Grinder_Rebuild_PWS_16_May_2016_Revision_1.docx

PERFORMANCE-BASED WORK STATEMENT FOR THE RETROFIT/REBUILD OF

BUTLER NEWALL O.D. GRINDERS AND CINCINNATI MILACRON I.D. GRINDERS FOR

309TH CMXG / 532 CMMXS LANDING GEAR SQUADRON HILL AFB, UTAH

10 March16 May 2016

Revision 1

TABLE OF CONTENTS

SECTION 1 – SCOPE 3

SECTION 2 – DESCRIPTION OF SERVICES 3

SECTION 3 – TASKS 3

SECTION 4 – GENERAL INFORMATION 6

SECTION 5 – PUBLICATION 11

APPENDIX A – BUTLER NEWALL GAP GRINDERS 12

APPENDIX B – CINCINNATI MILACRON GRINDERS 16

APPENDIX C – SAFETY, FIRE PROTECTION AND HEALTH SPECIFICATION 20

1.1. This Performance-Based Work Statement (PWS) outlines the tasks and duties required of the Contractor to retrofit/rebuild of two Butler Newall Gap Bed O.D. Grinders, Preventative Maintenance Numbers 7690 and 7691(Serial Numbers 4077 and 4078), and three Cincinnati Milacron I.D. Grinders, Preventative Maintenance Numbers 1305, 1307, 1308 (Serial Numbers 48668, 48669, and 48670) at Hill AFB, Utah 84056. All requirements in this PWS shall apply to the Grinders listed above.

1.2. Each grinder shall be retrofit/rebuilt to the requirements listed in this PWS and shall meet the tolerances tables and accuracies listed in Appendices A and B.

2. DESCRIPTION OF SERVICES

2.1. Requirements specific to the Butler Newall Gap Bed O.D. Grinders can be found in APPENDIX A.

2.2. Requirements specific to the Cincinnati Milacron I.D. Grinders can be found in APPENDIX B.

2.3. These machines shall be retrofit/rebuild in order so that only one Machine of each configuration is down for maintenance at a time. The order of machines being retrofit/rebuild will be established after award and will be determined by the Hill Air Force Base Subject Matter Expert (SME). The work on each machine must be completed and accepted by the Government representativeSME before work can start on additional machines, maximum 5 months per machine. Depending on workload, the Government representativeSME may authorize simultaneous work on two machines, one of each configuration.

2.4. Manuals: The contractor shall assemble, generate, and supply manuals that reflect all changes to the grinding machine and its related system within 7 days after successful completion of functional test. (CDRL A001)

2.5. Guarding: All guarding shall be in accordance with OSHA 1910.212, OSHA 1910.215 which specifically covers abrasive wheel machinery. All current OSHA required guarding on the machine shall be returned to the original operating state.

2.5.1. Pulley and Belt Guarding: All pulleys and belts shall be covered and guarded to prevent access while guarding is in place. All guarding of pulleys and belts shall be attached to the machine securely but removable as needed for maintenance and servicing of the machine. All current guarding on the machine shall be returned to the original operating state.

3. TASKS

3.1. Paint

3.1.1. Each machine shall be cleaned and painted after reassembly. Machine shall be free of oil, debris, or other contaminants that shall affect the adhesion and curing prior to painting the machine. The Contractor shall not paint surfaces and areas that would adversely affect the operation of the machine. Ways, chucks, centers, wheel hubs, tooling, and items not originally painted by the OEM shall not be painted in this rebuild. All accessory components shall be painted to match machine color. The machine shall be painted on-site and proper controls for overspray and contamination of adjacent areas are put into place. Painting shall be accomplished on site during the weekendSaturday’s only; Contractor shall schedule weekends Saturday painting with SME.

3.2. Testing

3.2.1. Functional Test: The Contractor shall submit the test plan, 45 days prior to completion and testing of the grinder. The Contractor shall operate the machine at a no load condition for no less than 12 hours. Proper operation of all controls, motors, adjusting mechanisms, and other accessories shall be verified during the test period. If the system fails under the no load testing, the deficiencies shall be corrected, and a new 12-hour test block shall be initiated. Functional testing shall continue until the upgraded grinder system can operate properly, with no deficiencies, for 12 continuous hours. After the functional test is complete, the Contractor shall perform a part run-off test which will consist of 2 parts and be observed and verified by the SME. The Government will provide condemned parts for the part run-off test which shall be processed in accordance with the applicable tech data. The Contractor shall generate and deliver the Acceptance Test Plan 3 days after successful functional testing. (CDRL A002 and A003)

3.2.2. After the system has passed the functional and part run-off tests, the system will be accepted by the SME. The SME will sign the test report indicating that the test was witnessed by a Work Lead and was performed in accordance with the testing plan.

3.3. Training

3.3.1. The contractor shall provide 40 hours of on the job training for 2 maintenance operators and 2 machine operators for 1 OD and 1 ID configuration (total of 80 hours). Training shall cover machine operation and preventative maintenance. Contractor shall training utilizing contractor provide training material on the updated systems and their functions for the operators to use as future references for each grinder configuration. This training shall be provided after the functional test for the first rebuild in accordance with CDRL A004.

3.4. Status Report

3.4.1. The contractor shall provide a monthly status report by the 15th of each month IAW CDRL A005

Services Summary

Para Performance Threshold

and

CDRL A001

The contractor shall assemble, generate, and supply manuals that reflect all changes to the grinding machine and its related system within 7 days after successful completion of functional test.

and

CDRL A002

Functional Test: The Contractor shall submit the test plan, 45 days prior to completion and testing of the grinder.

and

CDRL A003

The Contractor shall generate and deliver the Acceptance Test Plan 3 days after successful functional testing. (CDRL A002 and A003 Functional and acceptance test)

A004 The contractor shall provide 40 hours of on the job training for 2 maintenance operators and 2 machine operators for 1 OD and 1 ID configuration (total of 80 hours). Training shall cover machine operation and preventative maintenance. Contractor shall training utilizing contractor provide training material on the updated systems and their functions for the operators to use as future references for each grinder configuration. This training shall be provided after the functional test for the first rebuild.

A005 The contractor shall provide a monthly status report by the 15th of each month IAW CDRL A005

4.3.2 and

CDRL

A006 The contractor shall provide a QCP that shall identify the means by which the contractor will ensure quality effectiveness and demonstrate comprehensive management and review of data. The QCP shall be provided to the Contracting Office for acceptance 30 Day after award of contract.

CDRL

A007 and A008

4.8.1. The Contractor shall establish a complete Contractor Safety Program to ensure the requirements of this contract are provided as specified in appendix C. Obtain acceptance of the plan by the contracting officer, through coordination with OO-ALC Safety office, before the start of the performance period.

and CDRL A009 Provide from their OSHA 300 information the Total Case Incident Rate/Days Away Restricted or Transferred (TCIR/DART) rate by 15 January of each year.

4. GENERAL INFORMATION

4.1. Badging

4.1.1. The Contractor must meet the same security requirements as government employees for access to HAFB.

4.1.2. The Contractor shall complete and submit, to the COR or PM, the necessary forms to be issued a Base Access/Common Access Cards (CAC)/Defense Biometric Identification Systems (DBIDS) for each employee requiring access to Hill Air Force Base throughout the Period of Performance (PoP).

4.1.3. The Contractor shall complete and submit the necessary forms to the COR or PM for each employee who must have access to a controlled area at the installation.

4.1.4. The Contractor employees shall identify themselves by wearing a government-issued ID badge displayed above the waist at all times while on the Government installation. The identification shall clearly identify the individual as being a contractor employee.

4.1.5. During performance of the contract and at the termination or completion of the contract, the Contractor shall be responsible for prompt return of credentials for any employee who no longer requires access to the work site. Lost badges shall be reported to the Maintenance Group Security Officer within one working day of loss.

4.1.6. The Government, at the sole discretion of a government authority, may immediately remove from or denied access of any contractor employee to any government property, facility, and installation if that authority determines such action is necessary to protect or preserve government property, safety and security, or to maintain good order and discipline.

4.1.7. Contractor employees who have access to Hill AFB Government facilities, or critical information shall be trained annually on Operations Security (OPSEC), Antiterrorism and security education 90 days after initial assignment of the contract IAW AFI 10-245.

4.2. Tools, Materials, and Equipment Control:

4.2.1. The contractor shall establish a dedicated and secure Contractor Work Zone by providing a barrier around the work area with appropriate, equipment assembly, keep out, and warning signs to separate the Contractor Work Zones from production areas. All staging areas, material storage, and work areas shall be confined to the area inside the Contractor Work Zone. The size and location of the Contractor Work Zone shall be coordinated with SME so as to minimize the amount of disturbance to depot production activities.

4.2.2. The contractor shall maintain all tools, materials, equipment, and perform all work (as far as possible) in Contractor’s work zone.

4.2.3. If tools, and/or equipment are lost, the contractor shall report the loss to the SME within 30 minutes of discovering the item is lost. Every effort shall be made to recover the item before reporting it as lost.

4.3. Quality Control

4.3.1. Quality Control Plan (QCP) The contractor shall provide a QCP that shall identify the means by which the contractor will ensure quality effectiveness and demonstrate comprehensive management and review of data. The plan shall describe: what is measured; how often it is measured, tracked and provided; who reviews and assures that appropriate action is initiated when trends are unfavorable; who the Government will contact for contractor quality issues; what method and process is used to track and resolve issues; where reports are sent and maintained; how often quality issues are reviewed and reported; how the contractor identifies and resolves deficiencies; how the contractor identifies and maintains potential improvements, and makes efficiencies available to the Government; and documentation reflecting quality control inspections and any corrective actions taken (CDRL A006).

4.3.1.1. The Contractor shall provide copies of all discrepancies to the SME and the COR.

4.3.1.2. The QCP shall be provided to the Contracting Office for acceptance 30 Day after award of contract. Updates shall be provided whenever there is a change in any of the Quality System Elements.

4.3.1.3. The contractor shall establish and provide a QCP to ensure the requirements of this contract are provided as specified. The contractor shall ensure quality service is maintained throughout the life of the contract.

4.3.2. Labor Hours The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for respirator cleaning via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil. (DARS 37.102-90)

4.3.2.1. 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.

4.4. Quality Assurance

4.4.1. 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

4.4.2. The COR(s) or alternate(s) will inform the Contractor in person when discrepancies occur and will request corrective action. The COR(s) or alternate(s) will make a notation of the discrepancy on the assessment checklist with the date and time the discrepancy was noted and will request the task manager (or authorized representative) to initial the entry on the checklist.

4.4.3. 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).

4.4.4. 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).

4.4.5. The Government will periodically evaluate the contractor’s performance by appointing a representative(s) to monitor performance to ensure services are received. The Government representative will evaluate the contractor’s performance through inspections and receipt of complaints from base personnel.

4.4.6. The Government will inspect tasks and may 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.

4.5. Hours of Operation

4.5.1. The Contractor shall perform the services required under this contract during the following hours: Monday through Friday 0500 to 1800.

4.6. Observance of Legal Holidays and Excused Absence

4.6.1. Building access will be unavailable to the Contractor on Government holidays. The Government will observe the following Government holidays:

· New Year's Day

· Martin Luther King's Birthday

· President's Day

· Memorial Day

· Independence Day

· Labor Day

· Columbus Day

· Veteran's Day

· Thanksgiving Day

· Christmas Day

4.7. Records

4.7.1. The Contractor shall be responsible for creating, maintaining, and disposing of only those government required records that are specifically cited in this PWS. 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.

4.8. Safety Program Guidelines

4.8.1. Establish a complete Contractor Safety Program to ensure the requirements of this contract are provided as specified in appendix C. The Contractor shall ensure safety is maintained throughout the life of the contract, and shall establish and provide a contractor’s Safety Plan. The plan shall meet requirements of Appendix C. The contractor shall make appropriate corrections and modifications (at no additional costs to the Government) and obtain acceptance of the plan by the contracting officer, through coordination with OO-ALC Safety office, before the start of the performance period. (CDRL A007 and A008) .

4.9. Voluntary Protection Program (VPP)

4.9.1. Hill AFB, has adopted the VPP as recognized by OSHA. Consequently, VPP impacts all "applicable contractors" operating on Air Force Installations. It is the contractor's responsibility to ensure its employees and managers and subcontractors have a comprehensive understanding of VPP as well as full compliance with OSHA requirements. Detailed information on VPP is available on the OSHA website (http://www.osha.gov/dcsp/vpp/index.html). Contractors and subcontractors, whose employees work more than 1,000 hours per quarter, whether regularly involved in routine site operations or engaged in temporary projects such as service contracts, must follow the safety and health rules of the installation or VPP site.

4.9.2. Contractors are required to provide from their OSHA 300 information the Total Case Incident Rate/Days Away Restricted or Transferred (TCIR/DART) rate by 15 January of each year to the CO for submission as part of the installation's annual OSHA VPP self-evaluation report. (CDRL A009)

4.9.3. The contractor shall ensure their employees are made aware that the performance of these services will occur in industrial areas and shall not perform duties in a marked and signed regulated area there may be contact hazards with these materials during cleanup of dust, metal shavings, etc. The contractor shall ensure proper protective measures and training is taken to protect contracted employees from these hazards.

4.10. ENVIRONMENTAL CONTROLS:

4.10.1. 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. If there is an increase or decrease in cost as a result of the change, the Contractor shall inform the Contracting Officer pursuant to notice requirements and negotiate a modification to the contract.

4.10.2. Notification of Environmental Spills. If the Contractor spills or releases any substance into the environment listed in 40 CFR Part 302 Protection of the Environment, the Contractor, or its agent shall immediately call 911. If the call is made from an on base phone, it will go directly to Hill AFB dispatch. If using a cell phone it will go off base, ask the 911 dispatcher to be transferred to Hill AFB. The liability for the spill or release of such substances rests solely with the contractor and its agent.

4.10.3. Material Storage and Use. The Contractor shall follow manufacturer’s guidelines and professional recommendations for control of humidity, temperature, cleanliness, and materials handling. This includes hazardous materials.

4.10.4. Mishap Reporting. The Contractor shall report any mishap to the Contracting Safety Office as well as the Contracting Officer for all incidents resulting in damage to Air Force property. The Contractor shall cooperate with any and all government investigations. Additionally, the contractor shall secure the mishap scene and impound evidence/wreckage until released by the Government-Contracting Officer. The Contractor shall provide copies to the contracting officer of data related to the mishap, such as contractor analyses, test reports, summaries of investigations etc. as necessary to support a Government investigation.

5. PUBLICATIONS:

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

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

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

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

APPENDIX A

REQUIRMENTS SPECIFIC TO THE BUTLER NEWALL GAP GRINDERS

1. Tasks

1.1. Mechanical

1.1.1. The Contractor shall inspect all castings for excessive wear, cracks, distortion, and/or other damage/repair if it affects the functionality of the grinder.

1.1.2. The Contractor shall clean, inspect, and check all mating surfaces for corrosion, flatness, and repair as required.

1.1.3. The Contractor shall replace ball screws on the X and Z-Axis to meet the accuracy and repeatability listed in APPENDIX B, TABLE I of this PWS. Ballscrews shall be properly sized to meet the duty cycle requirements of this application.

1.1.4. The Contractor shall check X and Z-Axis ways for wear, if ways impair the repeatability and accuracy, the contractor shall repair or replace ways. Turkite may be used in the repair of ways.

1.1.5. The Contractor shall replace all damaged or worn gaskets, seals, o-rings, bearings, way wipers, and belts.

1.1.6. Tailstock: The Contractor shall clean, inspect and repair the Tailstock mounting surface, taper and the extension mechanism.

1.1.7. The Contractor shall clean the Z-Axis taper adjustment mechanism, and ensure proper operation.

1.1.8. Headstock:

1.1.8.1. Headstock Bearings: The Contractor shall check for trueness and the mating surfaces shall be checked for corrosion and repaired.

1.1.8.2. Headstock Rotation: The Contractor shall ensure that the headstock speed be infinitely variable in accordance with (IAW) APPENDIX B, TABLE I of this PWS.

1.1.8.3. The Contractor shall clean and repair the Headstock gap adjustment mechanism and the Air assist mechanism.

1.1.8.4. Headstock Motor: Contractor shall provide and install a brushless AC motor and variable frequency drive (IAW) APPENDIX B, TABLE I of this PWS. Existing motor specs: 10hp DC model# GE5CD373JA002A001.

1.1.9. Wheel head:

1.1.9.1. Wheel head rotation: The Contractor shall ensure wheel head speed be infinitely variable in accordance with (IAW) APPENDIX B, TABLE I of this PWS. The Contractor shall install a load meter on the control panel that will reflect the pressure on the grinding wheel.

1.1.9.2. Wheel head motor: The Contractor shall provide and install a variable frequency drive to the existing AC motor (IAW) APPENDIX B, TABLE I of this PWS. Existing motor specs: 460V 48Amp 40hp 60hz.

1.1.9.3. Auxiliary wheel head motor: The contractor shall provide and install a variable frequency drive to the existing AC motor (IAW) APPENDIX B, TABLE I of this PWS. Existing motor specs: 460V 9.7Amp 7.5hp 60hz.

1.1.9.4. Belt grinding attachments that are currently on the machine will be removed for the rebuild/retrofit process and reinstalled and made operational. This is to include all wires and hoses. The belt tracking switch will be incorporated into or attached to the controller. Superfinsh attachment that is currently incorporated into the beltgrinding attachment on PM#7690 will also be reinstalled and made operational this is to include all wires, hoses and the control box.

1.2. Electrical

1.2.1. The Contractor shall remove and replace the existing control system and all associated electrical components. The Contractor shall provide new (non refurbished controls) and current version of Fanuc 0i or equal. If providing an equal, it must be serviced by multiple vendors and contractor shall provide the government with unlimited data rights. This shall include motors, drives, servos, electrical hardware and computer hardware.

1.2.2. The Contractor shall replace all electrical components to meet current component or better. Junction boxes, switches, push buttons, solenoids, clutches, computers, memory, breakers, and wires shall be replaced.

1.2.3. Dressing Cycle: Dressing cycle shall allow for wheel dressing subroutine anytime during the grinding cycle. This shall be both programmed into the grinding cycle and there shall be a push button on the control panel to initiate the dress cycle. Once initiated the grinding wheel shall retract, work head stop, grinding wheel moves into position to dress, wheel dresses according to subroutine, grinding wheel returns to a standoff position, and grinding cycle resumes where it left off. Controller shall automatically compensate wheel size and work coordinates as necessary during dressing operations.

1.2.4. Automatic Cycle: The Contractor shall provide an automatic cycle for plunge and traverse grinding. The machine shall be designed with automatic infeed of the abrasive grinding wheel for traverse grinding operations. Selectors shall be provided for controlling in feed increments at desired reversal(s) of the traverse grind and for controlling the total infeed for the overall grinding cycle. The wheel feed mechanism shall be actuated upon each or alternate reversals of the table’s longitudinal movement at the choice of the operator. Speed during traversing shall be controllable through programming. Dwell time of the grinding wheel at traverse reversals shall be controllable through programming. Controllable number of spark-out strokes (dead passes) shall be included at end of program.

1.2.5. Automatic Retracted: the cycle will be used to retract the grinding wheel while the machine is in automatic grinding mode. For ID grinders it will return the grinding wheel to center line in the X-axis and retract to the home position in the Z-axis. For OD grinding wheel will retract to home position in the X and Z axis. Grinding wheel will stop rotating when the retract is engaged. Activation button will be on the controller and labeled.

1.2.6. In-Cycle Pick: The In-cycle Pick feature will be activated by a button on the controller. During the automatic grind cycle this feature will allow us to pick in the X-axis while the machine is in automatic mode. When this feature is used it will update the offsets on the machine also.

1.2.7. Manual Control: The Contractor shall provide a portable hand held pendant, with a manual pulse generator to control X axis, Z axis, and C axis movement.

1.2.7.1. The Contractor shall install a yellow push button on the control panel that when depressed will retract the grinding wheel 1” from the work piece, stop the work head, and stop the grinding wheel.

1.2.8. The Contractor shall provide coolant on and off programmable by M-code in automatic mode as well as an On/Off switch located on the control panel when used in manual mode and as an override during automatic operations.

1.3. Oil Systems

1.3.1. The Contractor shall replace the hydraulic power unit with a new hydraulic power pack suitable size to meet the requirement of the machine.

1.3.2. The Contractor shall completely disassemble, clean and inspectreplace the lubrication system. Damaged or worn components shall be repaired or replaced to meet current component or better. The oiling system shall be tested at the manufacturers operating pressure.

TABLE I

SPEEDS, FEEDS AND ACCURACIES

Headstock Speed in RPM Variable from 0 to 200+

Wheel head Speed in RPM Variable from 0 to 1,000+ Table Traverse Inches per Minute Variable from 0 to 100+

Test to be applied: Permissible

Infeed adjustments:

APPENDIX B

REQUIREMENTS SPECIFIC TO THE CINCINNATI MILACRON GRINDERS

Tasks

Mechanical

The Contractor shall install new ball screws on the X and Z-Axis to support the accuracies and repeatability’s listed in Table I of this PWS.

All castings associated with rework shall be inspected for excessive wear, cracks, distortion, or other damage. The Government shall be notified of any cracked casting and cause automatic suspension of work until further direction is received. Contractor shall provide the following information.

Function of the cracked casting Effect of the crack and its repair on the structural strength.

Alignment and operability of the machine.

Probability of successfully repairing the cracked casting.

Cost of a new casting, including installation.

Rebuild completion delay for purchasing/repairing casting.

The hydraulic system shall be completely disassembled, cleaned, and inspectedreplaced. This includes, but not limited to pumps, valves, pistons, cylinders, hoses, filters and reservoirs. Defective components will be replaced with new and shall meet Current component standard or better. The hydraulic system shall be tested at the normal operating pressure. All oils will be removed by the Government prior to repair.

The Air system shall be completely disassembled, cleaned and inspected. This includes but not limited to, valves, pistons, cylinders, hoses, and filters.

The Contractor shall check X and Z-Axis ways for wear, if ways impair the repeatability and accuracy, the contractor shall repair or replace ways. Turkite may be used in the repair of ways.

All gaskets, seals, o-rings and similar parts shall be replaced with new.

All bearings associated with rework shall be replaced.

All way wipers shall be replaced with new way wipers.

All belts shall be replaced with new of the same type or better if required to perform properly.

Worn parts that would impair the efficiency and accuracy of the machine shall be replaced.

The oiling system shall be completely disassembled, cleaned, and inspected. This includes, but not limited to pumps, valves, pistons, cylinders, hoses, filters and reservoirs. Defective components shall be replaced with new and current component standard or equal. The oiling system shall be tested at the normal component operating pressure. Oiling system shall provide adequate oil to ways. All oils will be removed by the Government prior to repair.

Headstock bearings and mounting surfaces shall be checked and replaced if impaired.

Headstock rotation shall be variable speed. Contractor shall allow the option of coolant on or off during headstock rotation for operator.

Wheel head rotation shall be variable speed. A load indicator shall be furnished for wheel head.

A measurable taper adjustment shall be equipped on machine.

Dressing system shall be cleaned and inspected to function properly and allow for wheel dressing subroutine.

Tail stock and mounting surfaces on machine shall be cleaned and repaired to function as originally manufactured.

Coolant

A coolant filtration system shall be furnished to allow dispensing of coolant onto a dispensing roll of coolant paper in a mesh tray over coolant tank.

Distribution of coolant to grinding wheel and recovery of the coolant shall be furnished on grinder. Contractor shall provide possible solutions for the Government to approve or disapprove.

Electrical.

The Contractor shall provide new (non refurbished controls) and current version of Fanuc 0i or equal. If providing an equal, it must be serviced by multiple vendors and contractor shall provide the government with unlimited data rights. CNC control package shall meet accuracies and repeatability’s listed in both Appendix A and B, Table I of this PWS. Controller shall be able to compensate for dressing. Head Stock shall turn off while dressing.

All electrical/electronic components that include enclosures, junction boxes, limit switches, selector switches, pressure switches, float switches, pushbuttons, solenoids, clutches, and wires shall be replaced.

Automatic Feed: The machine shall be designed with automatic in feed of the abrasive wheel for traverse grinding operations. Selectors shall be provided for controlling in feed increments at desired reversal(s) and for limiting the total in feed for the overall grinding cycle. The wheel feed mechanism shall be actuated upon each or alternate reversals of the table’s longitudinal movement at the choice of the operator.

Manual In feed: A portable hand held lever, pulse generator or other manually operated device shall be furnished for feeding the grinding wheel into the work piece. The hand feed shall have a coarse and fine feed with a graduated indicator.

Automatic Cycle: An automatic cycle shall be provided for plunge and traverse grinding. After setup for automatic cycle, the operator shall only be required to load the work piece, start the cycle by a single control and unload the work piece. The automatic cycle shall include, but not be limited to the following functions:

Plunge Grinding, Oscillation plunge, and Multi Plunge shall be provided on machine.

Traverse Grinding shall be provided on machine.

In cycle dressing and in cycle wheel retraction shall be provided on machine.

Constant surface speed will be maintained on the wheel and head stock.

Driving Mechanism: The driving mechanism for grinding wheel head assembly shall be powered by an electric AC driven brushless motor, with belt and pulley arrangement or direct drive by electric motor. Means shall be provided for adjusting belt tension unless belt tension is maintained automatically.

8.2.1.

TABLE I ACCURACY TOLERANCES

Test to be applied: Permissible

In feed adjustments:

Automatic in feed at table reversal, diameter reduction, range, inches 0.0001”

In feed motion of wheel slide Quick approach to the work repeats accurately to grinding position (6 repetitions), fine in feed 0.00005”

Encoder position measuring system. Resolution 0.00001”

Head Stock Total Indicator Run out. 0.0001”

Table Travel Total Indicator Run out .0002”/ 25” of travel Verify Plunge and Traverse grinding with dressing is in working order.

APPENDIX C

SAFETY, FIRE PROTECTION AND HEALTH

SPECIFICATION

INDUSTRIAL SAFETY REQUIREMENTS

OGDEN AIR LOGISTICS COMPLEX

UNITED STATES AIR FORCE

HILL AIR FORCE BASE, UTAH 84056

REBUILD OF

O.D./I.D. GRINDERS

DATE 18 Feb 2016 Prepared by:

Tim Helms

OO-ALC/SE

801-586-6038

Control Number: TH160204

SECTION I - GENERAL REQUIREMENTS

A. Safety Program Requirements.

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 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 will be accepted by OO-ALC/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 OO-ALC/SE (801-586-6038) or the Hill AFB Command Post (801-777-3007) after normal duty hours, and the designated Government Representative (GR), i.e., the ACO, PCO, or DCMA COR (Contracting Officer's Representative) 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 OO-ALC/SE. 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. The contractor shall cooperate with any and all government mishap investigations. Additionally if requested by government personnel or designated government representative (GR), i.e., the ACO, PCO, or DCMA COR, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by safety investigators.

3. The contractor shall provide copies of contractor data related to mishaps, such as contractor analyses, test reports, summaries of investigations, etc. as necessary to support the government investigation.

4. The contractor shall support and comply with the safety investigation and reporting requirements of AFI 91-204, Chapters 1 – 5.

C. General Safety Requirements:

Contractor personnel must receive Explosive Safety Awareness Training if their duties require entry into the Explosive Clear Zone. This training will be provided by the OO-ALC Safety Office. Contact Eric Covington at 586-0168.

A Risk Assessment will be required prior to any work being accomplished, if munitions will remain in the facility.

Compliance with OSHA and other applicable laws and regulations for the protection of contractor employees is exclusively the obligation of the contractor. Note: AFOSH STDs are annotated because many of the Air Force Standards exceed the OSHA standard criteria. If a conflict is noted, the most stringent requirement takes precedence. The government shall assume no liability or responsibility for the contractor's compliance or non-compliance with such requirements. The contractor shall furnish to each of his/her employees a place of employment, which is free from recognized hazards. The contractor shall brief his/her employees on the safety requirements of this contract and on hazards associated with prescribed tasks. The contractor is responsible for compliance with OSHA Public Law and the resultant standards identified within. In addition, the contractor is required to flow down the safety requirements/specification to all subcontractors. This applies to Federal Acquisition Regulation (FAR) 12 commercial acquisitions as well. This contract shall in no way require persons to work in surroundings or under working conditions which are unsafe or dangerous to their health. The contractor must coordinate and perform work so as not to impact the safety of government employees or cause damage to government property. This requires providing personnel with protective equipment and associated safety equipment as may be necessary. The contractor must also protect personnel from hazards generated by the work. If the contractor employs BILINGUAL speaking employees, they must post bilingual signs and have written procedures for specific tasks in applicable languages.

SECTION II – SPECIFIC REQUIREMENTS

The contractor’s prepared Safety Plan shall:

1. Demonstrate a management commitment to employee safety and health

1. Identify applicable rules and regulations

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

1. Identify work to be performed and location of expected operations

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

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

1. Identify employee safety and health training requirements and the documentation process

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

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

1. Identify procedures for accident reporting and investigation

1. Identify the process for tracking controlled hazards in contractors work area

The contractor shall ensure that each element identified below is adequately addressed in detail in the safety and health plan:

PEDESTRIAN CROSSWALKS: All contractor personnel are required to use the closest crosswalk, or traffic controlled intersection when crossing the road. Pedestrians must look both ways to ensure the coast is clear before stepping out into the crosswalk. Pedestrians DO NOT have the right of way unless they are already in the crosswalk. Contractor vehicle operators have the same responsibilities as pedestrians, to share the road and mutually observe and yield to pedestrians.

MOTOR VEHICLES: Contractor shall comply with the standards in: DoD Directive 5525.4, Enforcement of State Traffic Laws on DoD Installations", Nov 2, 1981, Para 3-4; DODI 6055.4, DoD Traffic Safety Program, 20 Jul 99; AFI 91-207, USAF Traffic Safety Program, 22 May 07; and AFI 91-207 AFMC SUP1, The US Air Force Traffic Safety Program, 1 Oct 07. Each applies to all persons at any time on an Air Force Installation and includes all leased, owned, or privatized property including housing areas. In addition: AFI 13-213, Airfield Management, 29 Jan 08, Paragraphs 1.3.6 and 4.4.2.1 applies to all contractors, sub-contractors, vendors, commercial delivery companies, and all other private business vehicles who operate anywhere on Hill Air Force Base, including the airfield (to include the industrial areas and any buildings or hangars located upon the airfield) in support of their mission.

HOUSEKEEPING: Housekeeping shall be conducted according to the requirements in OSHA Standard 29 CFR 1910.141. CLEAN AS YOU GO will be enforced.

The authorized Government Representative (OO-ALC 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

AFI 91-203 Chapters 6, 22

Hazardous Material Management AFI 32-7086 HAFBSUP 1

Personal Protective Equipment AFI 91-203 Chapter 14

Materials Handling Equipment AFI 91-203 Chapter 35

Storage and Materials Handling DoDI 4140.62 DoDI 41