HAAS CNC and Omax Waterjet Maintenance Plan SOW final.pdf

CNC AND WATERJET MACHINES-MAINTENANCE AND REPAIR February 3, 2023

STATEMENT OF WORK

This statement of work is for preventive maintenance and repair of the following Haas Computer Numerical Controlled (CNC) machines and the OMAX Waterjet located at the 911th Airlift Wing, Pittsburgh PA.

HAAS TL2 TOOLROOM LATHE SN: 3086841

HAAS TL2 TOOLROOM LATHE SN: 3119621

HAAS ST30 LATHE SN: 3114492

HAAS MINIMILL SN: 1160667

HAAS VF 4 SN: 1160652

HAAS VF 8 /40 SN: 1150895

OMAX 1530/M20 SN:M15305598

1. BACKGROUND/INTRODUCTION:

The 911th Maintenance Group (MXG) has numerous CNC machines and a Waterjet cutter that is required to be fully operational to support the demanding worldwide need for the C-17 Aircraft fleet that the MXG supports. Due to this stringent requirement, the 911 MXG needs an annual maintenance and emergency repair plan in place to ensure that all OEM required preventive maintenance is performed on time and that emergency support is available to minimize the time that these machines are down.

2. OBJECTIVE:

The objective of this contract is to ensure that with annual maintenance and technical support, the 911 Maintenance Group’s Fabrication Flight can support the C-17 fleet with engineering and design of parts needed without complications of equipment failure or malfunctions.

3. SCOPE OF WORK:

The contractor shall provide all, labor, material, parts, and equipment necessary to perform preventative maintenance and emergency repairs on the Haas CNC machines and the OMAX Waterjet.

4. DUTY HOURS:

The normal hours of operation are 7:00AM to 4:00PM, Monday through Friday.

4.1 RECOGNIZED HOLIDAYS:

New Year’s Day - 1 January Martin Luther King Day - 3rd Monday in January Washington’s Birthday – 3rd Monday in February Memorial Day - last Monday in May Independence Day - 4 July Labor Day - 1st Monday in September Columbus Day - 2nd Monday in October

Veteran’s Day - 11 November

Thanksgiving Day - 4th Thursday in November Christmas Day - 25 December

If these holidays fall on Saturday, the preceding Friday will be observed. If these holidays fall on Sunday, the following Monday will be observed. If a holiday falls on a scheduled service day, the Contractor will be responsible for rescheduling services for the first day post the holiday observance.

5. MAINTENANCE SERVICE REQUIREMENTS:

The contractor shall provide preventative and emergency maintenance services through technical support via telephone or email, onsite certified maintenance technicians and replacement parts delivery. The contractor’s certified personnel shall perform complete preventative maintenance on each Haas CNC machine once per calendar year in accordance with the machine classification. These services shall be accomplished within Pittsburgh ARS normal duty hours.

All preventive Maintenance (PM) shall be scheduled and accomplished in a period of six (6) week consecutives during Twelve (12) month calendar period. The contractor shall coordinate planned arrival dates with the government’s Technical Representative identified in Section 10.

The technician shall notify the Technical Representative upon arrival at Pittsburgh ARS, PA.

The contractor shall make every attempt to have the necessary repair parts needed to complete the repairs onsite upon arrival of the service technician. Only new OEM repair parts or components, or certified replacements of equal quality, shall be used to repair the equipment. All replaced parts shall become property of the Government. The contractor’s certified personnel shall arrive on site within seventy-two hours (three calendar days), after notification that onsite repairs are required.

5.1 Reports:

At the end of each reactive maintenance service visit, the contractor shall provide the government’s Technical Representative with a written report within 10 days of visit. The written report shall contain the following.

a. Status of the machine upon arrival

b. Corrective Action Statement: Description of malfunction. Corrective action. Repair time. Replacement parts required. Cost of required repair parts and labor to complete the job.

6. CONTRACTOR’S POINT OF CONTACT (POC):

The contractor shall provide the Government with a designated POC’s name and telephone number. The contractor shall also furnish a contractual point of contact to include: name, email address, phone and fax numbers.

7. WARRANTY OF PARTS/MATERIALS:

The Contractor shall warrant all workmanship and parts in accordance with standard commercial practices.

8. ANNUAL PREVENTATIVE MAINTENANCE:

The contractor’s certified technician shall perform preventive maintenance in accordance with the Statement of Work and all major maintenance checks recommended by Haas Automation, Inc. as well as backup machine parameters and apply software updates. The following shall also be accomplished during the specific preventative maintenance (PM) visit.

8.1 MECHANICAL SYSTEM- Mills and Lathes - The contractor shall perform the following, at a minimum, preventative maintenance tasks:

• Check to ensure machine is level. Level machine if required

• Verify spindle squareness with axes.

• Verify spindle sweep and spindle tram

• Check gear shift operation – if applicable

• Check spindle lubrication and Spindle air blast.

• Check spindle orientation alignment.

• Check shot pin operation – if applicable

• Change gearbox oil.

• Check backlash in X, Y, and Z-axis.

• Inspect drive belts.

• Inspect and adjust tool changer system.

• Inspect spindle taper condition.

• Inspect way cover wipers.

• Check draw bar height.

• Inspect rigid tap encoder operation.

• Check tool change operation.

• Clean/lubricate tool changer.

• Inspect counterbalance system.

• Inspect lines, hoses, and cables.

• Perform dynamometer test

• Perform spindle run-out test -if applicable

• Check drawbar stoke – ensure correct tool knockout dimension – if applicable

• Verify ATC tool change– if applicable

• Inspect ATC system – if applicable

• Lubricate ATC mechanism bearings – if applicable

8.1.1 During the PM or Performance Assessment – The contractor shall attempt to correct all deficiencies or tolerance issues and related conditions on the machine that can be corrected through adjustment via control parameters or mechanical adjustment of the machine. If the condition cannot be corrected through these means, the technician will determine what is needed to correct the machine and will notify the technical representative and the Contracting Officer of the estimated time of when the machine will be back in an operational status.

8.2 WAY LUBRICATION SYSTEM - The contractor shall perform the following, at a minimum, preventative maintenance tasks:

• Clean filters

• Inspect lines and fittings

• Check operation.

• Verify way lubrication and pump operation.

• Inspect each axis ways for indications of wear.

The government will be responsible for the disposal of all used way lubricants to be removed from Government owned Haas equipment. The government’s technical representative and the 911th Civil Engineering Environmental Section will be notified before the removal of any coolant, oils and fluids. The Contractor will be responsible for adhering to all Federal and State Environmental requirements when removing any coolant, oils and fluids, and will aid in the cleanup if found responsible for any unintended release or spill.

8.3 COOLANT SYSTEM - The contractor shall, at a minimum, remove/check pump and motor. The government will be responsible for the disposal of all used way lubricants to be removed from Government owned Haas equipment. The government’s technical representative and the 911th Civil Engineering Environmental Section will be notified before the removal of any coolant, oils and fluids. The Contractor will be responsible for adhering to all Federal and State Environmental requirements when removing any coolant, oils and fluids, and will aid in the cleanup if found responsible for any unintended release or spill.

8.4 AIR SYSTEM- The contractor shall perform the following, at a minimum, preventative maintenance tasks:

• Clean/Replace filters.

• Check pressure/adjust regulator.

• Inspect system for leaks.

8.5 ELECTRICAL SYSTEM- The contractor shall perform the following, at a minimum, preventative maintenance tasks:

• Check voltages.

• Inspect connections/terminals.

• Replace tool change relays.

• Inspect grounds.

• Check limit switches/safety locks.

• Clean electrical motor brush dust build up where applicable from electrical brushes.

8.6 GIB ADJUSTMENT – The contractor shall ensure that the Gibs are adjusted to maintain axis rigidity and accuracy – if applicable

8.7 WATERJET CUTTER REQUIRED MAINTENANCE

The contractor’s certified technician shall perform preventive maintenance in accordance with the Statement of Work and all major maintenance checks recommended by OMAX, as well as backup machine parameters and apply software updates. The following shall also be accomplished during the specific preventative maintenance (PM) visit.

• Inspect all ball screw and drive/bearing assemblies

• Replace all drive belts

• Replace all filters

• Review servo card stored histories/confirm normal load limits

• Calibrate z-axis motion

• Grease or oil all lubrication points

• Calibrate X, Y, Z-axis movement and square to primary home position

• Rebuild pump

• Clean/Inspect low pressure plumbing

• Clean/Inspect plungers, manifold, check valves, pump plumbing on high pressure side

• Inspect or rebuild swivels

• Inspect/Clean nozzles and flow components

• Check pressure settings

• Install latest version of OMAX software

• Review changes in software and machine settings with operating personnel

• Perform test cut

• Sample water and provide results

8.8 BALL BAR CALIBRATION- The contractor shall at a minimum, test circularity and verify the position accuracy.

8.8.1 The contractor shall, at a minimum, verify the turret/spindle and tailstock alignment. If the turret/spindle and tailstock alignment is out of tolerance the alignment shall be corrected. The service report shall indicate the before and after.

8.9 Vibration Analyzer Test- The contractor shall, at a minimum, perform vibration analysis to verify machine vibration against established criteria.

8.10 WATER TREATMENT SYSTEM REQUIRED MAINTENANCE

The contractor’s certified technician shall perform preventive maintenance in accordance with the Statement of Work. The following shall also be accomplished during the specific preventative maintenance (PM) visit.

• Pump water out of tanks into SRS hopper

• Clean or wipe out tanks

• Clean/Inspect pump white tank

• Remove and clean WRS pump suction screen

• Drain filter vessel, long handled brush, then rinse

• Clean Ozone Stone

• Clean/calibrate TDS probe

• Clean laminar flow filter

• Replace all CLS, RO or wall mounted filters

• Collect updated water samples for analysis

• Collect second sample at 60 days past service date to monitor for any change

8.11 TRAINING - During the PM Service the contractor shall be available to answer any questions regarding the operation, maintenance, or cutting of the machine. Reviews of new software changes should be provided to the end user.

9. REPORT:

At the end of each preventative maintenance visit, the contractor shall provide the government technical representative with a written report within 10 days of visit. The written report shall contain the following.

a. General Condition of machine.

b. Status of the machine.

c. Corrective Action Statement: Status of system and description of malfunction.

Location of system. Estimated repair time. Estimated time for parts to be received. Cost of required repair parts and labor to complete the job.

d. Ball Bar Test: A copy of the ball bar test results shall be included with the service report with a narrative prepared by the technician outlining the results/findings of the test.

h. Vibration Analysis: A copy of the results of the vibration analysis shall be included with the service report with a narrative prepared by the technician outlining the results/findings of the test.

10. GOVERNMENT POINTS OF CONTACT:

The following personnel are delegated as the government Technical Representatives and will coordinate directly with the contractor regarding all matters dealing with the maintenance of the CNC and Waterjet machines.

Primary:

MSgt Michael Howard 911 MXG/Fabrication Flight 412-474-8183 michael.howard.41@us.af.mil

Secondary:

MSgt Ashley Wiley 911 MXG/Fabrication Flight 412-474-8181 ashley.wiley@us.af.mil

10.1 Scope Changes: The Contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.

10.2 Surveillance/Communication: All technical surveillance of on‐site repair services will be performed by the Technical Representatives. After correction of each malfunction, the Contractor shall notify the Technical Representatives named in this contract. Communication of all technical matters pertaining to this contract shall be in writing directly between the contractor and the CO, 911 AW Pittsburgh ARS, ATTN:

Paul Davisson, 2375 Defense Ave, Building 210, Coraopolis, PA 15108.

10.3 Inspection - Technical Representatives from the Fabrication Flight or assigned maintenance personnel will monitor the contractor’s performance by physical inspection, review of reports/documents.

11. FACILITY ACCESS:

The contractor shall upon notification of contract award coordinate with the Technical Representatives identified in Section 10 to gain access to Pittsburgh ARS, PA. The contractor shall maintain as a minimum one (1) certified technician cleared for access to Pittsburgh ARS, PA at all times during the performance period of the contact. The Contractor’s Personnel shall complete any and all forms and training required for access to Pittsburgh ARS, PA that is deemed necessary during the contract period of performance.

mailto:michael.howard.41@us.af.mil mailto:ashley.wiley@us.af.mil

12. ACCESS AND GENERAL PROTECTION/SECURITY POLICY AND

PROCEDURES:

The contractor and all associated subcontractor employees shall provide all information and Real ID compliant identification required for background checks (DBIDS) to meet installation access requirements to be accomplished by the 911 AW Visitor’s Center. The contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204‐9, Personal Identity Verification of Contractor Personnel) as directed by DoD, USAF, AFRC, and/or local policy. In addition to the changes otherwise authorized by the change clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

12.1 Contractor shall acquire and need to return all issued U.S. Government installation badges, and/or access passes.

12.2 Contractor shall adhere to environmental regulations and practices in relation to Generation of Hazardous Waste, Prevention of Spills, Pollution Prevention/ Hazardous Waste Minimization.