Redacted_JA_Fanuc_Upgrade_14851.pdf

COORDINATION AND APPROVAL DOCUMENT

(also known as Justification Review Document)

CONTRACTING ACTIVITY: AFSC/PZIMC

PROGRAM/PROJECT: OC14851 CNC Upgrade AUTHORITY: 10 USC 2304(c)(1), as implemented by FAR 6.302-1(a)(2)

ESTIMATED CONTRACT COST:

TYPE J&A: (class or individual) Individual

JUSTIFICATION FOR OTHER THAN FULL AND OPEN COMPETITION

I. CONTRACTING ACTIVITY

U.S. Air Force

AFSC/PZIMC

3001 Staff Drive

Tinker AFB, OK 73145-9105

This Justification and Approval to request authority for Other Than Full and Open Competi-tion supports requirements generated for the Defense Logistics Agency, VI-IPE. The con-tracting authority for this is Defense Logistics Agency (DLA), VI-IPE. The purchase request number supporting this contracting action is M952.

II. NATURE AND/OR DESCRIPTION OF ACTION BEING PROCESSED

The Propulsion Maintenance Groups (PMXG) at Tinker AFB, OK requires a new sole source contract with Progressive Surface Technologies so that the CNC and its associated electronic components, including the controllers, servo drives, motors, and cables be retrofitted on the shotpeening CNC system. The CNC is required to interface with the current shotpeening system as well as the PLC.

The original system purchased for $0.00 in FY 02 was manufactured by Progressive surface.

The replacement CNC has the same requirement to communicate ladder logic between the shotpeening system, and the PLC. The current PLC contains PRIMS TM and Saturation Curve Software TM which is used to monitor and control the shotpeening parameters. All the pro-grams stored in the current PLC must be converted to interface. Updating the PLC requires converting the programs from the current software to new process monitoring software. The current CNC is controlled by Allen Bradley components which are now only being supported by purchasing refurbished parts.

Upgrading the CNC and its related components is critical to the proper operation of the shot-peening machine. When components on the CNC wear out they have to be replaced with re-furbished parts which are sometimes incompatible with the system and must be modified. It is necessary to upgrade this system to be one which is both reliable and supportable and for which new components can easily be obtained. If system failure occurs, a major delay in pro-cessing engine parts will occur due to the length of time it takes to obtain refurbished compo-nents. The new components must be compatible with current blast system components.

This activity will award a firm-fixed price (FFP), commercial “M” type contract to purchase the controller from Progressive Surface (Cage Code 06EH8). This is an Individual type of J&A.

The contract estimated award date is 7 months after the contract is awarded.

III. DESCRIPTION OF SUPPLIES/SERVICES REQUIRED TO MEET THE

AGENCY’S NEEDS

The equipment requirement is to upgrade the CNC controller, motors, servo drives, thermo-statically controlled air conditioner, and associated PLC, touch screen monitor, program con-versions, program software, and control panel, on the shot peen system. The system will also be shipped and installed onto our existing equipment. This system is used to precisely control critical shot peening parameters per industry standards purchased through CPP FY02. The current Allen Bradley CNC system is deteriorating and new replacement parts are no longer available to support it, resulting in lengthy downtimes and resorting to replacing them with re-furbished parts, which are difficult to obtain and configure with the existing equipment.

The CNC precisely positions the nozzle and the shot flow and air pressure parameters. It is used in conjunction with the motors and servo drives to control the robot. The equipment needs to be upgraded to supportable Fanuc 31iA servo motors and drives for the four robot axes, (X, Z, A, and B) and the spindle axis C, to ensure reliability of the equipment. It must also have a handy machine operator’s panel (teach pendant). It must also conform to RS-274 format for compatibility with existing programs. It also will require having a thermostatically controlled air conditioner to ensure consistent operation of electronic components. It must al-so have a separate teach pendant for creating programs and testing operation. This system is used to control the precise manipulation of the robot points and shotpeening parameters.

Therefore when the components are inoperable the entire process ceases. This equipment needs upgrading to prevent future breakdown of the machine.

The PLC is used to create, select, and monitor the programs which are then transferred to the CNC to peen the part. The PLC must be compatible with the new CNC components and should be updated to ensure latest technology iteration opportunities are maintained for this system. PRIMS® software is used on the PLC to interface with the user and develop pro-grams for peening parts exclusive use of this software minimizes the opportunity for single point failures due to compatibility between equipment and transferability between software.

Use of any other software would greatly increase the overall lifecycle acquisition cost of main-taining the equipment in production, and developing solutions for future repairs. Additionally the current programs on the machine would have to be transferred to the new system to re-duce the downtime of this upgrade affecting production. An industrial grade touch screen monitor that is mounted on an adjustable suspension arm with an industrial grade keyboard needs to be included as well for both operator use and for adding programs.

This upgrade will ensure that the machine has both reliability and reparability to minimize down time of the machine. It will also include updated drawings and manuals to allow for maintenance and serviceability on the machine. Progressive Surface is the original Equip-ment manufacturer and is the responsible source for programing the ladder logic necessary to allow the PLC to communicate with the CNC. They own the ladder logic used to ensure that the programs already in place will work with the new system, as well as the software used to operate the shotpeening machine.

CLIN Detail Quantity

CNC, PLC, Software, and Program Conver-sions, to include hardware, software, Manu-als/Drawings, shipping, removal, installa-tion, start-up, training, and calibration.

IV. STATUTORY AUTHORITY PERMITTING OTHER THAN FULL AND OPEN

COMPETITION

10 USC 2304 (c), as implemented by 6.302-1 (a) (2) (ii) (A) FAR 6.302-1 (b) (2). The approval level for this J&A is the Contracting Officer.

V. DEMONSTRATION THAT THE CONTRACT’S UNIQUE

QUALIFICATIONS OR NATURE OF THE ACQUISITION REQUIRES THE USE OF

THE AUTHORITY CITED ABOVE (APPLICABILITY OF AUTHORITY)

a) The original equipment which included the entire Shotpeen machine, not just the CNC and PLC components was purchased for $460,930.00 in FY 02 was manufactured by Progressive Surface. It is used to support the F100 core facility for PMXG. The ma-chine has a five robot axis system including the spindle axis as well as dual media ca-pabilities, for peening with a wide range of intensities. The current CNC and PLC sys-tem is similar to the many of the other shotpeening machines that use the same media and have some of the same capabilities and interfaces with the user using PRIMS® software. Due to this software, program transfer between shotpeening machines can be accomplished in the minimum amount of time due to similarity between systems.

Additionally having an entirely new system interface would require implementing an additional level of 20hrs of OJT every time a currently trained operator needs to work on that machine, despite its fundamental similarity to many of the other shotpeening machines. Therefore even if any other company was able to transfer the existing pro-grams from the current system to the new system it would not be in the government’s interest to use any other shotpeening user interface. PRIMS® software is used as the system interface for all of the CCW automatic shotpeening machines. Without this user interface all future process redundancy to prevent complete work stoppage will be se-verely retarded by having a user interface which is so much different from the other automatic shotpeening systems. This will ultimately lead to an increase in flow days, machine down time, and single point failure opportunities for the F100 core facility.

b) Progressive Surface is the only company who can provide the PRIMS® software to al-low the interface between programing the CNC and the PLC. They own the rights to that software and have asserted that no third party vendors would be granted permis-sions to install it on the PLC. They already have software developed to transfer the programs from the Allen Bradley controller to the Fanuc controller that will be compati-ble with the current system, which is critical to successfully upgrading the CNC and PLC system.

c) Award to any other source would result in substantial duplication of cost and unac-ceptable delays to the government that is not expected to be recovered through com-petition. Currently when one of the shotpeening machines is temporarily inoperable for an indefinite amount of time, due to the similarity between systems, a program can be transferred from one machine to another. This is generally done when repair time is expected to take more than 2 days and/or the part needs to be processed immediate-ly..

However, even with similarity between machines this process generally takes 2 days to qualify the process on a different machine. Using any other software would increase that time to 8 days to re-qualify a part on a similar machine, during which point both machines would not be running production. It takes longer to write an initial program than it does to transfer or modify a program. This would not only affect the F100 core workload but also the F100 Inlet fan workload which also often relies on OC14851 for redundancy to reduce the potential for single point failures when OC17500 or OC14850 are temporarily inoperable. Due to the dual media capability of this machine this is often necessary to continue production when either of the machines in the F100 Inlet fan shop is out of service.

In the last year, transferring programs between machines has been necessary for 7 different programs between these machines. This resulted in a stop in production for 14 days while the machine that was down was repaired and the program had to be transferred to another machine. With any other software interface than PRIMS® it would have taken 56 days to transfer these programs.

Additionally, if any other software was implemented other than PRIMS® a new training qualification would have to be required specifically for OC14851 to ensure that the op-erator was qualified to run that machine because it would be different from running any of the other machines. Currently due to similarity between machines and interfaces, this is not necessary. However, having different software would result in adding an ad-ditional 20 hrs of OJT to qualify an operator to be trained on different software. This would result in an additional cost of $ for training each subsequent operator, after the initial training as specified for this purchase.

d) Accordingly Progressive Surface is the only firm capable of providing the system de-scribed in section III above without the U.S. Air Force experiencing substantial duplica-tion of cost and delay in processing engine parts that could not be expected to be re-covered though competition. Progressive Surface Technologies is the original equip-ment manufacturer and can ensure that the programs that have already been qualified will work with the upgrade. Use of their proprietary PRIMS® software also aids in min-imizing the time it takes to be able to transfer a program from one machine to another which helps to prevent single point failure. Progressive Surface Technologies has a software program which can convert the Allen Bradley programs to Fanuc programs using their PRIMS® software. This would greatly minimize the time necessary to up-date all the old programs as well as writing any new programs since it is similar to the other Shotpeen systems already. It is crucial that the old programs transfer since there are currently 81 programs on this machine.

VI. DESCRIPTION OF EFFORTS MADE TO ENSURE THAT OFFERS ARE

SOLICITED FROM AS MANY POTENTIAL SOURCES AS DEEMED PRACTICABLE

Currently, Progressive Surface owns the proprietary software that the operators have already been trained on and familiar with it. Furthermore, since that software is already used on all of the automated shotpeening systems, it aids in minimizing the opportunity for single point fail-ure, when any of the older machines are inoperable. Since Progressive is the only company that makes PRIMS® software they are the only company that can meet the government’s need. 76th PMXG did contact five other sources. Engineered Abrasives was not interested in the modification at all, since it wasn’t their equipment. Surface Blasting Systems was inter-ested in the repair but upon investigation of the requirements determined that they would most likely not be able to perform the equipment upgrade. Empire Abrasive Equipment Co.

showed some interest in the modification but ceased responding to communications.

1. Engineered Abrasives Alsip, IL 60803 Phone: 888-495-8156, 708-389-9700 POC: Mike Warren

2. Surface Blasting Systems

002 84th St. S.W. Byron Center, MI 49315 Phone: 616-384-3351 POC: Kirt Walbrink

3. Empire Abrasive Equipment Co. CAGE: 19428

Langhorne, PA 19047 Phone: 215-518-0538 POC: Mark Bahmueller

VII. DETERMINATION BY THE CONTRACTING OFFICER THAT THE

ANTICIPATED COST TO THE GOVERNMENT WILL BE FAIR AND RESONABLE

The contracting officer will ensure that the buy contemplated for this acquisition will be negotiated at a fair and reasonable price to the Government. The contractor will be requested to submit other than cost or pricing data as necessary and price reasonableness will be determined through price analysis using commercial price listing, historical pricing, and/or other than certified cost or pricing data as necessary.

VIII. DETERMINATION OF THE MARKET RESEARCH CONDUCTED AND THE

RESULTS OR STATEMENT OF THE REASONS MARKET RESEACH WAS NOT

CONDUCTED

Market research was performed. Other software interfaces were identified; however, due to the need for compatibility of programs between shotpeening systems, it was determined that use of equipment from a different manufacturer would result in substantial duplication of cost to the Government, per FAR 6.302-1(a)(2)(ii)(A).

IX. ANY OTHER FACTS SUPPORTING THE USE OF OTHER THAN FULL AND

OPEN COMPETITION.

When contacting Progressive Surface to perform market research, they responded saying on February 24, 2016, “Since this system was manufactured and integrated by Progressive Sur-face, we made custom software and configuration to make it possible for the PC based oper-ator control to interface with all the mechanical systems of the machine. The PRIMS software is considered proprietary to Progressive and will not be shared with third party vendors for modification.” Therefore due to this response received from the OEM, we do not believe that acquisition of the upgrade can be obtained from any other source fulfilling the requirements for what is needed to ensure a smooth transition from the old system to the new system.

X. LIST OF SOURCES, IF ANY, THAT EXPRESSED INTEREST IN THE

ACQUISITION

Progressive Surfaces CAGE: 06EH8 4695 Danvers Dr. SE Grand Rapids, MI 49512

(616) 957-0871 ext.315

Surface Blasting Systems 002 84th St. S.W. Byron Center, MI 49315 Phone: 616-384-3351 POC: Kirt Walbrink

Empire Abrasive Equipment Co. CAGE: 19428 Langhorne, PA 19047 Phone: 215-518-0538 POC: Mark Bahmueller

These are all of the sources that expressed interest in the modification. See Market research or section VI for more information as to why the other two sources were excluded as being feasible.

XI. A STATEMENT OF THE ACTIONS, IF ANY, THE AGENCY MAY TAKE TO

REMOVE OR OVERCOME ANY BARRIERS TO COMPETION BEFORE MAKING

SUBSEQUENT ACQUISTIONS FOR THE SUPPLIES OR SERVICES REQUIRED

Competition was considered early in this program, as described in section VI. We were unable to re-move or overcome the steps necessary to foster competition because of the duplication of effort with operating another manufacturer’s product.

XII. CONTRACTING OFFICER’S CERTIFICATION

The Contracting Officer’s signature on the Coordination and Approval Document evidences that he/she has determined this document to be both accurate and complete to the best of his/her knowledge and belief.

XIII. TECHNICAL/REQUIREMENTS PERSONNEL’S CERTIFICATION

As evidenced by their signature on the Coordination and Approval Document, the technical and/or requirements personnel have certified that any supporting data contained herein, which is their responsibility, is both accurate and complete (FAR 6.303-2(B).