Performance Assurance SOW.docx

AIRCRAFT METALS TECHNOLOGY PURCHASE OF

PERFORMANCE ASSURANCE

STATEMENT OF WORK/SALIENT CHARACTERISTICS

FOR

60 MXS/MXMFA

24 FEBRUARY 2021

INTRODUCTION

The technical requirements for materials and the performance of work as required under this contract are contained in this document. This document contains the basic requirements for the Performance Assurance Plan. The 60TH MXS Fabrication Flight requires a Performance Assurance Plan with certified OEM technician(s) from HAAS, SODICK and OMAX to aid in the longevity of 31 manufacturing and aircraft sustainment equipment items. In turn, reducing equipment downtime, manufacture lead times and increasing primary duty training hours. This plan will provide the prescribed OEM technician(s), biannual, quarterly and reactive inspections/maintenance repairs. We require a single provider to oversee all services listed below in order to streamline communication, prevent downtime and reduce additional costs.

1. PROJECT LOCATION

Performance Assurance will be provided for the 31 equipment assets located in Building 803, Fabrication Flight on Travis AFB, CA.

1.1 Title

Statement of Work for purchase of Performance Assurance.

2. SCOPE

2.1 General

The contractor shall provide the following:

Performance Assurance Biannually & Quarterly with: Water Treatment System Service

The contractor shall provide services that meets the following specifications/salient characteristics:

Performance Assurance

· Includes Biannual & Quarterly with: Water Treatment System Service to the 31 applicable machines below.

· Encompasses all major maintenance checks as recommended by OEM from experienced technicians.

· Provide funding options with reactive service.

· A report left with the facility outlining work performed and the conditions of the machines as well as recommendations to bring machine to full specs

Maintenance Checklists by Machine Type: Hass

· Comprehensive Calibration Analysis

· Vibration Analysis

· Drawbar Force Test

· Geometry Inspection

· Renishaw Ball bar Test

Inspections specific to Mills and Lathes:

· Way Lube System

· Clean filters

· Inspect Lines and fittings

· Check operation

· Verify lube/pump operation

· Pneumatic System

· Clean filters

· Replace filters

· Check pressure/adjust the regulator

· Inspect for leaks

· Coolant System

· Remote/Check pump and motor

· Mechanical System

· Check machine level

· Verify spindle sweep

· Verify spindle tram

· Check gear shift operation

· Check spindle lube and air blast

· Check spindle orientation alignment

· Check shot pin operations

· Change gearbox oil

· Check backlash of X, Y and Z-axis

· Inspect drive belt

· Inspect and adjust tool changer system

· Inspect spindle taper condition

· Inspect way cover wipers

· Check drawbar height

· Drawbar dynamometer test

· Spindle run-out test

· Check drawbar stroke for correct tool knockout dimension

· Verify ATC tool change

· Inspect ATC system

· Lubricate ATC mechanism bearings

· Electrical system

· Check voltages

· Inspect connections/terminals

· Inspect grounds

· Check limits switches/safety locks

· Inspect and clean spindle sensor

· Clean electrical cabinet

· Check safety interlocks

· GIB adjustment

· Adjustment of Gibs to maintain axis rigidity and accuracy

Maintenance Checklists by Machine Type: Waterjet (OMAX)

· Table inspection, machine inspection report to be provided following the service. Test cut for accuracy, adjust if necessary

· Two major pump rebuilds to be performed on two of four visits

· Four scheduled visits, 8-hour days

· Two major pump rebuilds to be performed on two of the four total site visits, please expect additional costs if your machine possesses additional pumps

· If additional parts are found to be defective or require replacement, the customer will be responsible for the cost of those parts at a discounted rate of list minus 10%

Maintenance Checklist by Machine Type: Band Saws

· 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 wear, 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. 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. Recalibrate the blade speed indicator.

· Change Hydraulic oil and filter, if needed.

· Check the hydraulic system for leaks: inspect the solenoid valve, cylinders, gauges, fittings, et.

· 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. Recalibrate DRO and/or computer, if needed.

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

Maintenance Checklist by Machine Type: Grinding Machines

· Electrical

· Inspect for damage to switch gear, wiring and/or conduit

· Check isolator is lockable in off position

· Check operation of start/stop switch

· Check emergency stop where fitted

· Guarding

· Check all guards are secure and function correctly (includes latches, locks, and fasteners and/or interlocks if fitted)

· Fitment and Operation

· Clean machine of all foreign matter

· Check that wheels are not chipped, clogged (loaded), glazed or cracked

· Machine checks

· Adjust Gib strips on all sides

· Examine drive belts for flaws and correct tension, adjust if necessary

· Check gear train (Stud gear, change gear, etc.) for correct mesh and alignment, adjust if necessary

· Lubricate ways and slides

· Check and adjust saddle to apron screws

· Check operation of quick-change gear box if fitted

· Check machine operation

· Replace coolant at least once a year

Maintenance Checklist by Machine Type: Wire, EDM

· Re-level machine

· Check Y Axis

· Check X Axis

· Circuit Isolation

· Check Nc Power Supply

· Check Discharge Circuit

· Check Heavy Duty Unit

· Check Motor Drive

· Check Relay Switching Circuit

· Check Service Tank Circuit

· Circuit Voltage Adjustments

· Check NC Power Supply

· Check Discharge Circuit

· Check Heavy Duty Unit

· Check Motor Drive

· Check Relay Switching Circuit

· Check Service Tank Circuit

· Filter & Fan Inspection

· Air-Flow Filters

· Cooling Fans

· Dielectric Filters

· Aspirator Unit

· Clean & And Inspect

· Clean & Inspect All Pump Intakes And Resistivity Probe

· Solenoid Valves

· Check Functionality

· Discharge Cables

· Check for cracks or breaks

· Inspect Guides

· Check Wear (Lower, Awt & Split)

· Inspect Guide Cylinder

· Check Hydraulic Levels

· Inspect Conductivity Pieces

· Inspect Nozzles

· Adjust Lower Guide Height to Specifications

· Inspect Wire Path System

· Wire Spool Backup Motor

· Tension Clutch & Roller

· Lower Ceramic & Roller

· Wire Ejection Pinch Rollers

· Clean All Pulleys, Rollers, Float Sensor, Seal Jets

· Inspect Wire Chopper (If Applicable)

· Inspect Wire CHOPPER BLADES (IF APPLICABLE)

· Taper Cutter Accuracy

· Adjust Table to Lower Value (If Applicable)

· Adjust Table to Limits Value (If Applicable)

· AWT Adjustment

· Inspect Awt Pipe

· Inspect Cutters

· Clean & Grease Pipe Guide Rail

· Adjust Belts & Spring

· Check Alignment & Perpendicularity

· Check Awt Jet & U/V Offset (If Applicable)

· Discharge Voltage

· Inspect All Fuses

· Inspect Printed Circuit Board & Connections

· Verify Output Voltages

· Check Discharge Wave Forms (Oscilloscope) (If Applicable)

· Test Cuts

· Check Speed

· Check Accuracy

· Check Taper

Maintenance Checklist by Machine Type: Misc. Manufacturers

· Electrical connections

· Printed circuit boards

· All voltages

· Cables, switches, fans, motors, etc.

· All machine functions and safety features associated with it

· Check all bots and screws for tightness

· Calibrate or re-align geometric machine alignments

· Check ram and table alignment, if applicable

· Check all lines and connections

· Replace and/or clean filters

· Check any hydraulic pumps, and pressure relief valve(s) for maximum pressure

· Air lube system oil level and operation

· Proper operation of servo fans

· Run machine accuracy verification pattern

· Inspect turret drive gearbox, if applicable

· Auto index lubrication, if applicable

· Check flywheel and/or drive belts for tension, cleanliness, and wear

· Work clamp functionality

Water Treatment System Service (WTSS)

· Sump-pump water out of Clean/Dirty Tank into SRS Hopper

· Wipe out Clean/Dirty tanks. Customer is solely responsible for handling/disposing of any and all hazardous waste in accordance with their facilities hazardous waste procedures.

· Clean & Inspect Pump White Tank

· Remove and Clean WRS Pump Suction Screen

· Drain Filter’s Vessels and long handled Brush, and then Rinse

· Clean Ozone Stone

· Clean & Calibrate TDS Probe

· Clean Laminar Flow Filter

· Replace all CLS, RO or Wall Mount Filters

· Collect Updated Water Sample(s) for Analysis

· OMAX will collect a second water sample at 60 days to monitor for changes

· Phone call at two weeks after service from OMAX Phone Support to evaluate success

Government Point of Contact: The contractor shall coordinate with MSgt Christopher Lauer, TSgt March Tighe, or Mr. Jeffrey Bruns for any required coordination.