FA8224-14-R-0097 _PWS.pdf

PERFORMANCE-BASED WORK

STATEMENT (PWS)

FOR

MAINTENANCE SERVICE CONTRACT FOR THE

5-AXIS MACHINES LOCATED IN BUILDING 238 (REV 2)

309 CMXG/533 CMMXS

02 October 2013

PERFORMANCE-BASED WORK STATEMENT

TABLE OF CONTENTS

SECTION PAGE

1 DESCRIPTION OF SERVICES 3

2 SERVICES SUMMARY 5

3 GOVERNMENT FURNISHED PROPERTY 5

4 GENERAL INFORMATION 5

5 APPENDICES 8

1. DESCRIPTION OF SERVICES: This performance work statement (PWS) identifies requirements of the Commodities Maintenance Group at Hill AFB for a service contract to maintain three large computer numerical control (CNC) 5-axis gantry mill machines. The services shall consist of annual volumetric compensation, authorized repairs, and emergency repairs. The contractor shall provide personnel, support equipment, and documentation necessary to repair, test, and volumetrically compensate the equipment, as identified in this PWS.

2.0 Basic Services

2.1 Volumetric Compensation: The contractor shall perform annual volumetric compensation of the three 5-Axis gantry mill machines listed in Appendix B. The volumetric adjustments shall be performed in accordance with Appendix B, “Evaluation and Volumetric Adjustment Requirements for 5-Axis gantry mill CNC Machines in Building 238”.

2.1.1 The contractor shall coordinate specific dates of initial volumetric compensation through the Government Representative (GR). The contractor shall perform subsequent volumetric adjustment at 12-month intervals following the initial calibrations.

2.1.2 The contractor shall make volumetric compensation in accordance with (IAW) Appendix D.

2.2 General Repairs: The contractor shall be on site to evaluate the machine for needed repairs within three (3) business days of being notified by the GR. The contractor shall provide the GR an itemized cost estimate for repairs to include labor hours, travel and required parts/ materials as well as estimated repair time within one (1) business day of evaluation. If the repair is of such magnitude the GR will determine the time frame for the cost estimate and provide a schedule of repairs which will be agreed on by the GR.

2.2.1 The contractor shall coordinate with and receive approval from the GR and PCO prior to any repairs being made.

2.2.2 The contractor shall provide unlimited telephone support during normal business hours as specified in Section 5.2 to government personnel to assist with trouble shooting and maintenance functions.

2.2.2.1 The contractor shall respond to telephone calls within one (1) business day.

2.3 Emergency Repairs: The contractor shall respond to emergency calls within two (2) hours of being notified by the GR and be on-site within 24 hours. The contractor shall evaluate and provide the GR with an itemized cost estimate for repairs to include labor hours, travel and required parts/ materials as well as estimated repair time. The contractor shall provide all transportation, equipment, and labor to perform repairs. Emergency repairs will be determined by impacts to production and determined by the GR.

2.3.1 The contractor shall complete all emergency repairs within two (2) business days dependent upon parts availability and unless otherwise approved by the GR. The contractor shall coordinate with and receive approval from the GR and PCO prior to any repairs being made.

2.3.2 For each service/repair call made, the contractor shall document the work accomplished in a logbook that will be kept by the GR. As a minimum, the contractor shall document the following information:

a) Date and time the call was made by the GR

b) Check-in and check-out times

c) Services performed (e.g. general, emergency, volumetric compensation)

d) Components repaired and/or replaced

e) Names of all technicians performing the service

f) Agreed upon repair completion times

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

h) Government Representative functional test sign-off

i) Names and dates of personnel being trained

2.4 Functional Testing: Whenever the contractor finishes repairs or maintenance on equipment, the contractor shall contact the GR to coordinate a functional test. Proper operation of software/hardware, controls, motors, adjusting mechanisms, and other accessories shall be verified during the trial period. A qualified base maintenance technician or operator will run the functional test. Maintenance and repairs shall not be considered completed until the GR has signed the logbook (see 2.3.2).

2.4.1 If there is a malfunction determined by the GR to be a result of poor repair workmanship within 30 calendar days of completion of repair, the contractor shall be responsible for the cost of any parts and labor needed as a result of the re-work.

2.5 Parts: The contractor shall provide all repair parts. The contractor shall coordinate parts and delivery costs/methods for GR approval. The contractor shall use technical data specified parts.

If technical data specified parts are not available, the contractor shall request prior approval from the GR on proposed replacement parts from other sources.

2.5.1 The contractor shall replace parts and materials with new commercial off the shelf (COTS) parts and materials if available or to original equipment manufacturer (OEM) standards.

2.6 Training: The contractor shall provide on the job (OJT) trouble shooting, general maintenance and emergency repair training to government maintenance personnel in conjunction with performance of any maintenance. The training shall include basic troubleshooting using the onboard Siemens diagnostic software.

2.6.1 The contractor shall train government employees if changes are made to the programming software.

3. SERVICES SUMMARY.

Performance Objective PWS Para Performance Threshold Volumetric Compensation of the 5-Axis gantry mill Machines

2.1.1, 2.1.2 12-month intervals following the initial calibrations and IAW standards set in Appendix D

The contractor shall be on site to evaluate the machine

2.2 Within three (3) business

days.

The contractor shall respond to telephone calls

2.2.1.1 Within one (1) business day

The contractor shall respond to emergency calls

2.3 within two (2) hours of being notified by the GR

The contractor shall be on site for emergency repairs

2.3 Within 24 hours of being

notified by the GR.

The contractor shall complete all emergency repairs

2.3.1 Within two (2) business days

dependent upon parts availability and unless otherwise agreed upon between the GR and contractor

Maintenance/ Repair Log:

The contractor shall document the work accomplished in a logbook that will be kept by the GR.

2.3.2 100% Compliance

Functional Testing: The contractor shall contact the GR to coordinate and assist in performing a functional test.

2.4 100% Compliance

4. GOVERNMENT FURNISHED PROPERTY.

4.1 Maintenance and Technical Manuals. The government will provide available COTS manuals for the 5 Axis gantry mill machines. The contractor shall be responsible for acquiring any additional needed maintenance and technical manuals to support the requirements of this PWS.

5. GENERAL INFORMATION.

5.1 The GR will be responsible and ensure that the contractor is given clearance at the South Gate either by escorting the individual(s) or by phone clearance. The clearance process will be based on the security requirements at that time.

5.2 HOURS OF OPERATION. Normal Hours of Operation. The contractor shall perform the services required under this contract during the following: Mon - Fri, from 0600-1630, except Federal Holidays and any other days deemed appropriate by the government.

5.3 RECORDS. The contractor shall be responsible for creating, maintaining, and disposing of only those government-required records that are specifically cited in this PWS or required by the provisions of a mandatory directive listed in Appendix D, Applicable Publications and Forms. If requested by the Government, the contractor shall provide the original record or a reproducible copy of any such record within five working days of receipt of the request.

5.4 ENVIRONMENTAL CONTROLS. The contractor shall ensure their employees are made aware that the performance 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 inhalation of Hexavalent Chrome, Chemlease 41, Sealants, Calibration Gases as well as contact with Methylene Dianiline, Isocyanates. While the contractor will not perform duties in a regulated area (where exposures are expected to exceed the permissible exposure limits set by 29 CFR1910.10), 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 hazards.

5.4.1 Compliance with Laws and Regulations. The contractor shall be knowledgeable of and comply with applicable Interstate, Federal, State and Local laws, regulations and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor is required to comply as such laws come into effect.

5.5 FOREIGN OBJECT DAMAGE (FOD) AND TOOL CONTROL. The contractor shall follow the applicable guidance in chapters/paragraphs/sections of AFI 21-101 and HQ AFMC, Hill AFB, and 309MXW supplements to the AFI 21-101 concerning base tool (chapter 10 section B), and Foreign Object Damage (FOD) control policies (chapter 14, and sub paragraphs designated as 41), daily. Cloth rags are considered tools and will follow the same regulations and procedures as tools.

5.5.1 If tools, and/or equipment are lost, the contractor will report the loss to the GM/COR no later than two hours after discovery. If tools are lost or not accounted for, then the contractor shall implement the lost tool procedures of AFMC supplement to AFI 21-101, chapter 10, section B.

5.5.2 Contractors performing functions in industrial areas on the center shall have a method for controlling and accounting for all tools used. All contractors working on the center shall inventory their tools at the beginning and end of each shift and at the end of each task to check for any lost or missing tools.

5.6 SECURITY REQUIREMENTS. The Contractor shall be responsible for safeguarding and shall account for all Government property provided for Contractor use. At the close of each work period, Government facilities, property, and materials shall be secured

5.7 SAFETY REQUIREMENTS. The contractor shall implement a safety program that ensures protection of Government personnel and property.

5.7.1 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 A001) (DI-MGMT-81580)

5.7.2 In the event of an accident/mishap, the contractor shall take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence. A written or email copy of the mishap / incident notification shall be sent within three calendar days to the Government Representative, who will forward it to 309 MXW safety. (CDRL A002) (DI-SAFT-81563)

5.7 MANPOWER REPORTING. The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

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.

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

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.

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.

5.8 SPECIAL QUALIFICATIONS. The contractor shall assign employees who possess the knowledge of, trouble shooting, general maintenance, calibrating and repair of the Siemens 840D controller.

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

5.9.1 The government reserves the right to conduct site visits in all contractor-operated facilities in conjunction with the solicitation of offers for the follow-on contract. In the event the follow-on contract is awarded to other than the incumbent, the incumbent contractor shall cooperate to the extent required to permit an orderly change over to the successful contractor. With regard to the successor contractor’s access to incumbent employees, a recruitment notice may be placed in each facility.

5.10 PUBLICATIONS:

5.10.1. Compliance with publications, regulations and operating instructions provided by the Government is required when:

They pertain to the procedures for materials expediting herein and where the contractor is Authorized by the performance-based statement of work to accomplish the work specified in the publication, regulation or operating instructions.

The publications prescribe USAF policies, use of materials, procedures and processes applicable to the work requirements.

5.10.2. The contractor is required to acquire and work on the latest version of the publication.

5.13 TRAVEL REQUIREMENTS. Any All travel required shall be performed IAW FAR

31.20546. The contractor is responsible for making all necessary travel arrangements for their personnel, including air travel, car rental, lodging and subsistence. Travel is restricted to round trip coach airfare tickets, economy class car rental, and per diem rates not to exceed FTR rates for the TDY location. Contractor shall also provide applicable expenditure documentation, IAW FAR31.205-46, to the contracting officer for approval prior to travel. Receipts for contractor travel will be provided to the COR for validation. Government will approve all travel by the contractor for this contract effort in advance.

APPENDICES

A. ACRONYMS AND ABBREVIATIONS LIST

B. ESTIMATED WORKLOAD DATA

C. EVALUATION AND CALIBRATION DATA

D. Map of BUILDINGS Showing WHERE EQUIPMENT IS LOCATED inside

APPENDIX A

ACRONYMS AND ABBREVIATIONS LIST

Acronym/Abbreviation Definition

AF Air Force

AFB Air Force Base

AFMC Air Force Material Command

CFR Code Federal Regulation

CA Contract Administrator

CO Contracting Officer

DEPT Department

DOD Department of Defense

FAR Federal Acquisition Regulation

GR Government Representative

OSHA Occupational Safety and Health Act

PBSA Performance Based Service Acquisition

PM Program Manager

POC Point of Contact

PWS Performance-Based Work Statement

QA Quality Assurance

QAP Quality Assurance Personnel

QCP Quality Control Program

SS Services Summary

USAF United States Air Force

APPENDIX B

ESTIMATED WORKLOAD DATA

ITEM NAME PREVENTATIVE

MAINTENANCE

NUMBER

ESTIMATED

QUANTITY

Cincinnati Milacron 5-axis gantry mill Honeycomb Profiler With Siemens 840D Controller

009464 1 Per Year

Zimmerman High Speed Gantry Mill, Model: FZ32.021 With Siemens 840D Controller

011549 1 Per Year

Zimmerman High Speed Gantry Mill, Model: FZ32.024 With Siemens 840D Controller

011882 1 Per Year

APPENDIX C

Evaluation and Volumetric Adjustments Requirements for 5-Axis CNC Machines in Building 238

Scope:

The tasks identified in this document are required in accomplishing performance evaluations, calibrations, and alignment of the 5-axis gantry mill machines in building 238, using laser interferometer equipment and related test equipment. The machine evaluation tasks shall be accomplished in accordance with the basic and modified applicable portions of ANSI/ASME B5.54 as stated in the General Requirements. The calibration procedures shall comply with the requirements set forth in ANSI/NCSL Z540.3 and ISO/IEC 17025.

Applicable Specifications and Standards:

ANSI/ASME B5.54-2005 - Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers

ANSI/NCSL Z540.3-2006- Requirements for the Calibration of Measuring and Test Equipment

ISO/IEC 17025:2005 - General requirements for the competence of testing and calibration laboratories

General Requirements:

Measure and plot the existing “As-Found” conditions of all axes individually. The measurements shall include basic requirements of ANSI/ASME B5.54. (Note: Certain non-standard and/or non-typical measurement applications may arise due to the configuration of a particular apparatus. In this case, some measurements may need to be modified, limited, or omitted. Document such cases during the machine evaluation process to justify deviating from standard measurement procedures.)

Adjust the control parameters as needed to improve the accuracy and repeatability of the machine, to the extent of the machine’s capability (subject to the machine’s control functions and the degree of the machine’s mechanical and electrical/electronic integrity).

Control adjustments will include: positioning error compensation, sag or straightness compensation, backlash compensation, as well as other types of adjustments.

Document all “As-Found” and “As-Left” conditions.

Spindle Positioning Accuracy: Following all calibration adjustments, spindle position accuracy shall be within +.002 inch (volumetric positioning) for Zimmerman Mills (models FZ32.021 and FZ32.024) and within +.007 inch (volumetric positioning) for the Cincinnati Profiler (with respect to an ideal reference space, for any combination of axis positions of the five axes of the machines).

Cincinnati Profiler Table Flatness: The mounting table of the Cincinnati Profiler shall not deviate from an ideal horizontal plane by more than +.004 inch, when measured at locations adjacent to the 42 leveling screws.

Zimmerman Mill Accuracy: The Zimmerman Mills (models FZ32.021 and FZ32.024) shall meet the manufacturer’s accuracy specifications.

In the event of a discrepancy in the accuracy requirements specified herein (including reference document), the more stringent requirement shall apply.

Individual Tasks:

Linear Axes Positional Calibration: Measure and adjust the linear displacement accuracy and repeatability for the X1, X2, Y, Z axes. Use five (5) set-up measurements, including X at mid Y travel. A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: Several measurement routines, Pitch error compensation, and Backlash compensation adjustments, will be needed in the control parameters before a final axis calibration is accomplished.) Set-up two lasers and optics for Dual axis laser measurements of the X1 and X2-axes simultaneously.

Rotary Axes Angular Displacement Calibration: Measure and adjust the angular displacement accuracy and repeatability for the 2-rotary axes. (2 set-up measurements are needed.) . A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: Several measurement routines, Pitch error compensation, and Backlash compensation adjustments, will be needed in the control parameters before a final axis calibration is accomplished.)

Angular Pitch Measurements: Measure the angular pitch for the X, Y, & Z axes. (Three set-ups will be needed.) A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: No adjustments will be made with these measurements.)

Angular Yaw Measurements: Measure the angular yaw for the X, Y, & Z axes. (Three set-ups will be needed). A minimum of three bi-directional measurement routines shall be performed for each final axes calibration. (Note: No adjustments will be made with these measurements.)

Axial Straightness Calibration: Measure and adjust Axial Straightness for the X, Y, & Z axes. Two straightness error measurements set-ups shall be made for each axis, for a total of six set-ups. (Note: Several measurement routines and Sag/Straightness error adjustments may be needed in the control parameters before a final axis calibration is performed.) A minimum of three bi-directional measurements shall be performed for each final axes calibration.

Axial Squareness Measurements: Perform a squareness check for the XY, YZ & ZX planes. (Note: A telescoping ballbar or optical square can be used when performing these measurements). A total of six (6) measurements set-up will be needed. A minimum of three bi-directional measurement routines shall be performed for each plane. (Note:

Normally no adjustments will be needed for this measurement, unless a crash of the machine has occurred, or the machine has otherwise been subjected to excessive loads. If needed adjustments are beyond the scope of a normal calibration, a repair work order request may be needed to resolve the squareness issues. Document each occurrence.)

Dynamic circular interpolation: Perform a dynamic circular interpolation, using a telescoping ballbar or equivalent device, in the XY-Plane, YZ-Plane and ZX-Plane. A minimum of three bi-directional measurement routines shall be performed for each plane.

(Note: Two sets of tests will be needed over two separate machine table/bed locations for the Cincinnati Milacron Profiler and the FZ32.024 Zimmerman mill due to large table/bed areas. This means a total of six (6) set-up measurements will be needed for the two large machines listed here, but three (3) set-up measurements for the smaller Zimmerman mill may be adequate.)

Volumetric Laser Diagonal Measurements: Perform a volumetric laser diagonal measurement in each of the four quadrants (diagonals) of the rectangular workspace over the machine bed (four set-up measurements in total). A minimum of three bi-directional measurement routines shall be performed for each diagonal.

Table-Bed Level and Fatness: Measure and record the rise and fall of table-bed with respect to an ideal horizontal plane. Adjust the table bed level and flatness to within the machine’s accuracy capability. Repeat and record measurements as before, following final adjustments. Measurement locations shall be approximately evenly distributed over the table-bed, with a minimum number of locations as follows.

Cincinnati Milacron 5-axis Honeycomb Profiler: 36 locations (18 per table-bed section)

Zimmerman High Speed Gantry Mill, Model: FZ32.02 (PDL Lab): 16 locations (8 per table-bed section)

Zimmerman High Speed Gantry Mill, Model (CMM Room) FZ32.024: 24 locations, (8 per table-bed section)

Table-bed Position with Respect to Spindle Head: Measure and record the distance of the rise and fall of the table bed in relation to the spindle head in the x and y plane (with fixed Z-axis) at the various table-bed locations measured when adjusting the table-bed level and flatness. (Note: No adjustments will be made with these measurements.)

Documentation:

Provide a calibration certificate for each machine, documenting that the equipment has been inspected and meets the requirements of ANSI/ASME B5.54 Provide data plots and corresponding tables of the measurements made in the “As- Found” and “As-Left” conditions at each measurement point. Three complete CD-ROM copies of the data shall be provided in PDF format.

APPENDIX D