DRAFT PWS - HANKOOK SOURCES SOUGHT.pdf

NORFOLK NAVAL SHIPYARD

PERFORMANCE WORK STATEMENT

HANKOOK R80W SHAFT LATHE REPAIRS

1. General: Norfolk Naval Shipyard is seeking a service contract to provide maintenance and repair on a

Hankook Model R80W Computer Numerically Controlled (CNC) shaft lathe, Serial number: 43L09626.

The contractor shall provide all personnel, sub-contractors, equipment, supplies, facilities, transportation, tools, materials, supervision and non-personal services necessary to perform the maintenance and repairs to the Hankook R80W CNC shaft lathe as defined in this Performance Work Statement (PWS). The contractor shall perform these services described herein per industry standards while following all federal regulations and safety standards. Personnel employed by the Prime Contractor shall perform the maintenance and repair outlined in this PWS, to return the Hankook R80W, 43L09626 CNC shaft lathe to operational status. The Government shall not exercise supervision or control over the personnel and service providers performing the services herein. Contracted personnel and service providers shall be accountable solely to the prime contractor who, in turn is responsible to the government. The awarded prime contractor shall provide the government a primary point of contact for the contract who fluently speaks English.

1.1. Description of Services/Introduction: The service shall include an overall condition assessment, machine level & alignment, servo and drive overload repair, X-axis engagement repair, gibb and wiper service, carriage hydrostatic service, automatic tool/pallet changer repair, B-axis cable replacement, AC system installations, restoration of axis compensation & cutter compensation, repair or replacement of post processor (for functional g code output from Siemens NX10), factory defect repairs and perform testing per the Quality Assurance section herein this PWS.

1.2. Background: The known problems/defects with the Hankook R80W CNC Shaft Lathe.

1.2.1. The machine is out of alignment.

1.2.2. The CNC controller currently displays a servo overload while traversing the Z-axis.

1.2.3. X-Axis backs out of a cut when Z-axis engages.

1.2.4. Gibbs and wipers are not adjusted properly or need to be replaced.

1.2.5. Hydrostatic system is over pressuring causing, leaks in the hydraulic lines.

1.2.6. Automatic tool/pallet changer is currently misaligned and damaged.

1.2.7. B-Axis cable is damaged and needs to be replaced.

1.2.8. The original electrical cabinet AC systems need to be replaced.

1.2.9. CNC controller is currently unable to perform the following G-code operations G40, G41, and G42 (cutter compensation functionality).

1.2.10. Post processor does not output useable G and M code from Siemens NX10.

1.2.11. C-Axis drive is controlled by one relay, which is known to be a factory defect and can cause damage to the C-Axis servos.

2. Scope: This Performance Work Statement (PWS) describes the minimum requirements of the

Contractor for services on a Hankook R80W CNC Shaft Lathe. The services include condition assessment, equipment leveling and aligning of all axes and components, restoration of axis compensation, carriage hydrostatic system service, Gibb and Wiper adjustment or replacement, automatic tool/pallet changer repair, servo overload repair, cutter compensation feature restoration, functional and operational post processor output, AC system replacement, B-Axis cable replacement, factory defect repairs and Quality Assurance Testing.

2.1. Contract Objectives: Contractor shall perform the below objectives.

2.1.1. Perform condition assessment on the Hankook R80W lathe and report all deficiencies in writing to the Contract Officer, Contract Officer Representative and Technical Point of

Contact; this includes all known factory defects, discovered problems and known deficiencies listed here in under 1.2 Background. Then the contractor shall submit a quote to repair the identified deficiencies with the Hankook R80W not covered by the objectives here in or under 1.2 Background.

2.1.2. Level and align the machine to include ways/bed, carriage, steady rests {to include the manufacturing of steady rest alignment keys if required}, headstock, tailstock, automatic pallet/tool changer, machine way guards, and all machine axes within an acceptable margin of deviation from OEM alignment specifications.

2.1.3. Inspect and determine the root cause(s) of the axis drive overload(s) then quote to repair or replace the assemblies and components that shall remedy the problem(s) with the drive system overloading.

2.1.4. Inspect and repair issues causing the X-Axis to back off/out when the Z-Axis engages.

2.1.5. Inspect and adjust all machine gibbs within OEM specifications; if they are worn, damaged, or unable to be adjusted within factory requirements, they shall be replaced and installed with new gibbs which meet OEM specifications.

2.1.6. Inspect and replace all worn or damaged machine wipers; then adjust the alignment of all machine wipers for proper operation.

2.1.7. Carriage hydrostatic service shall include gauge replacements, hydraulic hose replacement (replacement hoses shall not be of a quick disconnect design and shall be of equal or greater pressure class rating than the OEM hydraulic lines), hydraulic fluid and filter change, and component tuning with reverence to OEM specifications.

2.1.8. Inspect, repair and align automatic tool/pallet changer as necessary then verify and demonstrate satisfactory tool/pallet changes after repairs and alignment are complete.

2.1.9. Replace or repair currently damaged B-Axis cable.

2.1.10. Install replacement AC systems for the electrical cabinets.

2.1.11. Restore Axis Compensation for continued accuracy, precision, and repeatability utilizing the OEM Specifications as desired functional state.

2.1.12. Restore or repair cutter compensation machining feature set for milling and turning.

2.1.13. Repair or replace post processor for Siemens NX10 in order to get functional G and M code output for production and manufacturing needs.

2.1.14. Contractor shall repair the factory defect with the C-Axis drive relay, wiring and routing.

2.1.15. Perform Quality Assurance Testing: All cut testing shall be performed with a Norfolk

Naval Shipyard (NNSY) supplied dummy shaft, to demonstrate all designed machine capabilities and identify any deficiencies’. Cut tests shall include rough turning, finish turning, milling and grinding operations in accordance to the Quality Assurance Testing

Section herein.

2.2. Special Qualifications:

2.2.1. The awarded contractor shall be an authorized Hankook Machine Tool service provider.

2.2.2. The awarded contactor’s personnel performing all contract objectives shall have specialized knowledge, experience, and certified training to repair Hankook Machine

Tools LTD lathes using the specialized and proprietary tooling and schematics unique to the original equipment manufacturer.

2.2.3. The awarded contractor personnel performing repairs to the Hankook R80W per contract objectives herein this PWS 2.1.11-2.1.14 shall have FANUC Maintenance Master

Certification.

3. Quality Assurance Testing:

3.1. Operational Test: The machine shall be operated at no load for more than 30 minutes for an initial warm-up period. Proper operation of all manual controls, servos, drives, motors, adjusting mechanisms and accessories shall be verified during the warm-up period. Upon completion of the initial check procedure, the machine shall have all of its systems cycled continually for three hours under computer numerical and manual control to demonstrate operability of the equipment and permit the machine to reach a steady operating temperature. The test shall include rapid travel across all axes, independently and simultaneously. During this time spindle speed and feed rates shall be verified.

3.2. Alignment Test: The machine and its components shall be tested for conformance with the OEM level and alignment specifications for the Hankook R80W CNC shaft lathe.

3.3. Steady Rest & Shaft Positioning System Test: The operation of steady rests and shaft positioning system shall be tested utilizing the Government provided test shaft. The Test shall include movement of carriage, cross slide, and tooling and accessory pallets past steady rests. At least two (2) lifts of work piece shall be made during demonstration. The Technical Point of

Contact (TPOC) will observe and/or measure the steady rest operation and clearances (Carriage, Cross slide and pallet) to verify that there is no evidence of stalling, or permanent distortion of machine or propulsion shaft during or after the test.

3.4. Performance Test: NNSY test shaft shall be turned and milled on the machine to test its machining accuracy and finishing capability. Speeds and feeds shall be based on the tooling and material used for the test. The test shall include at least one cut in each mode of slide departure and repeatability of slide position. The test cutting shall include straight turning, shoulders, face cut, grinding and milling (to include keyway and center-hole testing). The test cuts shall produce an acceptable finish and shall not fault out or overload the machine.

3.5. Horsepower Test: The machine shall be subjected to a test which applies not less than the full rated input power to the spindle motor for not less than one minute. Spindle speed shall be chosen by the contractor, the lowest speed practicable without applying torque in excess of the design maximum value of machine components. Material and dimensions of the work piece, depth of cut, tooling and feed-rate shall be at the option of the supplier, to provide the required loading. There shall be no apparent evidence of chatter, stalling, or permanent distortion during or after the test.

4. Government Furnished Items And Services:

4.1. Facilities: The Government will provide the necessary workspace for the contractor's staff to provide the support outlined in the PWS.

4.2. Utilities: The Government will provide 120 volt electricity and 90 psi air. The Contractor shall instruct employees in utilities conservation practices. The contractor shall be responsible for operating under conditions that preclude the waste of utilities, including turning off the water faucets or valves after using the required amount to accomplish cleaning.

4.3. Lifting and Handling: The Government shall provide all rigging services needed for this PWS that require the use of the overhead bridge cranes. Government lifts shall take priority over

Contractor requested lifting and rigging services.

4.4. Hydraulic and Hydrostatic Fluid Change: The Government will assist in the fluid changes including providing pumps, drums, and will take ownership of the used fluids and filters.

4.5. Test shaft: The Government shall provide a test/dummy shaft for testing.

5. General Information:

5.1. Recognized Holidays: The contractor shall not work on the following recognized holidays.

Martin Luther King Jr.'s Birthday Columbus Day

President's Day Veteran's Day

Memorial Day Thanksgiving Day

Independence Day Christmas Day

New Year's Day Labor Day

5.2. Hours of Operation: The contractor is responsible for conducting business, between the hours of

0700 - 1530, Monday thru Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. The Contractor shall at all times maintain an adequate workforce for the uninterrupted performance of all tasks defined within this PWS when the Government facility is not closed for the above reasons. When hiring personnel, the Contractor shall keep in mind that the stability and continuity of the workforce are essential.

5.3. Place of Performance: The work to be performed under this contract will be performed at

Norfolk Naval Shipyard, Portsmouth, VA. 23709

6. Safety and Security:

6.1. The Contractor and personnel shall need access to the Controlled Industrial Area (C.I.A.) and must have all necessary personal protective equipment (P.P.E.).

6.2. Per FAR 22.102-1(a) entitled "Safety", Contractors are hereby informed that their employees or representatives present on property under Norfolk Naval Shipyard cognizance shall follow all

Federal and State OSHA requirements; including Norfolk Naval Shipyard OSHE Program Manual, NAVSHIPYDNORINST P5090.2 requirements and the safety requirements for site specific location of the contract.

6.3. All work shall be accomplished using the current commercial practices and industry standards, while following all federal and state regulations and laws. The following documents shall be used as guidance and is not an all inclusive list.

6.3.1. Federal Acquisition Regulation 22.102-1(a) “Safety”

6.3.2. OSHA Standards of Occupational Safety and Health Act: 29 CFR 1910 (general), 1915

(shipyard), and 1926 (construction).

6.4. All arrangements for site visits shall be made through the Technical or Certifying Points of Contact.

6.4.1. The contractor shall submit business and personnel information to the Technical Point of

Contact to be issued to Base Security. This information shall be submitted at least ten business days in advance of arriving at N.N.S.Y.

Note: Contracted work shall begin once the badging process has been completed through the Contract Specialist, Technical or Certifying Points of Contact.

7. Period Of Performance: May 4th, 2020 – July 31st, 2020

8. Technical POC:

TBD

9. Certifying POC:

10. Contracting Officer Representative (COR):