PWS_Cincinnati_4049_(002).doc

PERFORMANCE-BASED WORK STATEMENT

FOR

Cincinnati Refurbishment, Installation, and Calibration Ogden Air Logistics Complex (OO-ALC) 309th Commodities Maintenance Group (CMXG) Hill AFB, Utah

21 June 2018

TABLE OF CONTENTS

SECTION

PAGE

DESCRIPTION OF SERVICES

BASIC SERVICES

SERVICE SUMMARY

GENERAL INFORMATION

APPENDICES

1. Description of Services The 309th Commodities Maintenance Group (CMXG) has a requirement of the refurbishment and installation of a Cincinnati 5-Axis Honeycomb profiler, serial number 4333A0186-0001(machine) in Bldg. 238 on Hill Air Force Base (HAFB), Utah. The contractor shall provide labor and resources to support the 309th CMXG in the replacement or rebuilding of all worn components required for the installation, alignment and calibration in order to make the Cincinnati 5-Axis Honeycomb profiler fully operational. The machine was disassembled in October of 2016 and is currently on pallets. All parts needing refurbishment will need to be loaded and shipped to the contractor facility at the contractors discretion at no additional cost under the contract. The contractor will be required to ship, refurbish, ship back, install, align and calibrate the machine. The contractor shall disassemble and replace or repair all worn bearings, guides and gear components of the X,Y,Z,A and C Axis while the machine is disassembled. The contractor shall reassemble the machine, installing it on the newly built cement pad in building 238. The contractor shall set and level the machine and the contractor shall test and certify the machine for accuracy and reliability. It is the Governments intent to receive a fully operational Cincinnati 5-Axis Honeycomb profiler to perform at OEM specifications at the fruition of the contract. The contractor shall provide familiarization for the machine once installation alignment and calibration have been completed (see appendix D for tolerances).

2. Basic Services

2.0.1 The contractor shall provide all services, parts and labor necessary to refurbish, repair, install, align and calibrate the Cincinnati 5-Axis Honeycomb profiler. The contractor shall ensure that all components are replaced with OEM components if available. If OEM parts are not available, a suitable substitute may be used through the approval of 309th CMXG/MXDEE Program Manager after being coordinated through Contracting Officer.

2.0.2 The contractor shall provide a tailored plan to include schedule for refurbishment, installation, and calibration upon contract award CDRL A001. This schedule will need to be approved by 309th CMXG/MXDEE and will need to align with the cement pad installation in building 238, HAFB. CDRL A001

2.1 Refurbishment. The contractor shall provide all labor, travel, shipping, parts, and material necessary to ship and refurbish the Cincinnati 5-axis Honeycomb profiler.

2.1.1 The contractor shall provide all rigging necessary and ensure all components are shipped back to the location where they will be refurbished.

2.1.2 The contractor shall perform a thorough inspection of the machine and refurbish the machine, replacing parts that are worn, broken or need to be replaced. The contractor shall replace or refurbish the parts listed in section 2.1.3. This includes the replacement of any incidental parts that would normally be replaced in with the refurbishment of any of the parts listed in 2.1.3.

2.1.3 The contractor shall replace/refurbish the following parts:

· Ways and ball screws for the Z and Y axis

· X-axis gear-box seals and bearings

· X-axis wipers

· X-axis carrier and side load bearings in lower upright

· Oiler supply lines

· Build new Powertrack to replace outdated system

· A-axis gear drive assembly

· X-axis pinion gears (qty 4)

· X-Axis Racks

· Sound dampening panels inside vacuum

· Red head spindle and bearings Serial Number (S/N): J03 7677

2.1.4 The contractor shall inspect the additional red head spindle S/N D01 7367 for wear or defects and identify it to the Program Manager. All rework will be completed at the contractor’s expense.

2.1.5 The contractor shall ensure that the machine is inspected prior to being shipped from the repair facility.

2.1.6 The contractor shall submit a monthly list of all parts replaced and inspected. For all parts replaced list part number of both old part and new part. For inspected parts, list condition of part, test results, and part number. CDRL A004

2.1.7 The contractor shall repaint all painted surfaces back to original color (attempting to match color in enamel paint).

2.2 Installation.

2.2.1 The contractor shall provide all rigging necessary and ensure all components are shipped back to Hill Air Force Base, where they will be reassembled. This shall be coordinated with 309th CMXG/MXDEE. The contractor shall ensure that all mating surfaces and bare metal surfaces are protected and shipped to HAFB in protective crates.

2.2.1.1 Electric forklifts are preferred, but if gasoline or diesel engines are to be used, notify 309th CMXG/MXDEE 7 business days prior to allow the Government time to cover all sensitive equipment.

2.2.2 The contractor shall reassemble the machine on the new cement pad in building 238. The contractor shall level and align the machine base. Any issues with the cement pad or the alignment of the machine shall be immediately reported to 309th CMXG/MXDEE.

2.2.3 The contractor shall install all gantry’s, uprights, slide assemblies, 3” brazed copper vacuum lines, wiring and connections necessary for normal operation of the machine. The contractor shall provide all new piping, cables, and conduit, required from the existing facility connection points. No facility structural modifications are allowed.

2.2.4 The contractor shall replace obsolete Powertrack with OEM approved redesign.

2.2.5 The facility will provide the following services:

Electrical—460VAC, 3 Phase, 60 Hertz (Hz), 40 Ampere (Amp) Breakers

Shop Air—100 psig

2.3 Calibration/Acceptance

2.3.1 The contractor shall calibrate the machine to specifications in Appendix D and provide certification of calibration. CDRL A005

2.3.2 The Contractor shall adjust the oil system to deliver oil at an appropriate rate to the roller bearings and wipers. The oiler control system needs to be adjusted to eliminate system errors.

2.3.3 The contractor shall debug the machine to insure there are no errors on the controller. The Human Machine Interface (HMI) Software currently used is creating issues, resulting in the flooding of the system with oil during operation. Each occurance results in a complete shutdown of system and is creating a hinderance to continued operation of the machinery. The current version of the HMI controller is 06.04.28.00 dated 12/04/2007 in conjunction with the NCU version 07.04.20 840d 12A 62.

2.3.4 The contractor shall coordinate with Government Representative’s (identified in CDRL A003) prior to performing the Site Acceptance Test (SAT), beginning calibration to ensure proper function of the machine. This SAT shall ensure proper fuction of the machine to include all axis’s and functionality of all item repaired or refurbished. The Government will accept or provide feeback within 14 business days of receiving the SAT. CDRL A003

2.3.5 The contractor shall provide three (3) eight (8) hour days of runoff support at the Government facility prior to final acceptance.

2.3.6 The machine will be considered accepted once all required machine position calibration, machine alignments, training and machine runoff as stated above have been satisfied, as determined by 309th CMXG/MXDEE.

2.4 Travel

2.4.1 The contractor shall be required to travel to support the objectives of the contract requirements. The contractor shall obtain approval from 309th CMXG/MXDEE fourteen (14) days in advance before traveling. The contractor shall be responsible for making all necessary arrangements for their personnel, including air travel, car rental, lodging and subsistence.

2.5 Reports

2.5.1 Calibration Quality Standard and Traceability – With Calibration Measurement Requirement Summary (CMRS): The Contractor shall ensure the developed system is capable of being calibrated and its calibration is verified in accordance with Air Force Metrology and Calibration (AFMETCAL) requirements. Calibration and measurement traceability shall be identified and documented in accordance with MIL-STD-1839D. MIL-HDBK-1839C shall be used for interpretive guidance to clarify requirements invoked by MIL-STD-1839D. The Contractor shall provide a means to perform calibration to meet these requirements. The Contractor shall provide all proprietary/unique software and peculiar/special hardware required to perform calibration and calibration verification. The Contractor shall develop and deliver a system calibration procedure verifying system performance to the performance specification contained within paragraphs 2.1 and 2.2 of this purchase specification. The Contractor shall deliver the Calibration Measurement Requirements Summary (CMRS) in accordance with DID DI-QCIC-80278A and the Contract Data Requirements List (DD Form 1423). CDRL A005/DI-QCIC-80278B

2.5.2 Evaluation and Volumetric Report: The Contractor shall provide an Evaluation and Volumetric Report provided in the Contractor’s format. This plan shall outline procedures for providing objective evidence that the new test equipment meets each requirement outlined in Appendix D. The Acceptance Test Plan shall contain the following critical events: CDRL A002/DI-ATTS-80282B and CDRL A008/DI-ATTS-80283B

2.5.3 Installation/Assembly/Relocation Manual- The contractor shall provide an installation/relocation manual for the machine. This shall be the manual used in the installation and assembly of the machine in building 238. This manual shall also detal the lifting plan needed for the machine. CDRL A006

2.5.4 Monthly report: The contractor shall submit a monthly report to include the status of parts needed, parts replaced, and schedule update. CDRL A007

2.6 Deliverables

3. SERVICE SUMMARY

The contractor shall create, perform, and ensure compliance with a Site Acceptance Test (SAT) for the 5-Axis machine

4. GENERAL INFORMATION

4.0.1 Government, other than CO and COR(s), may from time to time, with CO coordination, observe contractor operations. However, these may not interfere with contractor performance or make any changes to the contract

4.1 Total Case Incident Rate/Days Away Restricted or Transferred (TCIR/DART) Rates

4.1.1 Contractors are required to provide from their OSHA 300 information the Total Case Incident Rate/Days Away Restricted or Transferred (TCIR/DART) rates. Submit to the CO as part of the installation’s annual OSHA VPP self-evaluation report; Electronic copy delivered to: OO-ALC.OMO.VPPCTRTCIRDART@us.af.mil (VPP office) and the Contracting Officer Representative (COR).

4.2 Security Requirements

4.2.1 The Contractor shall be responsible to gain access to Hill Air Force Base through 309th CMXG/MXDEE. Once at Building 238, where the machine will be located, the contractor shall be escorted at all times.

4.2.2 If required, the government security manager 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).The Contractor shall coordinate with the Contracting Officer (CO) and security to gain access to Hill Air Force Base. The Contractor shall be escorted at all times while on site.

4.3 Physical Security

4.3.1 The contractor shall be responsible for safeguarding all government property provided for contractor use. At the close of each work period, government facilities, property, and materials shall be secured.

4.4 Hours of Operation

4.4.1 Normal Hours of Operation

4.4.2 The contractor shall perform the services required under this contract during the following hours: Monday through Thursday 0600–1530 – EXCEPT FEDERAL HOLIDAYS. All Friday times are to be negotiated with the 523 EMXS RF Shop Supervisor and are at the 523 EMXS RF Shop Supervisor discretion if Fridays are needed.

4.4.2Recognized Holidays

4.4.2.1 Unless otherwise required by the Government, the contractor shall not have access to Government facilities on the following federal holidays: New Year’s Day, Martin Luther King’s Birthday, President’s Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans’ Day, 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.

4.5 Manpower Reporting

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

4.5.2 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.

4.5.3 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

4.6 Conservation of Utilities

4.6.1 The contractor shall instruct their employees in utilities conservation practices. The contractor shall be responsible for operating under conditions which prevent the waste of utilities.

4.7 Environmental Controls

4.7.1 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: hexavalent, chrome, cadmium, beryllium, lead, and others. While the Contractor shall not perform duties in a regulated area (where exposure are expected to exceed the permissible exposure limits set by 29 CFR1910.10xx), 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 hazards. The 75th Air Base Wing (ABW) Bio-Environmental Engineering Flight produces BIO Survey of these areas which will be made available upon award.

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

4.7.3 If the contractor spills or releases any substance contained in 40 CFR 302 into the environment, the contractor or its agent shall immediately report the incident to the 309th CMXG/MXDEE. The liability for the spill or release of such substances rests solely with the contractor and its agent.

4.8 Safety Program

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

4.8.2 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. An email copy of the mishap / incident notification shall be sent within three calendar days to the 309th CMXG/MXDEE Shop Supervisor, who will forward it to OO-ALC safety.

4.9 Material Storage and Use

4.9.1 The contractor shall follow manufacturer’s guidelines and professional recommendations for control of humidity, temperature, cleanliness, and materials handling. This includes any hazardous materials.

4.10 GOVERNMENT OBSERVATIONS

4.10.1During the period that the contractor is working on the machine, Government personnel, other than CO, may from time‑to‑time, observe contractor operations. However, these personnel may not interfere with contractor performance.

APPENDICES

A. Acronyms & Abbreviations List B. Safety Plan

APPENDIX A

ACRONYMS AND ABBREVIATIONS LIST

Acronym/Abbreviation

Definition

ACO

Administrative Contracting Officer

AFB

Air Force Base

AFMC

Air Force Material Command

ALC

Air Logistics Center

CAC

Common Access Card

CAS

Cost Accounting Standards

CMXG

Commodities Maintenance Group

CO

Contracting Officer

COR

Contracting Officer Representative

DART

Day Away, Restricted, and or Transfer Case Incident Rate

DCAA

Defense Contracting Audit Agency

DCMA

Defense Contract Management Agency

DoD

Department of Defense

DLA

Defense Logistics Agency

FAR

Federal Acquisition Regulation

HAFB

Hill Air Force Base

IAW

In Accordance With

NUCAP

NADCAP Users Compliance Audit Program

OJF

On the Job Familiarization

OO-ALC

Ogden Air Logistics Center

OSHA

Occupational Safety and Health Act

P&A

Price and Availability

PCO

Procurement Contracting Officer

PWS

Performance-Based Work Statement

QA

Quality Assurance

QCP

Quality Control Program

SMAG

Supply Management Activity Group

SOW

Statement of Work

TCIR

Total Case Incidence Rate

TRC

Technical Repair Center

USAF

United States Air Force

VPP

Voluntary Protection Program

APPENDIX B

SAFETY, FIRE PROTECTION AND HEALTH

SPECIFICATION

INDUSTRIAL SAFETY REQUIREMENTS

OGDEN AIR LOGISTICS COMPLEX

UNITED STATES AIR FORCE

HILL AIR FORCE BASE, UTAH 84056

Cincinnati Refurbishment 1 Nov 16

Prepared by:

Tim Helms

OO-ALC/SE

801-586-6038 Control Number: TH161101

SECTION I - GENERAL REQUIREMENTS

A. Safety Program Requirements.

The contractor will implement a safety program plan that ensures protection of Government personnel and property. As part of the Contractor Safety and Health Program, the contractor shall assign in their plan, by name and phone number, a person who will be the primary point of contact for safety and health issues for the on-site operation. 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:

The contractor is solely responsible for compliance with all federal, state and local laws, the Occupational, Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards, OSHA Standards 29 CFR 1910 and 1926, as applicable, and the protection of their employees. Additionally, the contractor is responsible for the safety and health of all subcontractor employees. All documents required as a result of OSHA 29 CFR 1910 and 1926 regulations, (i.e. certifications, training, respiratory protection program, workplace hazard assessments), shall be made available to the COR upon request.

The contractor shall ensure assigned personnel are adequately trained and qualified for the task being performed. Brief all personnel on the hazards involved with operations and applicable precautions to be taken. Should unidentified hazards arise, cease operations until actions are taken to eliminate or mitigate hazards to safe levels.

Hazard Assessment. In accordance with 1910.132(d)(2), the contractor shall conduct a certified Hazard assessment on all work areas. A follow-on survey shall be conducted by the contractor when the workload or environment conditions change. If respirators are necessary to protect the health of the employee or whenever respirators are required by the contractor, the contractor employer shall establish and implement a written respiratory protection program according to 29CFR 1910.134.

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: 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:

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

· Identify procedures for accident reporting and investigation

· 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 accept/reject 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

Mishap Notification/Reporting

Appendix C, Section I

Facility Fire Protection

NFPA 13, 70, & 72

NFPA 409/410

AFI 91-203 para., 6.2.9 through

6.2.15, and para., 22.5 Handling, Storage and use of Flammable/

NFPA 30, 33

Hazardous Material Management

AFI 32-7086 HAFBSUP 1

(If performance is on Hill AFB)

Storage and Materials Handling

DoDI 4140.62

DoDI 4145.19-R-1

APPENDIX D

Evaluation and Volumetric Requirements for 5-Axis Cincinnati Honeycomb Profiler Machine in Building 238

Scope:

The tasks identified in this document are required in accomplishing performance evaluations, calibrations, and alignment of the Cincinnati Honeycomb profiler 5-axis gantry machine Serial number: 4333A0186-0001 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 (CDRL A005):

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 +.007 inch (volumetric positioning) with respect to an ideal reference space, for any combination of axis positions of the five axes of the machine.

The Cincinnati Honeycomb profiler shall meet the 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:

APPENDIX D

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, Axes C and A: 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. 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 of the Cincinnati Honeycomb Profiler due to large table/bed areas. This means a total of six (6) set-up measurements will be needed.

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 ±.004. Repeat and record measurements as before, following final adjustments. Measurement locations shall be approximately evenly distributed over the table-bed. The locations shall be in line witht the floor mounting bolts that control the machine leveling. The minimum number of measurement locations is 40, twenty on each side of the table.

Documentation: (CDRL A003)

The contractor shall Provide a calibration certificate, 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.

Cincinnati Refurbishment

CMXG