GFM_Ultrasonic_Cutter_Maintenance_PWS_(15_January_2013).doc

PERFORMANCE-BASED WORK

FOR

MAINTENANCE FOR GFM ULTRASONIC CUTTER

309th Maintenance Wing Commodities Maintenance Group (CMXG)

533 CMMXS

15 January 2013

PERFORMANCE-BASED WORK STATEMENT

TABLE OF CONTENTS

SECTION PAGE

1 DESCRIPTION OF SERVICES 3

4 APPENDICES 7

1. DESCRIPTION OF SERVICES. In support of the 309th Commodities Maintenance Group, the contractor shall provide management, tools, supplies, equipment, and labor necessary to repair and maintain the GFM Ultrasonic Cutter located in Building 238 at Hill Air Force Base Utah. The requirements consist of maintenance, calibration, trouble shooting and repair of a government owned GFM Ultrasonic Cutter. These services include planned annual maintenance, unscheduled repairs, telephone and email technical support, and replacement parts. Hereafter the GFM Ultrasonic Cutter will be referred to as the Cutter.

1.1. BASIC SERVICES.

1.1.1. The contractor shall provide planned annual maintenance, unscheduled repairs, telephone and email technical support and parts replacement for the Cutter.

1.1.2. The contractor shall arrange for delivery, handling, and removal of equipment, supplies and debris for the preparation, execution and completion of the contract.

1.2 SCHEDULED ANNUAL MAINTENANCE. Scheduled Annual Maintenance dates shall be coordinated through the Government Technical Representative (GTR). The contractor shall coordinate all findings and discrepancies immediately with the government representative and will provide documentation of the problem, type of repair required, and an estimate of the time and cost required for the repair for the following services within three to five business days (CDRLA001).

1.2.1 Calibration of the Cutter: The contractor shall perform annual calibration of the machine listed in Appendix B. Calibration shall be completed to ensure the cutter can maintain the following accuracy (CDRLA001).

1.2.2 Compensation of the Cutter: The contractor shall measure the flatness of the cutting surface and input recorded measurements into the Computer Numerical Controller (CNC) to compensate for any variations greater than 0.004 in. This process is also referred to as mapping (CDRLA001).

1.2.3 Maintenance of the Cutter: The contractor shall perform annual maintenance of the cutter in accordance with the Maintenance Manual for the Model US-40 Ultrasonic Cutting Machine, Section 16 and shall include at a minimum (CDRL A001).

· Inspect the couplings between the encoders and the servomotors to make sure that they are tight on the shafts and undamaged.

· Inspect the drift of the drive controller.

· Inspect the servo command voltage from the CNC (Computer Numerical Controller).

· Inspect the servomotor tachometer feedback.

· Check for calibration of the vacuum pressure switches that sense for low vacuum levels.

· Check that all three phases on each of the three phase motors on the vacuum pump are drawing the same amount of current.

· Check that all of the cooling fans in the CNC cabinet and on the Indramat servomotors are operation properly.

· Verify the correct operation of each over travel limit switch.

· Verify the correct operation of the light guards, safety mats, safety bumpers, and emergency stop buttons.

· Verify the perpendicularity of the crossbeam both electronically and mechanically.

· Inspect the contacts which supply the ultrasonic converter for wear and pitting.

· Check all of the solenoids for correct operation.

· Inspect the linear bearings on the x axis crossbeam, y axis carriage, and z axis slide for signs of wear or improper operation.

· Clean and inspect the gear racks and pinion gears on both the x and y axes.

· Inspect all compressed air lines for damage, and check all joints for tightness and leakage.

· Replace all air filters.

· Inspect Vyon cutting surface and replace any sections as necessary.

· Replace drive belts on the y, c, and p axes.

· Inspect the ultrasonic horn assembly for correct tightness and examine the carbon brushes.

· Verify the positioning cams for all of the axes have not worked loose.

1.3 On-Call Technical Telephone and E-Mail Support - The contractor shall provide technical support via telephone and e-mail, 6:00 a.m. to 6:00 p.m. Mountain Standard Time (MST), Monday-Friday and a recording device is acceptable. The contractor shall respond within the next business day.

1.4 Unscheduled Repair: Unscheduled repair may be required for repairs not covered under scheduled maintenance. The contractor shall coordinate a site visit and repairs with the GTR and notify the GTR when repairs are complete. All repair work shall be to the most current Original Equipment Manufacturer (OEM) configuration. The contractor shall coordinate all findings and discrepancies with the government representative and will provide documentation of the problem, type of repair required, and an estimate of the time and cost required for the repair for the service (CDRLA001).

1.4.1 Replacement Equipment, Parts and Materials. Unless otherwise authorized, all equipment, parts, or materials shall be of new, or like new (i.e., re-manufactured), original materials and shall be designed and fabricated specifically for the function to be performed. All parts being replaced shall be approved by the GTR prior to being ordered and installed.

1.5 Government Acceptance – The contractor shall not depart until an established production program has been successfully run on the cutter and accepted by the GTR.

1.6 Maintenance and Repair Log: For any calibration, compensation, maintenance, and unscheduled repair, the contractor shall document the work accomplished in a logbook that will be kept by the GTR. The contractor shall document the following information:

a) Date

b) Check-in and check-out times

c) Services performed

d) Components repaired and/or replaced

e) Names of all technicians performing the service

f) Other pertinent data (or remarks) needed to document the services

2. SERVICES SUMMARY.

(CDRL A001)

3. GENERAL INFORMATION

3.1 QUALITY ASSURANCE: The Contracting Officer Representative (COR) is the authorized government representative(s) who will perform assessments of the contractor’s performance. Subsequent to contract award, the identity of the COR(s), with a letter defining duties and authority will be promptly furnished to the contractor

3.1.1 The COR(s) or GR(s) will inform the contractor when discrepancies occur and will request corrective action. The COR(s) or GR(s) will make a notation of the discrepancy on the assessment checklist with the date and time the discrepancy was noted and will request contractor (or authorized representative) to initial the entry on the checklist.

3.1.2 Any matter concerning a change to the scope, prices, terms or conditions of this contract shall be referred to the Contract Officer (CO), not to the COR(s).

3.1.3 The services to be performed by the contractor during the period of this contract are at all times and places subject to review by the CO or authorized representative(s).

3.1.4 The COR will evaluate the contractor’s performance through inspections and receipt of complaints from base personnel.

3.1.5 The government may inspect each task as completed or increase the number of quality control inspections if deemed appropriate because of repeated failures discovered during quality control inspections or because of repeated customer complaints

3.2 GOVERNMENT FURNISHED PROPERTY AND SERVICES.

Work is to be performed at Hill Air Force Base, Ogden, Utah. The contractor will be provided access to facilities, equipment, and property as required.

3.3 SECURITY REQUIREMENTS.

3.3.1 The contract administrator shall complete a "Request for Identification Credential (AFMC Form 496)" for each employee of the contractor requiring access to Hill AFB. The requests shall be submitted to Pass and Registration (South or West Gate Visitors Center).

3.3.2 The contract administrator shall complete an “Unescorted Entry Authorization Certificate” (AF Form 2586) for each employee requiring entry into controlled areas. The request shall be submitted to Pass and Registration (Gates Visitor Center).

3.7 HOURS OF OPERATION.

3.7.1 Normal Hours of Operation. The hours of operation shall be coordinated with the GTR.

3.7.2 Recognized Holidays. The contractor is not required to provide service on the following days: New Year’s Day, Martin Luther King Day, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Days, Thanksgiving Day and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

3.8 CONSERVATION OF UTILITIES. The contractor shall instruct employees in utilities conservation practices. The contractor shall be responsible for operating under conditions, which prevent the waste of utilities, which includes the use of Government telephones shall be used only for official government business.

3.9 PHASE OUT: If there is a change in contractor or if the operation reverts to organic, the incumbent contractor shall provide familiarization to the government or the follow-on contractor, whichever the case may be. During phase-out familiarization period, the incumbent will be fully responsible for the operation of this contract.

3.10 SAFETY PROGRAM.

3.10.1 The contractor shall implement a safety program that ensures protection of Government personnel and property (See Appendix C).

3.10.2 As part of the Safety Program the contractor shall establish a Safety Plan and checklist IAW Appendix C of this PWS. The contractor shall submit the Safety Plan with the contract proposal (CDRL A002).

3.11 TRAVEL REQUIREMENTS.

The contractor will be required to travel to support the objectives of this PWS. The allowable baseline for airfare cost is the “lowest priced airfare available to the contractor as outlined in FAR 31.205-46(b) & (c) and in accordance with the Joint Travel Regulations. All travel requires Government approval/authorization and notification by the GTR. The contractor is responsible for making all necessary travel arrangements.

3.12 PUBLICATIONS/DOCUMENTATION & INSTRUCTIONS.

The contractor shall obtain the forms and publications expressly required to perform the work in this contract via internet at www.e-publishing.af.mil (See Appendix B). In the event that a form or publication is not available online, the GTR will provide the form, instruction, or publication to the contractor upon written request (e-mail is acceptable) by the contractor. In the event that laws, regulations, TOs, Air Force Instructions (AFI), Air Force Materiel Command Instructions (AFMCI) change during the term of this contract, the contractor is required to comply as such changes come into effect. Contractors delivering or handling official USAF records shall comply with the applicable records management regulations AFI 33-322, AFMAN 37-123, and AFI 37-138 (in their entirety).

3.13 ENVIRONMENTAL CONTROLS.

The contractor shall ensure their employees are made aware of the performances of these services will occur in industrial areas. The industrial complex at Hill AFB has the potential to expose workers to hazardous materials which may include, but is not limited to: Hexavalent Chrome, Methylenedianiline, and others. While the contractor will not perform duties in a regulated area (where exposures are expected to exceed the permissible exposure limits set by 29 CFR11910.10xx), there may be contact hazards with these materials. The contractor shall ensure proper protective measures and training is taken to ensure contracted employees are protected from these hazards.

3.14 ONSITE LABOR HOUR REPORTING.

3.14.1 The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the Cognizant Engineering Services for C-17 Landing Gear via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

3.14.2 Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar year. Contractors may direct questions to the CMRA help desk.

3.14.2.1 Reporting Period: Contractors are required to input data by 31 October of each year.

However, due to the delayed implementation, input of FY12 data is required by 31 Mar 13.

3.14.2.2 Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.

3.14.2.3 User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for government personnel and contractors are available at the Army CMRA link at http://www.ecmra.mil.

4. APPENDICES

A. Acronyms & Abbreviations List B. Publications/Forms C. Safety, Fire Protection and Health Specification Industrial Safety Requirements D. Building 238, Area K, Ultrasonic cutter room E. Summary of Deliverables

APPENDIX A

ACRONYMS AND ABBREVIATIONS LIST

Acronym/Abbreviation Definition

APPENDIX B

PUBLICATIONS/DOCUMENTATION/ & INSTRUCTIONS

http://www.e-publishing.af.mil/shared/media/epubs/AFI91-302.pdf

Reference Documents: The contractor shall comply with the latest issue of the following documents. These documents are to be considered as reference material for the purpose of interpreting the requirements of this PWS.

Document Number Title

OSHA 2206 OSHA Safety and Health Standards (29 CFR 1910), 1994 EDITION

NFPA 70 National Electric Codes

NEMA ICS-1 General Standards for Industrial Control and Systems

NEMA MG-1 Motors and Generators

Hill AFB Instruction 91-302 Control of Hazardous Energy (Lockout/Tag out)

APPENDIX C

SAFETY, FIRE PROTECTION AND HEALTH SPECIFICATION

INDUSTRIAL SAFETY REQUIREMENTS

TYPE WORK: GFM Ultrasonic Cutter Maintenance

PREPARED BY: Eric Covington, 309 OO-ALC/SE, DSN 775-2233

SECTION I - GENERAL REQUIREMENTS

A. Safety Program Requirements.

In context with AFMC Acquisition Reform initiatives, contract language will now focus on ensuring safety objectives are met through contractor risk management rather than the traditional method of providing specific government guidance for risk elimination. With this new “performance-based” language, the government will provide the contractor with areas of concern (Protection of government personnel and property) and the contractor will be free to meet those objectives in a manner that is consistent with corporate standards. The contractor will implement a safety program plan that ensures protection of Government personnel and property. The program will consist of, as a minimum:

1. Mishap reporting, as defined in paragraph B1 below.

2. A Safety Plan and corresponding site specific checklist that addresses, as a minimum, the subjects listed in Section II –Specific Requirements, and will be used during the performance of the work described in the contract. The Safety Plan and checklist will be approved by 309 MXW/SE (Safety Office) prior to commencement of any work described in this contract.

3. Routine and recurring surveillance to ensure the safety requirements of this contract are enforced.

4. Competent personnel to provide surveillance of the Safety Plan.

5. Identification of segregated work site locations for operations that cannot be co-mingled with general industrial operations and the process for ACO approval of operations and changes at these specific sites.

6. All contractor personnel shall be trained and qualified to perform their duties safely.

7. The contractor shall include a clause in all subcontracts requiring the subcontractors to comply with the safety provisions of this contract, as applicable.

B. Mishap Notification

1. The contractor shall notify 309 MXW Safety (Phone (801) 775-2233) who in turn will notify 75 ABW/SEG ((801) 777-3333) or 309 Wing Operations Center ((801) 777-3238), or the Hill AFB Command Post (777-3007) after normal duty hours, and the designated Government Representative, i.e., the ACO, PCO, or QAE within one (1) hour of all mishaps or incidents at or exceeding $2,000 (material + labor) in damage to DOD property entrusted by this contract, even if the government is wholly or partially reimbursed. This notification requirement shall also include physiological mishaps/incidents. A written or email copy of the mishap/incident notification shall be sent within three calendar days to the GR, who will forward it to 309 MXW Safety. For information not available at the time of initial notification, the contractor shall provide the remaining information no later than 20 calendar days after the mishap, unless extended by the ACO.

Mishap notifications shall contain, as a minimum, the following information:

(a) Contract, Contract Number, Name and Title of Person(s) Reporting

(b) Date, Time and exact location of accident/incident

(c) Brief Narrative of accident/incident (Events leading to accident/incident)

(d) Cause of accident/incident, if known

(e) Estimated cost of accident/incident (material and labor to repair/replace)

(f) Nomenclature of equipment and personnel involved in accident/incident

(g) Corrective actions (taken or proposed)

(h) Other pertinent information

2. Ensure government contract lease agreements determine convening authority prior to executing the contract/lease agreements, and that all contracts ensure the following, IAW AFI 91-204, paragraph 2.4.6:

· The contractor will support and comply with the safety investigation and report requirements of AFI 91-204

· A record of all mishaps involving Air Force resources will be entered into the Air Force reporting system

· A record of mishaps involving other DoD resources will be forwarded to the involved agencies

· When a mishap involves a contract managed by DCMA, DCMA safety personnel will review the final safety report and send their response to HQ AFSC

3. Ensure contract/lease agreements for aerospace vehicles state: The Air Force is responsible for the investigation of mishaps involving aerospace vehicles. The Air Force is authorized to investigate mishaps involving non-accepted Air Force aerospace vehicles (Non-delivered vehicles for which the government has accepted responsibility; DD Form 250. Material Inspection and Receiving Report, HAS NOT been executed).

4. If requested by authorized government personnel (ACO, PCO, QAE, safety representative, Fire Department, and Security Forces), the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by safety investigators.

C. General Safety Requirements:

If the safety plan is modified, the contractor shall submit the proposed modification, in writing, to the Contract Administration Office safety representative.

Follow all applicable federal, USAF, state, and local safety directives outlined in Section II below.

For emergencies on Hill AFB contact 911 ask to be transferred to Hill AFB 911 to report any emergency.

SECTION II – SPECIFIC REQUIREMENTS

The contractor’s prepared Safety Plan shall:

· Demonstrate a management commitment to employee safety and health

· Identify applicable rules and regulations

· Identify the roles and responsibilities of Management, Supervisors, Employees and Safety Coordinator

· Identify work to be performed and location of expected operations

· Provide a description of safety program, safety monitoring responsibilities, organizational structure, and contact information for on-site personnel

· Include a work hazard analysis of the worksite and operations to be performed to include baseline hazard identification and required control measures

· Identify employee safety and health training requirements and the documentation process

· Include emergency response plans and procedures that relate to protection of government personnel and property

· Include a workplace inspection frequency, to include the identity of the individual responsible for conducting the inspection

· Include hazard reporting procedures and identify individual(s) responsible for the correcting identified hazards

· Identify first aid and injury procedures

· Identify procedures for accident reporting and investigation

· Identify the process for tracking controlled hazards in contractors work area

· Provide a facility description to include the electrical wiring and fire protection systems (i.e., fire suppression, fire detection, fire extinguishers, fire walls, etc.), required equipment and any other items necessary to fulfill the elements referenced below for the protection of government personnel and property. The contractor’s safety plan shall meet or exceed the referenced standards below.

The authorized Government Representative (309 MXW Safety Office) shall approve the contractor’s procedures within the Health and Safety Plan as meeting the intent of the below referenced standards, with the exception of Mishap Notification /Reporting Procedures, which are outlined in Section I, paragraph B of this Appendix C.

Element/Requirement Referenced Benchmark

Contract Safety *AFPAM 91-210 Para. 6

NFPA 409/410

*AFOSH STD 91-501 Para. 6.2.4.5, 6.2.9, 6.2.10, 6.2.11, and 6.2.17

*Follow web link to obtain direct access to these documents

APPENDIX D

Building 238, Area K, Ultrasonic Cutter Room

APPENDIX E

Summary of Deliverables

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