24SNB57_SPECNOTE_att1.pdf

STATEMENT OF WORK

Statement of Work

For

Preventive Maintenance/Repair

1. Scope

This Statement of Work (SOW) sets forth the requirements to accomplish preventive maintenance/repair and satellite support (technical/phone) on various machines. These machines are used to manufacture various parts required for the support of a broad spectrum of Electronic Warfare tasks. The Electronic Warfare Program provides the warfighter with a broad spectrum of electronic surveillance, defense, attack, and countermeasure efforts. The machine shop equipment designation is identified in paragraph 1.1. Travel expenses shall be included in the cost of the preventive maintenance and or repair. This SOW provides the tasks for this effort.

1. Equipment Designation

The configuration of the equipment designated by manufactures name, model and serial numbers are as follows:

Manufacturer Model #/Nomenclature Serial # Initial

Maintenance

Annual

Maintenance

BLDG 41

Haas DS30Y Lathe 3116770 x x

Haas ST-25 Lathe 3100894 x x

Haas EC1600 Horizontal Mill 2054112 x x

Haas VF-5 Vertical Mill 26384 x x

Haas VF-4 Vertical Mill (1 of 2) 1050052 x x

Haas VF-4 Vertical Mill (2 of 2) 1060764 x x

Haas VF-4 SS Vertical Mill 1072578 x x

Haas TL-1 Lathe 69191 x x

Bridgeport Manual Mill J314690 x x

Hurco VMX42 Vertical Mill M442-164004090EHC x x

Maintenance

Annual

Maintenance

HE&M Saw Band Saw VT100HLA-60-

CTS

1310619 x x

Adira DNC880 Press Brake 66601225D x x

Grimco 1000 T Press N/A x x

Accushear 62506 Shear 02405 x x

Hardinge HLV-H Lathe HLV-H-155600 x x

Kellenberger Kel-Varia UR# IMF1000 Grinder

650592 x x

Harig 618 Hyd. Model, C6T34NC28A Man. Surface

Grinder

115658300 x x

Manford 5P500 EVSL/Kneemill 906466 x x

Haas VF-5XT/Mill 1126180 x x

BLDG 3234

Bridgeport Manual Mill 173521 x x

Instron 5984 Universal Testing

Machine 5984R6591 x x

Femco A-14 Horizontal Band Saw N/A x x

Omax 55100V Water Jet (1 of 2) B512398 x x

Omax 55100V Water Jet (2 of 2) B512576 x x

Extec Corp Labcut 5000 Advanced

Composite Saw 120110216 x x

Manford 5P500 EVSL Kneemill (1 of

3) 1415546 x x

Manford 5P500 EVSL Kneemill (2 of

3) 1415547 x x

Maintenance

Annual

Maintenance

Manford 5P500 EVSL Kneemill (3 of

3) 1212761 x x

BLDG 3224 & 3225

Polar King 1216 Walk-In Freezer A6064756 x x

Polar King L1316 Walk-In Freezer A18078676 x x

ASC EC2-8X4-320P700 Autoclave 03691 x x

ASC EC3-X52-00P650F Autoclave 08257 x x

American Autoclave

AA8-500150ELECT

Autoclave 12858 x x

BLDG 122

Hurco

VMX42DI Vertical Mill S443D1100659AFZCP x x

Hurco

VMX30DI Vertical Mill S343D11A0349AFZAH x x

Hurco VMX42SRTI S444T2300420DFBAH x x

Hurco VMX42 Vertical Mill M442-06025018EHA x x

Hurco VTXU/40T Vertical Mill MU44U-16001040DHCA x x

Hurco VMX42i Vertical Mill S443-1601077KFDCH x x

Willis 1250 II Vertical Mill 10933 x x

Willis 1050 II-EV Vertical Mill 13513 x x

Hurco TMX8MY Lathe TY801001049ACB x x

Haas TL2 Lathe 3118843 x x

Maintenance

Annual

Maintenance

Haas SL20 Lathe 63343 x x

Haas TL2 Lathe 3678647 x x

Hardinge HLV-H Lathe HLV-H-15748-T x x

Willis CP1550VS Lathe 07628 x x

Wilton 5211001 Drill Press 16474 x x

Wellsaw 1316A Band Saw 06905 x x

DoAll 2613-A Band Saw 441-01111 x x

Sodick LN2 Plunge EDM 00507 x x

Mitsubishi W31FSA-2 Wire EDM J2OM0545 x x

Arburg 375V 500-290 Vertical Injection Molding Machine

211100 x x

Milacron Q Series 400 / Injection Molding Machine

TC601DA010033 x x

Milacron MT225-18 Injection Molding Machine

T84A0100087 x x

Plastic Press Equipment DCA204E1PPE Injection

Molding Machine G39671 x x

Milacron MAGNA MV30 V0401AE020062 x x

Milacron MAGNA MV30 V0401AE020063 x x

Conair Franklin W025 Vacuum Loader 177083 x x

Conair Franklin W0025 Vacuum Loader 182128 x x

Conair HTR TH-1 Thermolator 408108 x x

Maintenance

Annual

Maintenance

Conair TW-V Thermolator (12 ea) 408343, 408295, 408341, 408293, 408342, 408292, 408294, 408296, 408345, 408344, 408401, 408352 x x

Conair DX25 Cart Dryer (3 ea) 408401, 408352, 408357 x x

Chevalier 618 Grinder A4919001 x x

Cincinnati N/A ID2TIZ-787 x x

Okamoto ACC16-32ST Grinder 88222 x x

Instron 5567 Universal Testing

Machine 5567R1113 x x

BLDG 198

Watson-Stillman 60-75 T Press x x

Denison 10 T Press GC10C01A68S05D15C29 x x

Hannifin 5 T Press 0GB-5B-5-2-1-M x x

Denison 2 T Press WR023MC202D366ACMR331A201 x x

JTM .75 T Air Press A1808 x x

Well MFG Group Cut-Off Saw K0E91159 x x

Monarch Manual Lathe 01954 x x

BLDG 3168

Dyna Mechtronics DM1007 Milling Machine N/A x x

ABB Automation Tech IRB2400L Robotic Arm N/A x x

2. Applicable Documents

There are no applicable documents other than the SOW. In the event of a conflict between any other documents and this SOW, the content of the SOW is the superseding requirement. Nothing in this document supersedes applicable Federal, State or Local laws and regulations unless a specific exemption has been obtained.

3. Requirements

The contractor shall document all efforts and progress in all areas of product/support. A Certificate of

Conformance (COC) shall be required for each individual repaired/preventive maintenance asset IAW ISO 9000 requirements.

The Contractor shall provide the requisite Subject Matter Expertise (SME), labor, material, equipment, resources, to repair, test and maintain the SME products and support components as listed in Paragraph

1.1. The contractor shall provide factory certified (or similar training/OTJ/certifications for technicians. Each individual Job Order shall provide the funding and specific tasking to execute the selected elements of the

SOW. The Contractor shall provide labor, material, and equipment to perform assigned tasks and shall include efforts to increase maintainability, reliability, testability, increase safety and cost. The major efforts for this requirement produce repair/rework of machines. The following sections outline the requirements for these efforts.

3.1 Repair of Repairables (ROR)/Rework Components

Repair of the machine shop’s assets will fall into CATEGORY 1 and 2 divisions as defined below:

CATEGORY 1 is for the evaluation, No Fault Found (NFF) fee and for the repairs.

CATEGORY 2 is for the firm fixed priced for annual preventative maintenance.

Firm Fixed Prices for Categories 1 and 2 will be negotiated between the vendor and the Naval Surface Warfare

Center (NSWC) Crane Division Procuring Contracting Officer (PCO).

CATEGORY 1: Clean, visually inspect and maintain machine shop assets. Disassemble to the extent necessary to verify failure and/or inspect for needed repair processes and parts of subassemblies as required. This process may include the removal and replacement of components in order to verify failures. If there is no evidence of failure, NFF, actions will include inspection and acceptance at

Destination by a Government representative. Items deemed Beyond Economical Repair (BER) after evaluation will be included in this category. Materials shall be shipped into NSWC Crane before the contractor will arrive to perform maintenance.

CATEGORY 2: Actions to be performed are annual maintenance of the machines listed in section 1.1. The annual maintenance requirements will be determined between NSWC Crane personnel and the contractor;

as machines may be added or subtracted from year to year. All maintenance performed shall be in accordance with the machine manufacturer. Comprehensive checks shall be made by factory trained technicians on the Mechanical, Electrical, Air, Coolant, Spindle and Way Lube systems. Contractor will provide all materials for maintenance and repair, and the government shall dispose of any HAZMAT.

Materials shall be shipped into NSWC Crane before the contractor will arrive to perform maintenance.

The address for shipment will be NSWC Crane, 300 Highway 361, BLDG 41NW, Crane, IN 47522-5001, Attention Scott Gamble.

Known OEM Maintenance and Checks Required Listed Below. This list does not include all of the machines listed in paragraph 1.1.

Mills and Lathes

Mechanical System Check machine level:

• Verify spindle sweep

• Check gear shift operation

• Check spindle lube and air blast

• Check spindle orientation alignment

• Check shot pin operation*

• 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 covers & 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

• Way Lube System

• Clean filters

• Inspect lines and fittings

• Check operation

• Verify lube/pump operation

• Coolant System: Remove/check pump and motor, (Inspect or Clean coolant tank and replace coolant as needed)

• Air System: Replace filters, Check pressure/adjust regulator, Inspect system for leaks

• Electrical System: Check voltages, Clean electrical cabinet, Inspect connections/terminals and grounds

• Inspect or replace tool change relays

• Replace or clean fan filter

• Check limit switches/safety locks

• Inspect motor brushes, clean & remove brush dust

• Lathe Only: Verify turret/spindle alignment

• Manual Machines: Change oil, filter and belts, Lubricate system and clean as necessary to be qualified as working properly.

• Adjust Gibs

• Check level and alignment

• Inspect general machine function

• Install the latest revision of software

Water Jet, OMAX

Machine areas inspected include but are not limited to:

• Inspect and grease ball-screws, pulleys and fittings.

• Replace all belts.

• Replace all filters.

• Rebuild and upgrade (when applicable) the OMAX pump, includes one Seal.

• Rebuild Kit and Check Valve Repair Kit, plus inspection of the bearings and plungers.

• Home the V pump.

• Rebuild all swivels using Swivel Rebuild kits

• Replace all High Pressure Tubing, Collars, Collets, Gland Nuts and Fittings.

• Install the latest revision of OMAX Software

Punch Presses

• Press drive oil level and filter

• Hydraulic system radiator

• Ram TDC stopping point

• No punch zones

• Turret guide bushing

• Clean and lubricate turret drive chains

• Air lube system oil level and operation

• Proper operation of servo fans

• Operations of interlock switches

• Run machine accuracy verification pattern

• Inspect turret drive gearbox

• Auto index lubrication

• Table lube system oil level and operation

• Clean leadscrews and way bars

• Condition of leadscrews and guide bearing wipers

• Flywheel V belts for tension, cleanliness and wear

• Workclamp functionality

• Table balls

• Clean slugs from lower frame and auto index area

• Clean shot pin bushings in turret

• Operation of auto index station

Press Brakes

• Electrical connections

• Printed circuit boards

• All voltages

• Cables, switches, fans, etc.

• All machine functions and safety features

• Check all bolts and screws for tightness

• Re-align back gauge and stops

• Adjust gibs on ram

• Check ram and table alignment

• Lubricate or grease all moving parts

• Check to ensure all safety features are in place

• Check all lines and connections

• Replace and/or clean filters (consumable items to be provided by customer)

• Pump and pressure relief valve(s) for maximum pressure

Wire EDM

• AWT: (Automatic Wire Threading) Cleaning thread jet.

• Inspect and adjust: Energizers: Index upper and lower energizers to ensure proper machining speeds: and operation.

• Inspect wire Spool: Hanging new wire on the machine.

• Inspect collection Box: Empty spent wire from collection box.

• Inspect rollers: Cleaning of the D, K,L,& M rollers,

• Inspect felt pads for rotating and clean

• Inspect and replace filters: (Main filters, AWT filter, Air filter).

• Inspect Di-Unit: Replace di-resin and clean conductivity probe.

• Inspect Guiding System: Check and clean all guides and perform wire alignment test.

• Inspect Powder Clutch Adjustment: Requires tensioning calibration.

• Inspect Water: Maintain reservoir water level Replace all water yearly.

• Inspect of machine heads, work tank, floats and seals.

• Install the latest revision of software

Band Saw

• Check all safety devices, emergency stops, safety interlocks, guards, covers, awareness barriers caution decals and warning decals are properly installed and are in good working order.

• Inspect gear reducer for external signs of bearing or gear ware, i.e. excessive shaft play or gear leash, seal leakage, or bearing noise. This is an external inspection only and does not guarantee the reducer from shaft, gear, or bearing failure.

• Check gear oil in reducer and oil seals, and recommend replacement if necessary.

• Check conditions of Vari drive, pulley wear and alignment. Align if needed. Check condition of belt. Check operation of powered speed changer, if equipped.

• Rehome the blade speed indicator.

• Change Hydraulic oil and filter, if needed.

• Check the hydraulic system for leaks: inspect the solenoid valve, cylinders, gauges, fittings, etc.

• On hydraulic saws: Inspect the oil cooler fan operation and change the filter, as needed.

• On all double column machines inspect the saw arm roller chain and lubricate.

• Service the blade tension assembly. Lubricate the slider plate and adjust the tension, if necessary

• Grease or oil all lubrication points as required i.e. idle wheel bearings, pivot points, guide rails, lead screws, pillow blocks and roller drive chain.

• On pneumatic machines: drain any water from system. Change or top off all hydraulic oil levels, i.e. tank, traverse control cylinder and feed rate control cylinder as required by manufacturer.

• On pneumatic machines: fill and adjust all airline lubricators. Lubricate lift cylinder and adjust all system pressures and check for air leaks.

• On hydraulic saws: adjust all system pressure and reset fine cutting pressure if so equipped.

• Check powered blade brush for proper operation and replace wire brush, if needed.

• Level saw base, feed and discharge table, if applicable

• Inspect all vises for vise plate ware and proper operation. Check the operations of the bar feed, check alignment of fee to saw, if applicable.

• Inspect the condition of carbide guides. Check the bumper block carbide for wear.

• Inspect band wheels for excessive wear, crowning of taper. Inspect the idle wheel bearings, and drive wheel run out.

• Check the alignment of guide arm assembly, check that saw base is square to vise and that the fall of the saw arm is within manufacturer’s specifications, if applicable.

Realign if needed.

• Inspect the blade tracking and adjust if needed.

Check the coolant system, if applicable. Check the pump operation and coolant mixture.

• Check the operation of all control switches and options. Check the alignment and operation of all limit switches. Test and run the machine in all operation modes.

• Test cut and checks for squareness and correct part length. Rehome DRO and/or computer, if needed.

• Provide recommended repair and spare parts list, if saw requires additional maintenance.

All Other Equipment listed in paragraph 1.1 shall be serviced to OEM specifications and where applicable, all software shall be updated to the latest revision.

3.1.1 Repair and/or Modification

a. The contractor shall furnish efforts including labor and materials as required to repair and /or modify repairable assemblies as specified in the individual Delivery Orders. The repairable assemblies shall be identified by manufacture’s name and serial number. (CDRL A001)

b. Units(s) to be repaired/ receive maintenance under this SOW shall be performed at NSWC Crane, Bldg. 41, B/C Bay, Bldg. 3234, Bldg. 122, Bldg. 198, Bldg. 3224, Bldg. 3225, and Bldg. 3168.

c. If and when repairs/maintenance are required, the Requiring Technical Activity (RTA) shall contact the

Contracting Officer for an on-site visit form from the contractor.

1. Advise the RTA if any portion of the required support is a result of the furnishing by the contractor of articles that were defective in material and workmanship or otherwise not in conformance with the requirements of the contract under which such articles were originally furnished, equipment with existing

GFE without replacement of GFE, or authorize the contractor to change the level of repair to reflect the effort in replacing the missing items. In the event the failed unit is determined to be Beyond Economical Repair

(BER), for this system defined as the cost to repair being 80% or greater than the cost to replace, the contractor shall notify the RTA within thirty (30) days of its receipt. Disposition of units(s) shall be as directed by the RTA.

3.1.2 Specification for Repair

a. The machines to be repaired under this contract are those identified in paragraph 1.1.

b. The contractor shall repair the subject units to the Ready For Issue (RFI) serviceable operating conditions and insure optimum reliability for the intended use in accordance with applicable contractor specifications.

c. Functions required to be accomplished in paragraph 3.1 shall consist of the following tasks:

1. Clean, visually inspect and maintain equipment.

2. Reassemble, functionally test and perform acceptance inspection.

3. Services changes, bulletins or modifications except as specified herein shall be incorporated by the contractor under the contract with prior approval from the Contracting Officer.

4. Acceptance testing shall be performed by the contractor and shall include all tests necessary to assure the material service conforms to the performance required to provide RFI material. The contractor shall retain the authority to conduct any test necessary to ensure compliance with the applicable specifications. The RTA will observe the performance test to ensure the repairs are complete.

5. The contractor shall provide status on its activities conducted under this SOW in a monthly status report. (CDRL A001)

3.2 Satellite Support

The Government requests satellite support (technical/phone support), which will allow for questions and support issues to be answered on a call in basis.

3.2.1 Program and Contract Management.

Contractor shall designate a Program Manager and Contracts Representative as POCs for all correspondence to and from the Government. Program support shall be conducted to ensure timely delivery of the required repairs and preventative maintenance.

3.2.2 Financial Status Reporting

Contractor shall track and report expenditures by individual repair and total expenditures on a monthly basis. See the attached Addendum (PM_REPAIR REPORTING DATA) for an example of the format for this information. (CDRL A002)

3.2.3 Repair Reporting.

The Contractor shall provide status on its activities conducted under the Repairs section of this SOW in a monthly status report. (CDRL A001)

3.4 On-Site Repair/Preventive Maintenance

The contractor shall be certified to perform tasks on each Manufacturer’s asset. The contractor shall adhere to all Government rules and regulations while on a Government installation and must be a U.S. citizen. The contractor will respond to the RTA within 48 hours of receipt of the required repair/preventative maintenance request.

4.0 Data Deliverables

The Contractor shall provide the following deliverables in accordance with the SOW & CDRL requirements:

Data Description Data Sequence Number SOW Paragraph DID Number

Repairable Item Inspection Report A001 3.1.1, 3.1.2, 3.2.3 DI-PSSS-80386A

Facilities Maintenance Report A002 3.2.2 DI-MISC-81423A