2015-582-4934-01_Statement_of_Work.docx

SOW 2015-582-4934-01 USAF AFMC 76 CMXG

76th Commodities Maintenance Engineering Group Oklahoma City Air Logistics Center Tinker Air Force Base

Statement of Work For Sheet Metal Guillotine Machine

SOW 2015-582-4934-01

September 2014 Version 2 Caution: This document may contain competitive, sensitive or other non-public information not intended for disclosure outside official government channels. Do not disseminate without the prior approval of the Office of the Assistant Secretary of the Air Force for Acquisition. No commitment of business related activity shall be interpreted because only a contracting officer can obligate the Government. If you are a recipient through error, please notify the sender and delete all copies of this document.

No classified data is contained herein.

Contents

Applicable Documents The following documents are referenced within this SOW. The latest revision at the date of this SOW is applicable.

GOVERNMENT REGULATIONS

OC-ALC Instruction 32-101 Air Quality Record Keeping Procedures

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

OTHER STANDARDS

NOTE: The Contractor shall follow all regulations, acts, laws and standards listed in this document and any additional Appendices.

Abbreviations and Acronyms.

(Latin exempli gratia)

Scope and Purpose General This SOW describes the design, manufacture and installation of a sheet metal production line herein referred to as the Guillotine Machine. The production work involves cutting rectangular shaped parts from a roll of sheet metal. The production line will be made up of three (3) distinct machines:

· Drive for a Roll of Sheet Metal

· Straightener Machine

· Cutoff Machine Machine power can be pneumatic, mechanical, electrical, or a combination of these. A general layout of the Guillotine Machine is shown in the figure below and is provided for conceptual purposes only. Actual configuration of the machines, controls, displays, etc. shall be determined by the Contractor and approved by the Government.

Figure 1: General Layout of Guillotine Machine The raw material may vary in material and thickness as shown in the following table.

Thickness

Table 1 – Material and Thickness Also included within this SOW are requirements for:

· Material carts (for handling sheet metal in roll form).

· Service manual documents.

· Warranty conditions.

Mechanical The Guillotine Machine shall be capable of producing parts at a rate of about 60 per minute.

Machines (excluding material carts) shall be supplied with steel mounting pads in order to properly distribute weight onto concrete shop floor.

Metal selection for the construction of the sheet metal guillotine machine shall comply with the requirements of MIL-STD-889.

Material Cart and Drive The Contractor shall supply three (3) material carts for handling rolled sheet metal. These carts shall be equipped with a 20” dia. mandrel (or spindle) upon which the sheet metal will wind. The carts shall be equipped with lockable wheels (or casters) suitable for being moved along a concrete shop floor. The carts shall be of sufficient width and length so as to prevent them from tipping over during normal use. The maximum size and weight of a sheet metal roll is shown in the following figure below.

Figure 2: Max. Size of a Sheet Roll Positioned on a Cart A means shall be provided for aligning the material cart into feeding position next to the straightening machine and locking (or holding) into proper alignment. A dedicated drive shall be provided to feed the sheet metal into the straightener machine at the required rate.

Straightener Machine The straightener machine shall be equipped with a dedicated feed mechanism and shall not be permitted to actively pull material from the sheet metal roll. The straightener machine shall be adjustable to match the requirements for varying materials and thicknesses. The sheet metal shall not change dimensional thickness as a result of passing through the straightener.

Cutoff Machine The cutoff machine shall employ upper and lower shear blades with an adjustable blade gap in order to enable cutting of different material thicknesses with a reduced edge burr.

Shear blade gap adjustments shall be made by bringing the lower blade to and from the cut zone. The cutoff machine shall automatically adjust the blade gap to match the Operator commanded settings.

Cutoff motion shall be made by the upper blade coming downward in a guillotine fashion.

The upper blade of the cutoff machine may have a fixed shear angle in order to improve cutting efficiency. Contractor shall determine the optimal shear angle. (See figure below.)

Cutoff machine shall be able to detect misalignment of material and report the condition to a display. Alignment of cut shall be +/- 0.1° along the edge. Contractor shall determine best method to remedy blade misalignment; manual gib adjustment, though not desirable, is acceptable to resolve misalignment of cut.

Edge burr (or edge deformation) shall be no greater than 0.001 inch along the cut edge.

Overall part lengths shall be cut to within +/- 0.025 inch tolerance.

The cutoff machine shall be equipped with a dedicated feed mechanism and shall not be permitted to actively pull material from the straightener machine.

Figure 3: Blades of the Cutoff Machine Electrical The electrical and control systems shall conform to NEMA ICS 1 Industrial Control and Systems General Requirements.

Power Feed Electrical and pneumatic power will be provided within 25’ of the Guillotine Machine. The Guillotine Machine shall use the power source available. Available voltages are 480VAC, 208VAC and 120VAC. Any necessary electrical transformers are to be included with the machine. Pneumatic power is available at a pressure of 80-120 psig with almost no limit on volume. Contractor shall provide a regulator, filter/dryer, lubricator at the front of any pneumatic system.

Grounding The entire machine line shall have a single point grounding stud 5/8" diameter or larger. The resistance between the grounding stud and all other exposed metallic parts shall not exceed 2.0 Ω. The grounding requirement shall be clearly indicated on the electrical schematic.

Electrical Enclosure The Contractor shall provide a NEMA type 6 electrical enclosure to contain electrical switches, contactors, control devices, etc. Refer to NEMA 250 Enclosures for Electrical Equipment.

Electrical Conduit The Contractor shall utilize PVC coated galvanized rigid conduit and all fittings with green urethane interior coating. The PVC coated galvanized rigid conduit shall meet the UL listed standard 6. This material shall be used in general electrical runs.

The Contractor shall utilize Carflex® Liquidtight Flexible (by Carlon) conduit and fittings where applicable. Contractor may use a superior flexible conduit and/or fittings by showing product superiority to the Government. Flexible conduit shall be type LFNC-B as specified in article 356 of NEC, compliant with UL 1660 and NFPA 79-1985, paragraph 15-6. Flexible conduit shall be UL listed as: outdoor use, nonconductive, noncorrosive, crush resistant, abrasion resistant and strain resistant.

Controls and Sensors Mounted at the Operator’s location shall be an “E-Stop” push button (pull to reset) and illuminated “Power On” push button.

A backup battery shall be provided to provide power to the PLC during temporary power losses in the facility for a minimum of 30 minutes. Machine control wiring shall be run in conduit to the PLC.

· All electrical, electronics, and controls shall conform to the National Electric Code (NEC) a.k.a. NFPA 70.

· All controls shall be interfaced with the PLC; i.e. no stand-alone control circuits.

· PLC shall provide system status and fault information.

· System shall be capable to sense, track, and adjust the speed of the sheet metal from roll feed to finished part.

· System and program to automatically adjust machine settings based on type, thickness, length of parts. System shall be installed with an audio and visual alarm which alerts personnel when limits are being approached and when any fault limits are exceeded.

During an emergency (such as power outages or emergency stops) all devices shall stop. Machine failure modes shall be identified in the manuals, training, drawings, and schematics to the Government. The Contractor shall supply surge protection for all equipment.

Figure 4: Machine Functions Require Sync Main Disconnect The Contractor shall provide a master shutoff switch for the machine. It shall be a labeled electric power disconnect switch located about 4 feet above the floor near the electrical/control panel. Actual location of the master switch shall be coordinated with the Government. All electrically powered components of the machine shall be controlled by the main disconnect.

Human Machine Interface The Contractor shall provide a Human Machine Interface (HMI) that includes the following:

· Touch Screen

· Programmable Logic Controller (PLC)

· Software The Contractor shall decide how to mount, support, and locate the HMI in order to achieve best performance.

Touch Screen Contractor shall provide a Touch Screen that is suitable for shop use. The screen and enclosure shall be durable against manufacturing oils, common cleaning solvents, dirt, and vibration.

Programmable Logic Controller The PLC shall comply with the requirements of IEC 61131.

Software The software shall consist of a base program that is secure (locked) from being altered on the shop floor. The base program shall provide data fields to the Touch Screen for the Operator to enter parameters for production run(s).

e.g.: material type, material thickness, length of material cutoff, etc.

These parameters (and other parameters as deemed necessary by the Contractor) shall be save-able within the PLC under “Operator-determined” file name(s). These files shall be capable of being retrieved by the Operator and shall not require the Operator to re-enter “already-supplied” parameters.

Safety System Safety The Contractor shall design the machine to meet the following safety requirements:

All rotating components, pulleys, belt(s), chain drives, and other hazardous parts not protected by a safeguarding device, as specified in AFOSH 91-501, paragraph 18.4.2.13, shall be guarded per AFOSH 91-501, paragraph 18.4.2.14 Switches/controls for shutting the machine down shall be readily accessible to the Operator Electrical components shall be insulated or enclosed (electrical conduit).

When possible, equipment and components which are “fail safe” shall be selected and supplied. When “fail safe” devices are not possible, Operator shall be protected against hazard(s) as specified in AFOSH 91-501, paragraph 18.4.2.14 Safety design feature shall prevent the upper blade from colliding with the lower blade due to over-adjustment of the lower blade. i.e.: not enough gap between blades.

Each component shall be designed such that a fault or failure does not trigger an unsafe condition or series of other failures.

Interface sensors/proximity switches shall detect presence of Operator(s) at location of moving parts in order to prevent injury.

Where possible the machine shall be designed to dissipate stored energy in instances of lost power or utility outage.

Protect workers from shock and arc flash hazards per NFPA 70E Standard for Electrical Safety in the Workplace The Contractor shall design the machine so that during a utility outage all power connections fail in the closed/off position. The Contractor shall identify these control devices on the schematics. After an outage (when power is regained) the machine shall not run or restart without Operator command.

The machine must be Lockout/Tagout (LOTO) capable for maintenance and repair as specified in 29 CFR 1910.47. Refer to Control of Hazardous Energy at the following website:

https://www.osha.gov/SLTC/controlhazardousenergy/ Signage The Contractor shall provide signage warning of hazard(s), moving machine components, and other safety materials. All safety signage on the machine shall be yellow (or yellow and black) in color.

Noise Levels The Contractor shall take necessary steps to ensure that that the Guillotine Machine does not exceed 85 dB with all motors and mechanisms running and functioning in compliance with AFOSH 48-20, paragraphs 2.6 and 2.11.

Human Factors Human engineering design factors as applicable and as detailed in MIL-STD-1472 Design Criteria Human Engineering shall be considered in the design of the Guillotine Machine and/or in selection of individual components.

Environmental Protection and Occupational Safety The Contractor shall be knowledgeable of and comply with all applicable federal, state and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health. The Contractor shall comply with any laws, instructions or regulation changes during the term of this contract.

Hazardous Material (HAZMAT) If no HAZMAT will be brought on base or used in performance on this contract, the contractor shall certify “No HAZMAT will be brought on base” or “No HAZMAT Usage” in writing on company letterhead. This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the certification, the requirements of this section no longer applies. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall not store chemicals or hazardous material (HAZMAT) on Tinker AFB. Contractors shall be compliant with HAZMAT management procedures per Oklahoma City Air Logistics Complex (OC-ALC) Supplement to AFI 32-7086, “Hazardous Materials Management”. The Contractor shall maintain a log of all HAZMAT that is used on base. This usage log shall be provided to the COR monthly, the last business day of each month, or when the required work is completed. The COR will forward the records to the Unit Environmental Coordinator (UEC) no later than the fourth (4th) day of the following month or the first (1st) subsequent business day.

Material Safety Data Sheet/Safety Data Sheet (MSDS/SDS) Upon COR receipt of the “No HAZMAT Usage” certification, the requirements of this section no longer applies.

The Contractor shall not transport, ship or use any chemical, material or substance used in the performance of this SOW on Tinker AFB before written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The Contractor shall submit to the COR, ten (10) calendar days after contract award date all Material Safety Data Sheets (MSDSs) or Safety Data Sheets (SDSs) and a completed OC-ALC Form 152, MSDS/SDS Information Sheet. The Contractor shall receive approval from the COR prior to shipping any chemical, material or substance to Tinker AFB. A copy of the manufacturer MSDS/SDS shall accompany the shipment. Contractor shall comply with the effective dates for SDS requirements IAW the Occupational Safety and Health Administrations (OSHA) Hazardous Communication Standard, Title 29, Code of Federal Regulation (CFR) Part 1910.1200. The COR will forward all MSDS/SDS submittals to 72 ABW/CEIE for approval. A current manufacturer MSDS/SDS shall be submitted to the COR if the Contractor changes manufacturer or vendor for any chemicals that were prior approved. The Contractor shall maintain copies of manufacturer MSDSs/SDSs for all chemicals and MSDSs/SDSs shall be readily accessible at all times by Contractor personnel as well as government employees.

Hazardous Waste If no HAZWASTE will be generated during performance of this contract, the contractor shall certify “NO Hazardous Waste Generation” in writing on company letterhead. This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer applies. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall dispose of contaminated solid waste, spent or processed chemical solutions, used rags and hazardous waste in government furnished waste containers located in the shop or area the work is being performed. The Contractor shall notify the COR if the required waste containers are not available on site.

Discharges Any discharges into Tinker’s Industrial Waste Treatment Plant (IWTP) or sanitary sewer will be approved and done IAW Tinker Industrial Waste Water Discharge Permit as instructed by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The COR will submit the required notice of intent documentation to the UEC for 72 ABW/CEIE approval. The Contractor shall maintain records of written approval issued by 72 ABW/CEIE for discharges into IWTP and sanitary sewer.

Off-Site Discharges For discharges outside of Tinker AFB, the Contractor shall ensure waste water discharges, that may contain pollutants resulting from any contracted service, go to a state or federal permitted treatment facility such as a municipal Publicly Owned Treatment Works (POTW). The Contractor shall provide a letter ten (10) calendar days after contract award date to the COR from the POTW that states the POTW is permitted for all pollutants that the Contractor may discharge during the contracted service.

Environmental Training Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer applies.

Contractor personnel performing duties in the service of this SOW shall have training that acquaints the person with the details of Resource Conservation Recovery Act (RCRA) regulations in 40 CFR 260 through 279; applicable State Laws and regulations; DoD, Air Force and local requirements. This training can be obtained through creditable training institutions or companies. All training shall be approved by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). RCRA training is available at http://www.natlenvtrainers.com/RCRA-hazardous-waste.htm; http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000, and http://www.lion.com/Storing-Hazardous-Waste-for-LQGs at the Contractor’s expense. Prior to obtaining training, the Contractor shall provide the name of the training institution or company and course description to the COR for approval within ten (10) calendar days after contract award date. Once written approval is received from the COR, the Contractor shall provide the environmental training certificates for employees performing duties in the service of this SOW to the COR, within thirty (30) calendar days after contract award date. In addition to the required environmental training, Contractors shall be compliant with Tinker AFB procedures per TAFBI 32-7004, “Hazardous Waste Management”.

Quality Standards of Manufacturing Off-the-shelf components of the machine shall be of the manufacturer’s latest applicable, proven design, new and unused.

Machine(s) shall be fabricated by same manufacturer or provided by single-point Contractor. Single-point Contractor shall be responsible for integration of designs and elimination of potential dimensional discrepancies Quality Assurance Contractor shall have an active QA program at their manufacturing facility. QA data that is relative to the nominal operation of the Guillotine Machine shall be made available for Government review. Such QA data includes inspection records, quality corrective actions & functional testing records.

Daily Clean Up (Installation) Contractor shall be responsible for daily and final project clean-up of all associated areas. These areas include but are not limited to: interior work site, utilized road way, utilized facility aisles, utilized ramps and outside area. All generated debris, waste materials, trash shall be swept up and removed. All chemicals shall be removed from job site each day or stored in HazMat cabinets. If stored onsite, Contractor must coordinate volumes and location with the Government in order to keep production building within compliance of HazMat and fire regulations. The Contractor shall be aware that the construction area is a FOD control area; the Contractor is responsible to perform FOD walks (i.e. inspections) of the construction area to eliminate FOD. The Contractor is responsible for the disposal and removal off all trash from the job site. Contractor may place a dumpster on site (location shall be coordinated with the Government) in order to accomplish this. The area shall be cleaned prior to the Contractor leaving the job site each day.

Technical Interchange Meeting Prior to delivery, Contractor shall attend a one (1) day TIM at TAFB with the following objectives:

a. Review the proposed schedule that is provided in Appendix A and attach dates to major events.

b. Verify compliance with this SOW

c. Tour physical location for the Guillotine Machine within production building

d. Identify utility provisions (i.e. electrical and pneumatic drops)

e. Review machine footprint & floor loading against production building allowable

f. Identification of obstacles, constraints, preferences Maintenance Repair and Maintenance The Contractor shall design the Guillotine Machine so that all mechanical and electrical devices are accessible for maintenance.

The machine shall be maintenance capable with consideration of NFPA 70B Recommended Practice for Electrical Equipment Maintenance.

An electrical schematic shall be attached to the inside of the electrical panel with all components labeled and identified.

Electrical/Control panel(s) shall be lockable.

Cutoff machine shall provide for ease of blade change-out with a minimal amount of disassembly. Contractor shall provide two (2) additional sets of blades with the machine.

Manuals and Drawings The Contractor shall provide all OEM manuals for subcomponents.

Installation, Operator’s, and Maintenance manuals shall be written by the Contractor and provided to the Government in both electronic and paper format. The electronic manuals shall be provided in .doc or .pdf format, copied onto CD(s), and provided to the Government.

All printed manuals shall be bounded or placed in 3 ring binder(s). Manuals shall be written in the English language and shall include as a minimum the following provisions:

Installation Manual The Installation Manual shall include:

Operator’s Manual Operator’s Manual shall include:

Maintenance Manual Maintenance Manual shall include:

Software and Program The Contractor shall provide the operational, system, and technical architecture of the software program. The controller shall be programmed and configured to provide all logic control necessary for automatic operation, sequencing, and safety interlocks. The Contractor shall provide back-up software. Copies of all operation and diagnostic software used on the machine shall be provided to enable TAFB to reload all programming data. Operating systems, utilities, source codes shall be provided as necessary with replication rights and modification rights. Successful demonstration of the program shall be accomplished and the programming shall be “bug” free, if a “bug” or “bugs” are found the Contractor shall make the corrections and retest to ensure compliance at no additional cost to the Government.

Unlimited Rights The Contractor shall provide the Government unlimited full rights to all drawings, schematics, calculations, replication, manuals, program, software, and any other applicable documents and designs to this machine. This includes but is not limited to replication rights. “Contractor providing unlimited full rights” shall mean the Government owns the rights to all drawings, schematics, calculations, replication, manuals, program, software, and any other applicable documents and designs to this machine. The Contractor shall provide a written document stating that the Government owns all right to the drawings, schematics, calculations, replication, manuals, program, software, and any other applicable documents produced for or in used in conjunction with this machine.

Final Acceptance Delivery The Contractor shall provide for packaging, lading, and shipping of all machine parts, components and material to TAFB, production building. i.e. FOB Destination, Freight Prepaid.

A detailed Bill of Lading shall be included with the shipment for the purpose of the carrier transferring ownership of the kits to the Government.

A Packing Slip shall be included with the shipment for the purpose of verifying the completeness of each container and to ensure that no components have been separated or lost.

Any items requiring special handling to prevent damage shall be properly labelled. Instructions shall be provided so as to prevent damage to the items through improper unpacking, handling, care, use. i.e. “CAREFUL! DO NOT CRUSH. Lay flat for storage.”

The Contractor shall be responsible for offloading all equipment when it is onsite.

Installation Contractor is responsible for moving equipment into position and providing a complete installation of the Guillotine Machine.

Performance Test After installation, the Contractor shall apply power and perform a checkout of the Guillotine Machine. If necessary, the Contractor shall make changes to achieve correct performance of the machine at no additional cost to the Government. The Contractor shall demonstrate to the Government that the machine is fully functional. As a part of the performance test, the Contractor shall simulate machine failures to demonstrate the proper operation of all safety devices and controls. The Contractor shall demonstrate the full functionality of software within the machine. Failure of machine to pass any portion of the performance test shall be cause for rejection.

In the event of a failure or noncompliance with this SOW, the Contractor shall be responsible for all machine modifications and additional performance testing at the Contractor’s expense until the requirements of this SOW are met. Once completed, TAFB will provide Contractor with a signed letter of record stating the successful completion of the performance test.

Training Contractor shall provide a training class to TAFB personnel. Length of the training session is expected to be a minimum of (4) to (8) hours and shall cover the contents of the Operator’s Manual with emphasis on the following:

· Safety practices.

· Maintaining quality and accuracy

· How to maximize productivity.

· Maintenance and calibration.

Size of the class will be between (6) and (10) people and will take place at TAFB during regular business hours.

Deliverables Remittance will be made to the Contractor after all deliverables have been documented as completed, received, and approved.

List of Deliverables

Note: Software is included within the Maintenance Manual.

Warranty The Contractor shall provide a document to TAFB that warrants the Guillotine Machine, any special tools (if applicable), software, manuals and workmanship to be free of defects for a period of (1) year after acceptance.

The Contractor shall be notified of defects by the Government in writing. The Contractor shall respond via phone or e-mail within 12 hours to all reported problems. The Contractor shall have personnel onsite to further define and remedy the issue within 72 hours. The Contractor shall obtain a TAFB gate permit and comply with all base policies. The Contractor’s personnel shall troubleshoot the machine and determine the exact cause of the issue. Once the issue has been determined, the Contractor shall submit in writing the root cause and proposed solution. The Government reserves the right to accept or deny the corrective action.

The Contractor shall provide all labor, materials, and incidentals to correct the issue back to a fully function system. Defects and service call shall be resolved at no cost to the Government within 10 calendar days. If issue causes a change to equipment or the way the system works, the Contractor shall provide updated manuals, as built drawings, Bill of Materials, software modifications, calibration data, training, and any other deliverables reflecting any and all changes. Contractor shall be responsible for correcting any found defect or inconsistency with this SOW to the Government’s satisfaction at no cost to the Government. If the defect or inconsistency persists beyond the 365 calendar day period, the Contractor shall still be responsible for corrective action until the issue is rectified.

All equipment will be subject to usage 24 hours a day, 7 days a week. Warranty shall start after all deliverables have been accepted. All materials and labor for corrective action, modifications, and defects shall be supplied by the Contractor, including a tracking number and carrier emailed to the government POC. The period of performance for this contract shall include the one (1) year warranty. The Contractor shall be liable to pay damages to the Government if the issues are not resolved in a timely manner, times are stated above.

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