60942 - Purchase Description - SIP JIG Bore.pdf

Purchase Description

For

Rebuild/Retrofit of SIP JIG Bore Machine

08 January 2020

1.0 DESCRIPTION. The Contractor shall provide all tools, parts, materials, equipment, labor, transportation, and supervision necessary to integrate a Fanuc 0i-MF digital Computer Numerical Control (CNC) to the 3-axis SIP Jig Bore machine for the 402d Commodities Maintenance Group (CMXG) at Robins Air Force Base (AFB), Georgia. The servos and the magnetics used to control the machine will be housed inside the existing electrical cabinets. Miscellaneous components such as motor starters, contactors, and control relays, etc. may be re-used. The Contractor shall also rebuild/retrofit the following 3-axis SIP Jig Bore machine to original like new condition:

Make Model Serial Number WR Asset Number

SIP MP54 906 WR002518

2.0 SPECIFIC TASKS.

2.1 The Contractor shall disassemble the machine to the level required to perform the following tasks:

2.1.1 Integrate a Fanuc 0i-MF digital CNC to the 3-axis SIP Jig Bore machine

2.1.2 Adapt and mount new Fanuc Alpha-Is servo motors onto the machine. Motors shall match or exceed the torque and speed specifications presently equipped on the machine. Motors shall be configured with integral absolute feedback devices.

2.1.3 Install new Fagor absolute linear scales on the –X and –Y Axes

2.1.4 Re-surface the existing control cabinet to accept the liquid crystal display (LCD) display, keyboard, and Machine Tool Builder (MTB) panel.

2.1.5 Rewire machine as necessary. Continuous flex cable shall be used for cables that experience continual movement.

2.1.6 Worn or damaged pushbuttons, selector switches and limit switches shall be replaced.

2.1.7 Install/integrate new coolant pump with the existing coolant tank.

2.1.8 The existing oil skimmer shall be integrated with the control to only cycle as desiredwhen the machine is operational.

2.1.9 A new hydraulic system shall be installed to replace the overheating unit.

2.1.10 The spindle shall be disassembled, rebuilt, and reassembled replacing or repairing all damaged and worn parts.

2.2 The contractor shall provide the following items:

2.2.1 CNC Control equipment

2.2.1.1 One (1) Fanuc 0i-MF control - with 10.4 inch color LCD display

2.2.1.2 One (1)horizontal machine operation panel with Feed Rate Over-ride (FRO), Spindle Speed Over-ride (SSO), and Manual Pulse Generator (MPG)

2.2.1.3 One (1) iPendant with Hand Pulse Generator (HPG) with retractile cord

2.2.1.4 One (1) 24VDC power supply

2.2.1.5 One (1)Fanuc 16 point digital input modules

2.2.1.6 One (1) Fanuc 16 point digital output modules

2.2.1.7 One (1) Servo Power Supply Alpha IPS 11HV

2.2.1.8 Two(2) Alpha is-8HV 4000RPM servo motors w/absolute feedback

2.2.1.9 One (1) Alpha is-12HV 4000RPM servo motors w/absolute feedback and brake

2.2.1.10 One (1) Alpha 40/40/40 high voltage (HV) servo drive

2.2.1.11 Two (2) Fagor absolute linear scales for X and Y

2.2.1.12 One (1) Coolant pump

2.2.1.13 One (1) Hydraulic system (pump/tank/pressure reg/filter)

2.2.2 Mounting and wiring of equipment

2.2.3 Re-wire of machine where necessary

2.2.4 Replacement of worn damaged electrical equipment

2.2.5 Hardware and software engineering to allow the CNC to properly control the machine

2.2.6 Adapting and mounting new servos onto machine

2.2.7 Wiring of machine to the CNC

2.2.8 One complete set of drawing documentation which shall include (A001, Developmental

Design Drawings, Models and Associated Lists, DI-SESS-81002F)

2.2.8.1 B-Size wiring diagrams of the machine

2.2.8.2 Machine parameter source

2.2.8.3 Ladder source

2.2.9 One complete electronic set of commercial documentation (A002, Commercial Off-the Shelf Equipment Manual Requirement, DI-TMSS-80527C/T)

2.2.10 Nameplates. A nameplate shall be securely attached to each machine. The nameplate shall contain the information listed below.

• Nomenclature

• Manufacturer's name

• Manufacturer's model designation

• Manufacturer's serial number

• Power input (volts, total amps, phase, and frequency)

• Contract Number or Order Number

• National Stock Number or Plant Equipment Code

• Date of manufacture/Rebuild

2.2.11 Replacement Parts. All replacement parts shall be new and equal to or better than original parts. When a part requires replacement and an improved part has been developed as a replacement for the original part, the improved version shall be used.

2.2.12 Reutilization of Parts. All parts reutilized whether repaired or satisfactory without repair shall be in a condition to assure original part function and fit as well as original machine capabilities, performance, accuracies and life expectancy.

2.2.13 Safety. After the rebuild, all machine parts, components, mechanisms, and assemblies furnished on the vertical mills, whether or not specifically required herein, shall comply with all the requirements of OSHA 29 CFR 1910.

2.2.14 Warranty. All work to include labor, parts, etc. shall be warranted against defective workmanship for one year from the date of acceptance at Robins AFB by the contractor. Control components and replacement parts shall carry the standard Original Equipment Manufacturer (OEM) warranty and will be limited to the replacement of failed components. The Fanuc 0i shall have a standard 24 months parts warranty.

2.2.15 Machine Shipment/Delivery. The Contractor shall be responsible for shipment FOB Destination of the machine/components FROM Robins AFB to the Contractor’s facility and BACK to Robins AFB. Retrofit of the Fanuc 0i-MF Computer Numerical control to SIP Jig Bore is 12 weeks after Receipt of the Order. Delivery of the Rebuilt SIP Bore Spindle(SIP MP54, serial number 906, WR002518) is to be 4 weeks after receipt of order.

2.2.16 Acceptance. After all rebuild/retrofit work and services are complete the contractor shall perform a final run-off and functional test of the Jig Bore machine to ensure proper operation after integration at Robins AFB. The contractor shall demonstrate that machine is capable of producing a completed part that meets CMXG's specifications. The Government Representative listed in paragraph 4.1 will observe the functional test results. The contractor will coordinate the demonstration date with the Government point of contact.

2.2.17 Contact Information. The Contractor shall provide the Government Representative with contact information to include telephone number and email address. This information shall be provided to the Government Representative no later than five (5) calendar days after the contract period of performance start date.

3.0 GOVERNMENT FURNISHED PROPERTY AND SERVICES. The Government will provide the following property and services:

3.1 The Government will make the following Jig Bore machine available to the Contractor for rebuild/retrofit – specified parts are listed below:

Make Model Serial Number WR Asset Number

SIP MP54 906 WR002518

The following parts of the above asset will be shipped to the contractor as Government Furnished Property:

Electrical Cabinet – 1 each - no part or model number

Spindle – 1 each - no part or model number

Servos – 1 each – part number a8/4000HV ls

Pendant – 1 each - no part or model number

Hydraulic/Lube system – 1 each no part or model number

Coolant system – 1 each no part or model number

3.2 The Government will disconnect the Jig Bore machine for disassembly and transport of parts to the Contractor’s facility (transportation is FOB Destination) by the contractor and the Government will reconnect the machines upon completion of integration at Robins AFB.

3.3 The Government will provide the equipment and operator to load and unload the parts for Contractor transportation.

4.0 GENERAL INFORMATION.

4.1 The Contractor shall coordinate pick-up, delivery, and all Jig Bore machine rebuild/retrofit activities with the following Government Representative:

Name: Scott Mayfield

DODAAC: FB2065

Organization: 402 CMXG/MXDEB Bldg. Number: 140 Address: 455 First Street Robins AFB, GA 31098 Phone: 478-222-5282 Email: ronald.mayfield.2@us.af.mil

4.2 Access to Government Facilities. The Government Representative will ensure Contractor personnel are escorted by Government personnel at all times while the Contractor is working on Robins AFB. The Air Force has mandated visitors, to include all non-DOD cardholders, to consent to a check of their criminal history prior to being allowed access to installations. The check will be conducted at the Visitor Control Center (VCC) located by the Watson Boulevard Gate (main gate) to the base.

4.2.1 Contractor personnel will need a valid driver’s license or state-issued ID and a social security card, which will be checked by name, dates of birth and social security number.

Contractor personnel who wish to drive on base must present a valid driver’s license, vehicle registration, and proof of vehicle insurance.

4.3 Pick-up/Delivery Location and Hours of Operation. Jig Bore machine part pick-up and delivery shall be at building 140 on Robins AFB. Services shall be performed between the hours of 6:30 am and 3:00 pm (EST), Monday through Friday, excluding Federal holidays and Energy Days observed by Robins Air Force Base. Working any hours outside this period shall be coordinated with the Government Representative and approved by the Contracting Officer.

4.4 Security Requirements.

4.4.1 Security Clearance. The Contractor will not require a security clearance. Contractor personnel shall not be authorized access to classified and/or sensitive, but unclassified, information and/or materials or be permitted to work on classified and/or sensitive, but unclassified, projects and/or programs.

4.4.2 Access to Government Systems. The Contractor will not be granted access to any Government Systems.

mailto:ronald.mayfield.2@us.af.mil

4.4.3 Access to Government Facilities. The Contractor shall ensure Contractor personnel who require access to Robins AFB or other Government facilities comply with the security procedures of the facility.

4.4.4 Operations Security (OPSEC). The Contractor shall ensure Contractor personnel who perform work at Robins AFB or another Government facility comply with the OPSEC procedures of the facility.

4.4.5 Security Incident or Violation. The Contractor shall immediately notify the Government Security Office of any potential or actual security incidents or violations including potential or actual unauthorized disclosure or compromise of classified and/or sensitive, but unclassified, information.

4.5 Affirmative Procurement Programs (APP). In accordance with FAR 23.404(b)(1), 100% of purchases of Environmental Protection Agency (EPA)-designated products included in the Comprehensive Procurement Guidelines (CPG) list [https://www.epa.gov/smm/comprehensive-procurement-guideline-cpg-program] and/or United States Department of Agriculture (USDA)-designated products included in the bio-based product listings [http://www.biopreferred.gov] shall, at a minimum, meet the EPA or USDA standards for recovered materials or bio-based content, respectively, unless an item cannot be acquired competitively within a realistic timeframe, meet appropriate performance standards, and/or be acquired at a reasonable price.

4.5.1 In accordance with FAR 23.404(a)(iii), the Contractor shall provide estimates and verification of recovered material for EPA-designated CPG products and certification for both EPA-designated CPG products and USDA-designated bio-based products. In accordance with the Robins Air Force Base, Georgia / Green Procurement Program (GPP) Plan, the Contractor shall provide estimates and certifications to the Government for completion of the applicable attachment(s) to be included in the Purchase Request (PR) package.

4.6 Environmental Management System (EMS). Environmental Management Systems (EMS) Awareness Training: All Contractor personnel working on Robins AFB who perform activities on the installation are required to complete Air Force-provided initial EMS Awareness Training.

It is the responsibility of the Prime Contractor to ensure that all sub-Contractors, vendors, and employees complete this training prior to beginning work on Robins AFB. Notification of training completion shall be sent to both the Robins AFB Contracting Officer (CO) to be maintained in the contract file and Environmental Management, 78 CEG/CEIE, (78ceg.cev.FrontOfc@us.af.mil) for tracking purposes. Failure to provide documentation of EMS Training may result in termination of the contract.

4.6.1 EMS training is provided by Environmental Management at (478) 327-8104 or

(478) 926-9645. Contractors have two options to satisfy the mandatory EMS Awareness Training requirement. Contractors that do not have a Common Access Card must exercise Option 2.

4.6.2 Option 1 (Preferred Option): The Air Force version of EMS Awareness Training is available through the Advanced Distributed Learning Service (ADLS) website:

https://golearn.adls.af.mil/kc/rso/login/ADLS_login.asp. EMS Awareness Training is located under the miscellaneous tab. This option is only available to Contractors who have a CAC and takes approximately 10 minutes to complete.

4.6.3 Option 2: Contractor requests a copy of the Robins EMS Awareness Training Power Point Presentation from Environmental Management. The request should be sent to the Environment Management Workflow Box at the following email address, 78ceg.cev.FrontOfc@us.af.mil.

Once the presentation is received, the Contractor is responsible for ensuring that all his/her employees view the training.

4.7 Contractor’s Safety Requirement. The Air Force is part of the OSHA Voluntary Protection Program (VPP). All shall familiarize themselves with the requirements of VPP. Information on the VPP can be accessed at http://www.osha.gov/dcsp/vpp/index.html. Additionally, the Contractor is responsible for the safety and health of all contractor employees.

4.7.1 Safety and Health Plan. Within 10 calendar days after contract award, the Contractor shall provide a copy of their company Safety Plan that is required to ensure compliance with the Occupational Safety and Health Act (OSHA) (Public Law 91-596). The Safety Plan shall be provided to the Safety Office for review. The Safety Office will provide acceptance or non-acceptance within 5 working days of receipt to the Government point-of-contact who will notify the Contracting Officer (CO). (CDRL A003, Contractor’s Standard Operating Procedures, DI-SAFT-82080/T)

4.7.2 The Contractor Safety Plan shall address in detail the items listed in the Contract Appendix C, Part II through Part IV as applicable. For task specific procedures identified in the Contract Appendix C, the Contractor’s internal procedures for those tasks must be identifiable within the submitted Safety Plan or shall be provided in an amendment or addendum to the company’s Safety Plan. If task specific procedures identified in the Contract Appendix C, are not submitted with the Contractor’s Safety Plan, the submitted Safety Plan will be returned as NOT ACCEPTED. The Contractor will have five (5) working days to resubmit the Safety Plan, amendment or addendum to address or correct issues identified for non-acceptance. The Safety Office will provide acceptance or non-acceptance of the resubmission within five (5) workings days of receipt to the Government POC who will notify the CO.

4.7.3 Safety Mishap/Incident Reporting. The Contractor shall report all mishaps/incidents in accordance with the Contract Appendix C. The Contractor shall immediately secure the mishap scene, damaged property, and impound pertinent maintenance and training records until released by the Government’s Safety Office (78ABW/SE). Such release shall be accomplished through the CO. The Contractor shall cooperate and assist Government personnel in the investigation of the incident and submit an Accident/Incident Report within 24 hours of the accident/incident.

The Contractor shall require all subcontractors to comply with required safety, health and fire standards. (CDRL A003, Accident/Incident Report, DI-SAFT-81563 NOT 1/T)

5.0 APPENDICES. The documents below are relevant to this requirement. The Contractor shall be familiar with the following:

Publication Number Title Date Publication

Reference

29 CFR 1910 Occupational Safety and Health Standard (OSHA) 1 July 2013 In its entirety as applicable

NFPA 70 National Electric Code 2017 In its entirety as applicable