requirements:

The contractor is solely responsible for compliance with all federal, state and local laws, the Occupational, Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards, OSHA Standards 29 CFR 1910 and 1926, as applicable, and the protection of their employees. Additionally, the contractor is responsible for the safety and health of all subcontractor employees. All documents required as a result of OSHA 29

CFR 1910 and 1926 regulations, (i.e. certifications, training, respiratory protection program, workplace hazard assessments), shall be made available to the COR upon request.

The contractor shall ensure assigned personnel are adequately trained and qualified for the task being performed. Brief all personnel on the hazards involved with operations and applicable precautions to be taken. Should unidentified hazards arise, cease operations until actions are taken to eliminate or mitigate hazards to safe levels.

Contractor personnel must receive Explosive Safety Awareness Training if their duties require entry into the Explosive Clear Zone. This training will be provided by the

OO-ALC Safety Office. Contact Tom Caygle at 586-0081.

A Risk Assessment will be required prior to any work being accomplished, if munitions will remain in the facility.

Compliance with OSHA and other applicable laws and regulations for the protection of contractor employees is exclusively the obligation of the contractor. Note:

The government shall assume no liability or responsibility for the contractor's compliance or non-compliance with such requirements. The contractor shall furnish to each of his/her http://www.osha.gov/pls/oshaweb/owasrch.search_form?p_doc_type=STANDARDS&p_toc_level=0 employees a place of employment, which is free from recognized hazards. The contractor shall brief his/her employees on the safety requirements of this contract and on hazards associated with prescribed tasks. The contractor is responsible for compliance with OSHA

Public Law and the resultant standards identified within. In addition, the contractor is required to flow down the safety requirements/specification to all subcontractors. This applies to Federal Acquisition Regulation (FAR) 12 commercial acquisitions as well. This contract shall in no way require persons to work in surroundings or under working conditions which are unsafe or dangerous to their health. The contractor must coordinate and perform work so as not to impact the safety of government employees or cause damage to government property. This requires providing personnel with protective equipment and associated safety equipment as may be necessary. The contractor must also protect personnel from hazards generated by the work. If the contractor employs BILINGUAL speaking employees, they must post bilingual signs and have written procedures for specific tasks in applicable languages.

SECTION II – SPECIFIC REQUIREMENTS

PEDESTRIAN CROSSWALKS: All contractor personnel are required to use the closest crosswalk, or traffic controlled intersection when crossing the road. Pedestrians must look both ways to ensure the coast is clear before stepping out into the crosswalk. Pedestrians DO NOT have the right of way unless they are already in the crosswalk. Contractor vehicle operators have the same responsibilities as pedestrians, to share the road and mutually observe and yield to pedestrians.

MOTOR VEHICLES: Contractor shall comply with the standards in: DoD Directive 5525.4, Enforcement of State Traffic Laws on DoD Installations", Nov 2, 1981, Para 3-4; DODI 6055.4, DoD Traffic Safety Program, 20 Jul 99; AFI 91-207, USAF Traffic Safety Program, 22 May 07;

and AFI 91-207 AFMC SUP1, The US Air Force Traffic Safety Program, 1 Oct 07. Each applies to all persons at any time on an Air Force Installation and includes all leased, owned, or privatized property including housing areas. In addition: AFI 13-213, Airfield Management, applies to all contractors, sub-contractors, vendors, commercial delivery companies, and all other private business vehicles who operate anywhere on Hill Air Force Base, including the airfield (to include the industrial areas and any buildings or hangars located upon the airfield) in support of their mission.

HOUSEKEEPING: Housekeeping shall be conducted according to the requirements in OSHA

Standard 29 CFR 1910.141. CLEAN AS YOU GO will be enforced.

Element/Requirement Referenced Benchmark

Mishap Notification/Reporting Appendix C, Section I

AFI 91-204 Para. 4.9

Facility Fire Protection NFPA 13, 70, & 72

NFPA 409/410

AFI 91-203 Chapters 6, 22

Handling, Storage and use of Flammable/ NFPA 30, 33

Hazardous Material Management AFI 32-7086 HAFBSUP 1

Storage and Materials Handling DoDI 4140.62