L1WC04 PD-Robotic Shot Peen.Final.pdf

PURCHASE DESCRIPTION

ROBOTIC SHOT PEEN (L1WC04)

1 June 2021

1. Scope: This commercial supply with incidental service acquisition is to acquire one robotic shot peen system in support of 402 CMXG/MXDEE. The system shall be designed with the capacity to shot peen 280 steel shot size and 550 steel shot size using a robotic arm. The internal area shall be at minimum 5 feet by 8 feet by 10 feet (l by w by h). This system shall be installed in Building 142.

1.1 The effort shall include the system, delivery, installation, testing/verification, training/familiarization, and warranty for the systems. The contractor shall be responsible for any variability in the site that may impact the installation of the equipment. Also, the contractor shall be responsible for disposal of any assembly packaging/scrap material.

Installation fit and finish shall be to the satisfaction of the Government.

1.2 The contractor shall provide all materials, equipment, labor and shipping necessary to deliver and install the system.

1.3 All work shall be completed in accordance with this purchase description and subject to the terms and conditions of the contract.

1.4 The system shall be installed no later than 12 months after contract award with training and production support not to exceed 3 months following installation. The contractor shall have the system completed within 15 months.

1.5 Certain components of this effort have been specifically called out by brand name for this purchase description. The robot and industrial control for this effort shall be of the brand Fanuc and Rockwell Automation, respectively. “Or Equal” will not be accepted.

2. Design: The system shall be new and complete, custom built to meet our applications, and ready for immediate operation after installation, acceptance testing and training are completed.

3. Equipment Description: The Contractor shall provide all Commercial Off-the-Shelf (COTS) Equipment Manuals for the components of the Robotic shot peen system. (CDRL A001, Commercial Off-the-Shelf (COTS) Equipment Manual Requirements, DI-TMSS-80527C). The system shall consist of the following.

3.1 Robotic Shot Peen

3.1.1 Layout

3.1.1.1 The system shall have an enclosed work envelope, where the shot peening occurs.

The floor footprint available is approximately 21’ wide x 20’ long x 17’ tall.

3.1.2 Work Envelope The approximate dimensions of the enclosed work envelope should be: 60” wide x 100” deep x 120” tall.

3.1.2.1 The system shall have enough maneuverability to allow shot peening of the area of interest for C-17 slat tracks and C-130 propellers with both types of parts mounted vertically. The robots’ reach and positioning shall be such that the enclosed work envelope’s usable space is maximized. The system shall also have the capability to shot peen the inside of the C130 propeller taper bore in the horizontal configuration utilizing a peening lance.

3.1.2.2 The robot shall be mounted on the ceiling or on a pedestal in the enclosed work envelope such that it does not impede assets from being placed in the enclosed work envelope.

3.1.2.3 The system shall have a turntable installed such that the top of the table is flush with the floor.

3.1.2.4 The turntable shall be positioned such that the parts can be rotated 360 degrees. The turntable shall be sized such that it can smoothly rotate and accurately position each of the parts and part fixtures. The turntable shall be capable of infinite rotary motion, thus eliminating the need to “rewind” the table.

3.1.2.5 The contractor shall design and build a fixture that holds and rotates the current part.

3.1.2.6 The turntable and/or fixtures shall utilize Fanuc motors and shall be included as extended axes, thus allowing coordinated motion with the robot.

3.1.3 Robot Hardware/Software

3.1.3.1 The system shall consist of a Fanuc robot with a payload of greater than or equal to 45kg.

3.1.3.2 The robot controller shall be of type R-30iB or later with an i pendant.

3.1.3.3 The robot controller shall not be located in the work envelope or impede the entrance of the work envelope. The robot controller shall be positioned such that it is protected from the hazardous dust and kept at the proper operation temperature.

3.1.3.4 The robot teach pendant shall reach all areas in the work envelope.

3.1.3.5 The robot shall employ Fanuc Dual Check Safety (DCS) and Collision

Guard.

3.1.4 Subsystem Hardware

3.1.4.1 Any Programmable Logic Controllers (PLC) and remote inputs and outputs (I/O) shall be of the brand Rockwell Automation/Allen-Bradley PLC (Logix 5000 family).

3.1.4.2 The communication protocol used for communication between the robot, PLC, Human Machine Interface (HMI), any remote I/O, and any other devices shall be Ethernet/IP.

3.1.5 Subsystem Software

3.1.5.1 If a PLC is used, the software shall be latest version of Rockwell

Automation Logix 5000 Pro Edition and shall be loaded on the PC.

3.1.5.2 The Government shall be provided and shall own all the source code developed for the system, including the PLC code and have unlimited data rights. No parts of the code shall be password protected, unless the Government will be given the password.

3.1.6 Shot Peening

3.1.6.1 The system shall have manual, robotic, and lance peening stations.

3.1.6.1.1 The manual station shall have a table on which other assorted parts can be shot peened.

3.1.6.2 The system shall have a closed-loop media flow control for both the robot and manual stations.

3.1.6.3 The system shall feature a swinging jib hoist, to be mounted in a location that facilitates the complete loading and unloading of parts into/out of the peening system.

3.1.6.4 The cabinet flip doors and roof shall be constructed in such a manner as to enable the jib hoist chain access for loading parts onto the part manipulation spindle.

3.1.6.5 The part manipulation spindle shall have a large hardened table top, and be servo controlled.

3.1.6.6 There shall be a part holding fixture for orienting C-130 propellers and C-17 slat tracks in the vertical position on the spindle.

3.1.6.7 There shall be a part holding station/fixture for holding the C-130 propellers butt face tight to the outside of the cabinet.

3.1.6.8 There shall be a rotating lance system for peening the taper bores of C- 130 propellers.

3.1.6.9 There shall be a vibratory media classifier.

3.1.6.10 The media control loop shall use a dual stage, continuous blast pressure pot system with closed loop blast pressure control.

3.1.6.11 There shall be two media adder hoppers with a media size exchange system. Changing between the two media sizes shall take less than one hour.

3.1.7 Programing:

3.1.7.1 After installation is complete , the contractor shall provide a total of six

(6) non-consecutive weeks of programming support through 15 month from date of award. The contractor shall be onsite within one (1) weeks of being notified that onsite support is required.

3.1.8 Cybersecurity Requirements: There is a new requirement for PIT Systems (Platform Information Technology Systems) (CDRL A002, Cybersecurity, DI-MGMT- 82002A).

3.1.8.1 The contractor shall follow the Uniform Facilities Criteria - UFC-4-10-6 process in compliance with Air Force Guidance Memorandum - AFGM2017-32-01.

3.1.8.2 The contractor shall administrate the Department of Defense “eMass” process to prepare the system, documents, and recovery media required to obtain an Authority-To-Operate (ATO).

3.1.8.2.1 The contractor shall refer to Appendix I for Risk Management Framework (RMF) Control Correlation Identifier (CCI) Requirements.

3.1.8.3 Contactor Qualifications, the qualifications can be met via subcontract action.

3.1.8.3.1 The contractor shall be Control System Integrators Association (CSIA) certified.

3.1.8.3.2 The contractor shall be a Rockwell Automation Solution Provider (SP)

Certified in Control, Information, and Industrial IT.

3.1.8.3.3 The contractor shall be a Fanuc Authorized System Integrator.

3.1.8.3.4 The contract shall have a Global Industrial Cyber Security Professional

(GICSP) on staff.

3.1.8.3.5 The contractor shall have Cisco Certified Network Associate (CCNA) -

Industrial certified engineers.

4. Design Reviews

4.1 A telephone “Project Kick-Off Meeting” with the Government will be set up by the contractor within 15 calendar days after contract award. The Government Point of Contacts and Contracting Officer will review the contract and related Purchase Description with the contractor. The contractor shall then provide design reviews at specific points along the way.

4.1.1 Preliminary Design Review (PDR) - The PDR evaluates if design concepts are feasible and technically adequate. The PDR will establish if the system is ready to proceed into more detailed design. The PDR will review at a minimum the preliminary schedule (Gantt Chart), preliminary component selection and integration of components, preliminary lay-out of the entire system, contractor identified issues/questions. The PDR shall be conducted at Robins AFB or via a conference call. The contractor will coordinate the date, time, method for the PDR between the contractor, Government POCs and Contracting Officer. The PDR presentation material shall be delivered to the Government.

(CDRL A003, Conference Minutes Preliminary Design Review (PDR), DI-ADMN- 81250B)

4.1.1.1 On or before three (3) months after contract award, the contractor shall provide a single Gantt Chart showing the project schedule from contract award through final inspection for the system. Additionally, the Gantt Chart shall be provided monthly after the initial project schedule. (CDRL A008, Project Planning Chart, DI-MGMT-80507C)

4.1.2 Critical Design Review (CDR) – The CDR provides the team with an objective look at what the final design will likely be. The review shall ensure the system can proceed into production, demonstration, and test and can meet stated performance requirements within cost, schedule, and risk. The CDR will review at a minimum the updated schedule (Gantt Chart), component selection and integration of components, lay-out of the entire system, contractor identified issues/questions. The contractor will coordinate the date, time, method for the PDR between the contractor, Government POCs and Contracting Officer.The CDR shall be conducted at Robins AFB or via a conference call. The CDR presentation material shall be delivered to the Government. (CDRL A004, Conference Minutes Critical Design Review (CDR), DI-ADMN-81250B)

4.1.3 Final Design Review (FDR) – The FDR provides one last look at the entire system design before the final system is setup at the contractors facility. The FDR will review at a minimum the updated schedule (Gantt Chart), final component selection and integration of components, final lay-out of the entire system, contractor identified issues/questions.

The contractor will coordinate the date, and time for the FDR between the contractor, Government POCs and Contracting Officer. The FDR shall be conducted at Robins AFB.

The FDR presentation material shall be delivered to the Government. (CDRL A005, Conference Minutes Final Design Review (FDR), DI-ADMN-81250B)

5. Acceptance Testing:

5.1 The complete factory and site acceptance plan for the system shall be developed by the contractor; reviewed and modified/approved (as appropriate) by the Government POC technical representative; and mutually agreed upon prior to conducting any test.

Documentation verifying the acceptance testing and verification shall be provided to the Government.

5.2 Robotic Shot Peen - Factory Acceptance Testing (CDRL A006, Factory Acceptance Test Plan, DI-QCIC-80553)

5.2.1 The contractor shall completely setup the entire system, robot hardware/software, subsystem hardware/software.

5.2.2 Once the setup is completely assembled, working and the Government has approved the test plan, the contractor shall notify the Government POC via email and within thirty

(30) days the Government shall send representative(s) to verify all the requirements in Section 3 have been met.

5.2.3 Upon successful demonstration of the above, the Government will give approval to ship the system to Robins AFB for installation.

5.3 Site Acceptance Testing (CDRL A007, Site Acceptance Test Plan, DI-QCIC-80553)

5.3.1 Once installation at Robins AFB is completed and the Government has approved the test plan, the contractor shall notify the Government POC via email and within one (1) week the Government representative(s) shall verify all the requirements in Section 3 have been met.

6. Installation:

6.1 The systems shall be installed by the contractor/vendors qualified representative(s) in the government’s designated facility/location on Robins AFB, GA. All items shall be assembled and installed utilizing best commercial practices and manufacturer’s installation procedures.

The government shall supply all required utilities within ten (10) feet of the installation site.

To have the utilities installed and ready for connections, the contractor shall provide a list of all required utilities along with the required quantity and description, within the initial project planning chart (CDRL A008, Project Planning Chart, DI-MGMT-80507C)

7. Training:

7.1 Within fifteen (15) days of installation and site acceptance testing completion, operator and maintenance training will be provided for up to 10 Air Force civilian equipment operators and service technicians by the contractor’s qualified representative. The listed training shall be provided for the system installed. The contractor shall provide an operators training manual, maintenance manual, and a programming manual for the system installed. (CDRL A009, Training Materials, DI-ILSS-80872)

7.2 Training shall include:

7.2.1 Two (2) weeks of operator training, to include production runs on assets and review of the operation manual.

7.2.2 One (1) week of maintenance training, to include a complete preventive maintenance cycle, basic troubleshooting, review of the electrical/mechanical drawings and maintenance manual, and review of the HMI/PLC code.

7.2.3 Two (2) weeks of programming/engineering training, to include a complete part creation sequence and review of the programming manual.

8. Additional Requirements:

8.1 Contractor shall have robotic shot peening and machining experience and depot level experience.

8.2 A final walk through inspection shall be conducted with the Government Technical POC after the installation has been completed. The contractor will coordinate the final inspection/acceptance walk through date and time with the Government POC. Any components damaged, missing, or installed improperly will be identified and corrected by the contractor in a timely manner prior to completion of the contract. Only the Contracting Officer is authorized to make changes to the resulting award document and/or contract on behalf of the Government.

9. Delivery and Shipping Instructions. Delivery and installation shall be no later than twelve (12) months after contract award date. The Contractor shall ship the robotic shot peen system Freight on Board (FOB) Destination, according to commercial packaging recommendations, and shall coordinate the date and exact location for delivery in advance with the Government POC.

Ship To:

402 CMXG/MXDEE

Building 142 Robins AFB GA 31098

DODAAC: F3QCCM

ATTN: Chad Steger, 478-222-4720 Alternate: James Prince, 478-222-4070 Alternate: Scott Swartz, 478-222-4087

10. General Information

10.1 Government POCs: The on-site Government points of contact are:

Primary: Alternates:

Chad Steger James Prince Scott Swartz

402 CMXG/MXDEE 402 CMXG/MXDEE 402 CMXG/MXDEE

Robins AFB, GA Robins AFB, GA Robins AFB, GA Comm 478-222-4720 Comm 478-222-4070 Comm 478-222-4087

10.2 Recognized Holidays. Unless otherwise required by the Government, the Contractor shall not have access to Government facilities to work on the following federal holidays: New Year’s Day, Martin Luther King Day, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Days, Thanksgiving Day, and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

10.3 Access to Government Facilities. The Government POC will ensure Contractor personnel are escorted by Government personnel at all times while the Contractor is working in building 142. The Air Force has mandated visitors, to include all non-DOD cardholders, to consent to a check of their criminal history prior to being allowed access to installations. The check will be conducted at the Visitor Control Center (VCC) located by the Watson Boulevard Gate (main gate) to the base.

10.3.1 Contractor personnel will need a valid driver’s license or state-issued identification and a social security card, which will be checked by name, dates of birth, and social security number.

Contractor personnel who wish to drive on base must present a valid driver’s license, vehicle registration, and proof of vehicle insurance.

10.4 Security Requirements.

10.4.1 Government Security Regulations. The Contractor shall ensure personnel, information, system, facility, and international security requirements are met in accordance with DoD 5220.22- M, Air Force Instruction (AFI) 31-101, Integrated Defense.

10.4.2 Contractor Security Clearance: Contractor personnel are not required to have a security clearance to perform the required services. Contractor personnel shall not be authorized access to classified and/or sensitive, but unclassified, information and/or materials or be permitted to work on classified and/or sensitive, but unclassified, projects and/or programs without a proper security clearance and a need-toknow.

10.4.2.1 All Contractor personnel that do not possess a security clearance will be escorted by Government personnel 100 percent of the time while working within a secure Government facility or on the flight line on a Government installation.

10.4.3 Communications Security (COMSEC). The Contractor shall use only secure communications methods and/or equipment to transmit or otherwise transfer classified and/or stegersensitive, but unclassified, information in accordance with DoD 5220.22-M. 9

10.4.4 Government Automated Information Systems. Contractor personnel will not require be provided, access to Government Automated Information Systems to include access to the Robins Air Force Base network.

10.4.5 Operations Security (OPSEC). The Contractor shall ensure compliance with OPSEC requirements including procedures to protect classified and/or sensitive, but unclassified, Government projects and/or programs. The Contractor shall ensure Contractor personnel who perform work at Robins AFB or another Government facility comply with the OPSEC procedures of the facility.

10.4.6 Security Incident or Violation. The Contractor shall immediately notify the Government Security Office of any potential or actual security incidents or violations including potential or actual unauthorized disclosure or compromise of classified and/or sensitive, but unclassified, information.

10.4.7 Contractor Identification. Contractor personnel shall wear visible identification designating them as Contractors at all times while on Robins Air Force Base.

10.5 Contractor Safety Program.

10.5.1 The Contractor shall establish and maintain a safety and health program in accordance with the elements listed in the Appendix C (Safety Requirements). The Contractor shall submit a Safety and Health Plan 10 days after award for review and acceptance by the WR- ALC/SE (Safety Office). The Contractor shall ensure their Safety and Health Plan addresses, in detail, the items listed in the Appendix C. If task specific procedures are incorporated into a company local document, ensure those procedures are included/attached to the company's Safety and Health Plan.

Referencing the company's local procedure/ document in the safety plan is not adequate. If the company's local procedure/document is not attached; Safety Plan will be returned “Not acceptable.”

(CDRL A010, Contractor’s Standard Operating Procedures, DI-MGMT-82080/T)

10.5.2 The contractor Safety Plan shall address in detail the items listed in the Contract Appendix C, Part II through Part IV as applicable. For task specific procedures identified in the Contract Appendix C, the contractor’s internal procedures for those tasks must be identifiable within the submitted Safety Plan or shall be provided in an amendment or addendum to the company's Safety Plan. If task specific procedures identified in the Contract Appendix C, are not submitted with the contractor's Safety Plan, the submitted Safety Plan will be returned as NOT ACCEPTED. The contractor will have 5 working days to resubmit the Safety Plan, amendment or addendum to address or correct issues identified for non-acceptance. The WR-ALC Safety Office will provide acceptance or non-acceptance of the resubmission within 5 workings days of receipt to the COR who will notify the CO.

10.5.3 Mishap/Incident Reporting: The Contractor shall report all mishaps/incidents in accordance with the contract Appendix C. The Contractor shall immediately secure the mishap scene and damaged property and impound pertinent maintenance and training records until released by the Government's Safety Office (WR-ALC/SE). Such release shall be accomplished through the CO. The Contractor shall cooperate and assist Government personnel in the investigation of the incident and submit an Accident/Incident Report within 24 hours of the accident/incident. The Contractor shall require all subcontractors to comply with required safety, health and fire standards.

(CDRL A011, Accident/Incident Report, DI-SAFT-81563/T)

10.6 Agency Affirmative Procurement Programs (formerly GPP). In accordance with FAR 23.404(b)(1), 100% of purchases of Environmental Protection Agency (EPA)- designated products included in the Comprehensive Procurement Guidelines (CPG) list [https://www.epa.gov/smm/comprehensive-procurement-guideline-cpg-program] and/or United States Department of Agriculture (USDA)-designated products included in the bio based product listings [http://www.biopreferred.gov] shall, at a minimum, meet the EPA or USDA standards for recovered materials or bio based content, respectively, unless an item cannot be acquired competitively within a realistic timeframe, meet appropriate performance standards, and/or be acquired at a reasonable price.

10.6.1 In accordance with FAR 23.404(a)(iii), the Contractor shall provide estimates and verification of recovered material for EPA-designated CPG products and certification for both EPA-designated CPG products and USDA- designated bio based products. In accordance with the Robins Air Force Base, Georgia / Green Procurement Program (GPP) Plan, the Contractor shall provide estimates and certifications to the Government for completion of the applicable attachment(s) to be included in the Purchase Request (PR) package.

10.7 Environmental Management System (EMS). Environmental Management Systems (EMS) Awareness Training: All contractor personnel working on Robins AFB who perform activities on the installation are required to complete Air Force-provided initial EMS Awareness Training. It is the responsibility of the Prime Contractor to ensure that all sub-contractors, vendors, and employees complete this training prior to beginning work on Robins AFB. Notification of training completion shall be sent to both the Robins AFB Contracting Officer (CO) to be maintained in the contract file and Environmental Management, 78 CEG/CEIE, (78ceg.cev.FrontOfc@us.af.mil) for tracking purposes. Failure to provide documentation of EMS Training may result in termination of the contract.

10.7.1 EMS training is provided by Environmental Management at (478) 327- 8104 or (478) 926- 9645. Contractors have two options to satisfy the mandatory EMS Awareness Training requirement.

Contractors that do not have a Common Access Card must exercise Option 2.

10.7.2 Option 1 (Preferred Option): The Air Force version of EMS Awareness Training is available through the Advanced Distributed Learning Service (ADLS) website:

https://golearn.adls.af.mil/kc/rso/login/ADLS_login.asp. EMS Awareness Training is located under the miscellaneous tab. This option is only available to contractors who have a CAC and takes approximately 10 minutes to complete.

10.7.3 Option 2: Contractor requests a copy of the Robins EMS Awareness Training Power Point Presentation from Environmental Management. The request should be sent to the Environment Management Workflow Box at the following email address, 78ceg.cev.FrontOfc@us.af.mil. Once the presentation is received, the contractor is responsible for ensuring that all his/her employees view the training.

10.8 Mission-Essential Functions. Mission-essential functions as defined in DFARS 252.237- 7023(a)(2) do not apply to this requirement.

11. Government Furnished Property (GFP): None.

12. Other instructions.

12.1 Contractor shall provide signs, barricades, and lights as required to protect base personnel.

12.2 Schedule. The contractor shall schedule and perform the work as to minimize negative impacts on production.

12.3 The contractor shall remove all packing materials and residue from the area and properly dispose of these off base. The work area shall be maintained in an uncluttered and safe condition at all times or work will be terminated until the conditions are corrected.

12.4 Under no circumstances shall the contractor use Government equipment such as forklifts, ladders, stools, tools, etc., during equipment installation.

12.5 The systems shall include all of the necessary consumables required for initial operation including media to be used in shot peen.

13. Warranty: All standard Warranty provisions shall be included with the bid package but as a minimum shall include one (1) year parts and labor from the time of acceptance for defects in material and workmanship.

14. Bid Package Requirements:

14.1 Robotic Shot Peen (L1WC04)

14.1.1 Total cost for each system

14.1.2 Break down cost – per priced CLIN:

14.1.3 Basic system layout, to include:

14.1.3.1 Robot

14.1.3.1.1 Robot model (for example only- Fanuc R-2000iB)

14.1.3.1.2 Robot controller model (for example only- Fanuc R-30iA)

14.1.3.2 Booth, top view of booth layout showing:

14.1.3.2.1 Operator control station/HMI location

14.1.3.2.2 Robot location

14.1.3.2.3 Work envelope

14.1.3.2.4 Robot control cabinet location

14.1.3.2.5 Subsystem control cabinet location

14.1.4 RoboGuide simulation to demonstrate work envelope and robot reach with the C-130 propellers and C-17 slat tracks mounted on a representation of the contractor designed fixture.

14.1.5 Estimated schedule

15. Data Deliverables/Contract Data Requirements Lists (CDRL):

CDRL # Ref. Para. Description A001 3 Commercial Off the Shelf Equipment Manuals and

Associated Documents (Operator/Maintenance Manuals, Spare Parts List, Schematics)

A002 3.1.8 Cybersecurity A003 4.1.1 Conference Minutes PDR A004 4.1.2 Conference Minutes CDR A005 4.1.3 Conference Minues FDR A006 5.2 Acceptance Test Plan-Factory A007 5.3 Acceptance Test Plan-Government Site A008 4.1.1.1, 6.1 Project Gantt Chart A009 7.1 Training Material A010 10.5.1 Contractors Standard Operating Procedures A011 10.5.3 Mishap Report

15. Data Deliverables/Contract Data Requirements Lists (CDRL):