Vinyl Cutter SOW.pdf

STATEMENT OF WORK

(SOW)

For

AUTOMATED VINYL AND INSULATION PATTERN

CUTTING AND INKING SYSTEM

To Support

Fuels & Fabrication Accessories

552MXDRAB/MTCML

Tinker A.F.B., OK 73145

Date: 06 May 2011

INTRODUCTION

1.1. BACKGROUND

1.1.1. The textile and life support shop supports the KC135, E3, and B52 by manufacturing insulation panels. The current process requires manual cutting for the vinyl and fiberglass insulation layers. This is a project to purchase and install a new automated vinyl and insulation pattern cutting and inking machine for the shop.

1.2. SCOPE OF WORK

1.2.1. The Contractor shall furnish all engineering, plant, labor, tools, equipment, instrumentation, materials, supervision, transportation, and incidentals necessary to manufacture, install, verify, and service the automated vinyl and insulation pattern cutting and inking machine in building 229, Tinker AFB, OK, in accordance with this Statement of Work (SOW). The Contractor shall provide training in the operation and maintenance of the automated vinyl and insulation pattern cutting and inking machine. This equipment and training shall be used to cut insulation panels for fuels and fabrication accessories.

1.2.2. The Contractor shall be responsible for the complete effort; however, the government shall monitor and coordinate on Contractor activities throughout the project to assure compliance with requirements in a timely manner. No ordering of equipment or assembly shall commence without written coordination by the

Contracting Officer on the automated vinyl and insulation pattern cutting and inking machine, its installation, or applicable portion thereof.

1.3. BASIC REQUIREMENTS

1.3.1. The Contractor shall provide a high speed single ply or low ply static table cutting system capable of simultaneously cutting one layer of vinyl over one layer of 1 ¼” fiberglass insulation on continuous rolls. In addition, the system shall be capable of marking and cutting a single piece of the same vinyl material. After the two patterns have been cut, Tinker AFB employees will then match the vinyl and fiberglass cut pieces with the marked vinyl piece.

1.3.2. The vinyl product is a plain weave basic fiberglass cloth coated with plastic vinyl material with a cloth weight of 6.5 ounces per square yard minimum. The material is abrasion resistant, aromatic hydrocarbon fluid resistant, corrosion resistant, fire resistance, and waterproof. The material is supplied in 52 inch wide rolls.

1.3.3. The layers shall be held in place with a pneumatic vacuum system on a static table.

1.3.4. The system shall include a cutting head, basic tool package including cutting tools and maintenance tools, control cabinet, and integrated vacuum system.

1.3.5. The system shall be capable of marking a layer of vinyl utilizing an inking system, either pen holder-type (ball point pen or permanent marker) or spray ink. The pen holder shall be capable of annotating, drawing lines, and plotting files.

1.3.6. At a minimum, the system shall include an easily accessible safety switch for emergency shut off.

1.3.7. The contractor shall supply a computer control cabinet to house the Tinker Air

Force Base supplied computer, monitor, and peripherals.

1.4. MANUFACTURING REQUIREMENTS

1.4.1. The system shall be made in the USA.

1.4.2. No used or pre-owned equipment shall be allowed. New equipment is a requirement.

1.4.3. The successful bidder shall provide documentation that they have manufactured this type of equipment for at least five years.

1.4.4. The Contractor shall provide at least three customer references.

1.5. PROVIDED COMPONENTS

1.5.1. In order to comply with Tinker AFB LAN requirements, Tinker Air Force Base shall supply a computer, monitor, and peripherals for the automated vinyl and insulation pattern cutting and inking machine. The machine is loaded with

Windows 7 software and comes with a CD/DVD ROM drive. Tinker Air Force Base restricts the use of USB removable media devices such as memory sticks and external hard drives on Tinker AFB-owned computers.

1.5.2. Tinker AFB shall supply a forklift and operator to offload equipment and move it inside the shop. The forklift is rated for 4,850 pounds. The contractor shall be responsible for all moving of equipment and parts after the initial delivery and subsequent movement into place. If the Contractor requires equipment or forklifts with higher capacities than what forklift is available, then it shall be the

Contractor’s responsibility to provide said equipment and a forklift operator.

1.6. SYSTEM FEATURES AND ACCESSORIES

1.6.1. Dimensions: The table height of the system shall be 36 inches. The physical table size shall be six feet wide by twelve feet long. See attachment A for the selected location footprint of the system.

1.6.2. Effective/Addressable Cutting Area: The effective cutting width shall be no less than 70.5 inches, and the effective cutting length shall be no less than 96 inches.

1.6.3. The cutting surface shall be made of a smooth surface to ensure ease of positioning the fiberglass on the cutting surface.

1.6.4. Indexing: The system shall be able to re-index or re-align the cutting head using a laser light to compensate for parts longer than the effective cut length of the equipment. The process for re-indexing a part shall take no longer than three minutes to complete from the time the last cut was performed to the time the finishing cut begins.

1.6.5. Tool depth and pressure controls: The system shall include tool depth and pressure controls to avoid damage to tooling, controls, or the cutting table.

1.6.6. Accuracy: The system shall be accurate to within +/-0.076cm (0.030 inch).

1.6.7. Digitizer Accessory: The Contractor shall supply a means of converting cardboard patterns into digital drawings, the installation of such device, and two years of service and parts coverage on the device. A single digitizing device is required for both machines on these contracts, and shall be installed on a shared computer workstation utilized by operators of both the automated vinyl and insulation pattern cutting and inking machine and the automated carpet cutting machine.

1.6.8. Vacuum System: The vacuum system shall be at least 7.5HP with a low current start-up. The decibel level of the vacuum shall not exceed 81db. The Contractor shall include a pneumatic shut-off valve to disengage the vacuum.

1.6.9. The contractor shall supply an additional 50 cutting blades.

1.6.10. Nameplate - All words on indicating plates and on instruction plates shall be in the English language. Words shall be engraved, etched, embossed, or stamped in boldface letters on a contrasting background. The captions listed below may be shortened or abbreviated, provided the entry for each such caption is clear as to its identity. The nameplate shall contain the information listed below.

Nomenclature

Manufacturer’s name and contact information.

Manufacturer’s model designation

Manufacturer’s serial number

Power input (volts, total amperes, full load amperes, phase, frequency)

Date of Manufacture

Contract Number

1.7. UTILITIES REQUIREMENTS

1.7.1. Compressed air: Compressed 100 psig max air is located overhead. The

Contractor shall be responsible for any connections made from the system to the overhead compressed air connections, which includes but is not limited to, air hose and a blow off nozzle.

1.7.2. Electrical: The system shall require 208V, 3 phase. Any computer equipment shall require 110V, 1 phase, 60 Hz. The contractor shall provide all electrical connections to the system from the electrical panels including all necessary electrical panel breakers. All work shall be performed by a licensed electrical contractor. Tinker AFB will perform a final inspection on all electrical work performed by the contractor. The contractor shall be liable to make any changes required as a result of the final inspection results. The layout of the electrical panels and new equipment location is located in attachment A.

1.1.1.1. Equipment power pole wiring: The contractor shall provide two electrical conduit raceways to the equipment power pole, from the drop ceiling to the floor. At the power pole, the contractor shall install an electrical junction box with an emergency shut off control. The contractor shall install one each

120V-20A electrical quadplex down the inside of the power pole for a total of four receptacles at standard recep height. The contractor shall provide two circuits, one for each duplex receptacle.

1.1.1.2. Computer workstation power pole wiring: The contractor shall install one electrical conduit raceway to the computer workstation power pole, from the drop ceiling to the floor. The contractor shall install one each 120V-20A electrical quadplex down the inside of the power pole for a total of four receptacles at standard recep height. The contractor shall provide two circuits, one for each duplex receptacle.

1.1.1.3. As equipment and wiring vary from manufacturer, the contractor may modify the drop locations of the wiring plan in Attachment A with Tinker engineering’s advance approval.

1.1.2. Codes and Standards

1.1.2.1. In addition to the requirements of this specification, the electrical construction and all equipment and materials of construction shall be in conformance with the latest requirements of the following:

1.1.2.1.1. NFPA 70, National Electrical Code (NEC)

1.1.2.1.2. NEMA Standards

1.1.2.1.3. Insulated Power Cable Engineers Association (IPCEA)

1.1.2.1.4. Institute of Electrical and Electronics Engineers (IEEE) Standards

1.1.2.1.5. Instrumentation, Systems and Automation Society (ISA)

1.1.2.1.6. American Petroleum Institute (API) Recommended Practices

1.1.2.1.7. Any Federal Enforcing Authority

1.1.2.1.8. Where a conflict exists between any of the above codes or standards, the more stringent shall apply.

1.1.2.1.9. When listing is available, all equipment and materials of construction shall be listed for the intended service by Underwriters

Laboratories, Inc. (UL), or other Nationally Recognized Testing

Laboratory (NRTL) such as CSA, ETL, or FM.

1.1.3. Electrical Equipment

1.1.3.1. Material Criteria

1.1.3.1.1. All material shall be new.

1.1.3.1.2. Unless otherwise agreed the vendor shall select components for the package from approved manufacturers listed in a mutually acceptable equipment list.

1.1.3.1.3. Specific substitution of materials stated in this specification or data sheets shall be submitted to 76 CMXG/QI for approval.

1.1.3.2. Conduit and Fittings

1.1.3.2.1. All aluminum conduit and fittings shall be copper free (0.4% max.

copper) aluminum and shall be installed in a manner to be isolated from steel using appropriate non-corrosive materials.

1.1.3.2.2. PVC coated conduit shall have a minimum 40 mil thickness. All beam clamps and miscellaneous attachment hardware shall be PVC coated or otherwise designed to prevent damage to the PVC coating.

1.1.3.2.3. All Conduit bushings shall be of metal construction with a plastic insulating throat.

1.1.3.3. Wiring

1.1.3.3.1. All grounding wires and grounding bonding jumpers shall have green insulation.

1.1.3.3.2. An equipment grounding conductor shall be installed in all conduits containing power wiring.

1.2. SOFTWARE

1.2.1. All software shall have user interfaces in the English language.

1.2.2. The Contractor shall supply a CAD program and a program or programs that incorporate the supplied CAD program designs into tool path and manual and automated part nesting modules.

1.2.3. The nesting feature shall allow the user to drag and drop parts, pack parts tight together, rotate and flip parts, detect overlap, cut, copy, and paste parts, anchor parts in place, snap to a grid, and array and duplicate layouts.

1.2.4. The contractor shall supply a tool path program that allows the user to define different layers that correspond to separate cuts and annotations.

1.2.5. The user shall be able to change the sequence in which parts are cut, change the start points and cut direction, remove common lines, and preview how a job is programmed to cut beforehand.

1.2.6. The contractor shall supply one CAD program for both textile cutting machines on these contracts and shall be installed on a single shared computer workstation utilized by operators of both the automated vinyl and insulation pattern cutting and inking machine and the automated carpet cutting machine.

1.2.7. The contractor shall supply one copy of software for the tool path and manual and automated part nesting modules on the single shared computer workstation designated for of both the automated vinyl and insulation pattern cutting and inking machine and the automated carpet cutting machine. This is the same computer workstation referenced in 1.8.3.

1.2.8. The contractor shall supply one copy of software for the tool path and manual and automated part nesting modules on the computer workstation designated for the automated vinyl and insulation patter cutting machine.

1.2.9. The Contractor shall provide a minimum of one computer license for each instance of installed software with one year of support and licensing fees included.

1.2.10. The CAD/computer system shall have the ability to network with other computers via LAN connection through file sharing.

1.2.11. The CAD software shall be able to read, import, create, and export AutoCAD DXF drawings.

1.2.12. The software shall be capable of assigning notches, punches, and polylines to its own layer so that specific tooling with customizable parameters can be assigned to the layer.

1.2.13. The software supplied by the contractor shall be capable of constructing, saving, and deleting bills of material (BOM). A bill of material is a list of the raw materials, sub-assemblies, intermediate assemblies, sub-components, components, parts and the quantities of each needed to manufacture an end product. Each end item and the individual subassemblies are assigned a unique identifying number. The software shall allow the end user to enter an end item part number, and the automated vinyl and insulation pattern cutting and inking machine will cut all subassemblies listed under the bill of material entered. The software shall have the capability to allow the end user to easily remove any number of unneeded subassemblies from the bill of material on a temporary basis.

1.2.14. The equipment cutting software shall provide real-time operating parameters such as vacuum level and cut speed. In addition, it shall provide performance http://en.wikipedia.org/wiki/Product_(business) metrics such as how long the cutter was in operation during a shift, how many times or how long the cutter stopped, average cut speed, and total inches of cut product.

1.2.15. Any computer interfaces shall be Windows 7 or newer.

1.3. SHIPPING AND FREIGHT

1.3.1. FOB Destination included

1.4. INSTALLATION

1.4.1. The contractor is responsible for turn-key installation which includes, but is not limited to electrical wiring to the electrical panel, compressed air connections, and all installation technicians’ travel, accommodations, and living expenses.

1.5. TRAINING PLAN

1.5.1. The Contractor shall develop and provide a draft training plan and training program syllabus for training of operators, maintenance mechanics, AutoCAD designers, and engineers in the use and operation of the automated vinyl and insulation pattern cutting and inking machine and all associated support equipment and software provided under this contract.

1.5.2. The Contractor shall provide on-site individual training sessions for up to four machine operators, and two each: maintenance mechanics and AutoCAD designers, in accordance with the contractor developed training plan. The training shall begin within seven days after the successful install and start-up of the automated vinyl and insulation pattern cutting and inking machine. All training for operators and maintenance technicians and/or mechanics shall be performed on-site at Tinker Air Force Base during normal business hours from 0700 to 1600 hours.

1.5.3. Operator training shall include, but not be limited to the system overview, basic system operation, and software usage. Two operators shall receive additional training on CAD part design. Training shall last a minimum of two days.

1.5.4. Maintenance technician training shall include, but not be limited to basic system operation, troubleshooting and repair, machine calibration, and daily, weekly, monthly, and annual maintenance checks. Training shall last a minimum of three days.

1.6. MANUAL

1.6.1. The Contractor shall develop and provide a new manual in the English language for the automated vinyl and insulation pattern cutting and inking machine. The manual shall have separate sections that include Operation Instructions, Programming Instructions, Calibration Instructions, and Maintenance Instructions.

The Contractor shall present the manual in a standard format of their choosing as dictated by their own protocols. The Contractor shall provide two hard copies of the manual and one electronic copy of the manuals no later than seven calendar days prior to delivery of the system. The Contractor shall provide the electronic copies of these manuals in Microsoft Word version 2007 or later.

1.6.2. Operation Instructions - The Contractor shall provide a complete set of instructions in the English language on the operation of the individual controls for each equipment item on the automated vinyl and insulation pattern cutting and inking machine. The instructions shall include operation of the software and controls.

1.6.3. Programming Instructions - The contractor shall provide commercial manuals in the English language for all software provided. The Contractor shall provide legal licensed copies of all software utilized in the automated vinyl and insulation pattern cutting and inking machine. The Contractor shall provide one electronic backup copy of all programmed software.

1.6.4. Maintenance Instructions - The Contractor shall provide a complete list of materials and description, including manufacturer and model number, for all components utilized in the automated vinyl and insulation pattern cutting and inking machine in the English language. The list shall also include an original equipment manufacturer source for all materials and parts. Drawings shall show applicable schematic diagrams and equipment layout.

1.7. WARRANTY

1.7.1. The contractor shall provide a minimum of a full one year warranty which shall begin once the automated vinyl and insulation pattern cutting and inking machine is fully installed and operational. The warranty shall cover all non-consumable materials and workmanship.

1.7.2. All repairs covered under the warranty shall include all transportation, labor, and material costs.

1.7.3. The Contractor shall respond to all warranty issues within 3 business days of notification from a Tinker Air Force Base representative.

1.7.4. The Contractor shall provide unlimited telephone and email technical support.

1.8. PROJECT MANAGEMENT

1.8.1. Program Management - The Contractor shall establish a single management focal point and maintain a supporting program management system tailored to accomplish administrative, management, and technical requirements of this contract.

1.8.2. Contractor Personnel - The Contractor shall provide the name of the Project

Manager and any alternate(s) who shall act for the Contractor when the manager is absent in writing to the Contracting Officer within 5 calendar days after contract award. The Contractor shall provide telephone numbers for Contract Manager and alternate(s) where these persons may be contacted at any time. The Contract

Manager or alternate shall have full authority to act for the Contractor on all matters relating to operation of this contract at Tinker AFB. The Contract Manager or alternate shall be available to discuss problem areas with Government Project

Manager/personnel designated by the Contacting Officer. The Contractor shall provide a Contract Manager who can read, write, speak, and understand English fluently.

1.8.3. Terms and Conditions - The Contractor shall provide a written list of all exceptions to any terms, requirements or specifications contained in this SOW to the Contracting Officer with the submission of their bid proposal. The Contracting

Officer shall provide written approval or disapproval for these exceptions prior to contract award.

1.9. PROJECT CONTACTS

1.9.1. Note: WAWF Acceptor BPN: F3YCFH

Ship to following address:

Attn: Robyn Miller

Arnold Ave & D Ave, Building 229

Tinker AFB, OK 73145

Alternate: David McElrath