MATERIAL_ORDERING_DATA_&_STATEMENT_OF_WORK_REVISED.pdf

SPECIFICATIONS FOR VERTICAL STORAGE SYSYTEMS

DOCS 90386450 THROUGH 90386454

1. General Description of Vertical Storage Systems

1.1. This specification covers the minimum Government requirements for two (2) Vertical Lift Storage Systems and one

(1) Carousel storage system. The systems must be designed, built and installed to seismic zone 4 specifications. The systems shall have the capability to store various types of materials. Each storage system shall have a computerized lift/extractor at the center of the cabinet, with storage shelves/containers in front and behind the extractor. An operator shall be able to store/retrieve an item via a push button controller, using a micro-processor controller, mounted on a swivel arm to the side of the access opening. Containers/shelves (that hold parts) shall be delivered to an operator comfortably, at an optimum ergonomic height. Each Lift shall hold 88,000 lbs. overall. The carousel shall hold 1,296 lbs. per carrier. The Vertical Lift Storage Systems and Carousel storage systems shall be designed in accordance with requirements identified in these specifications.

2. General Lift Specifications:

2.1. The exterior dimensions shall be 117.16” wide by 163.69” deep by 192.5” high.

2.2. Each Lift shall have 13 pans. Each pan shall have a minimum width of approximately 96.8”, a minimum depth of approximately 50” and a height of approximately 3” and shall be galvanized, unslotted. Each pan shall have a minimum payload capacity of 1,544 lbs.

2.3. The extractor shall be driven by a four corner, metal chain drive system. This design ensures precise alignment of the extractor when retrieving or returning a pan. It also allows you to place all of the weight in one corner of a pan since it eliminates the tilting and skewing of shelves and containers that could lead to “crashes” caused by lateral tolerances of center supported or belt driven systems. Center supported, belt driven systems are unacceptable.

2.4. End Frames: modular

2.5. The front and back storage locations shall have the capability to automatically adjust for optimum storage of parts.

The pans/storage locations shall have supports that are positioned approximately every 3 inches, to allow for storage flexibility of various height parts.

2.6. The system shall automatically adjust the shelf/container height, performed via an advanced microprocessor, and on-board height sensing feature. This shall occur without the need for mechanical or electronic adjustments, and without operator intervention (allowing for optimal storage of parts).

2.7. The system shall have a programmable energy saving feature that will power down the inactive carousel after a predetermined time of inactivity in four stages or levels. Level 1, the background lighting of the TFT display is turned off. Level 2, the components of the electrical control system are turned off. Level 3, the lighting is dimmed.

Level 4, the carousel is turned off at the main switch.

2.8. The system shall have an optimization run feature with access priority that when activated will relocate the most often used pans or parts closest to the access opening ultimately reducing retrieval times and allowing for increased productivity. It will also create additional space by moving the pans together whenever space opens up between them due to the removal of larger items from a pan.

2.9. Self-monitoring LVS light curtain shall be installed at the operator access opening. This shall provide safety features that protect the operator from injury when the shelf/container is moving. This feature shall stop the shelf/container from moving, when an operator’s hand/arm is in danger of injury.

2.10. A Multi-layer safety system with a safety bypass system must provide redundant backups for all safeties, height sensors, positioning, and memory to eliminate down time. Backups to include:

2.10.1. Safety System Bypass – If the light barrier fails the system will work by operating with the door closed.

2.10.2. Height detection override – The unit can still operate if the height detection fails.

2.10.3. Positioning System – System operation can continue utilizing the backup positioning sensors.

2.10.4. Access Point Sensor System – The backup sensor allows continued operation if the first sensor fails.

2.10.5. Extractor (Lifting Platform) Sensor System – The backup extractor sensor allows continued operation if the first sensor fails.

2.10.6. Extractor (Lifting Platform) Limit Switch – Provided the first extractor limit switch at the top or bottom of the storage space fails, the backup limit switch takes over.

2.10.7. Shelf Memory – Safe unit operation can be continued without changing the inventory heights if shelf memory fails.

2.10.8. Drive Catch (Fingers for engaging shelf travel) Sensor – The second drive catch sensor is activated in a failure with the first sensor.

2.11. The system must provide at least 4 fail-safe overrides to ensure continuous operation that are easily activated by the operator via a micro-processor control system.

2.12. Lockable sliding door(s) with keys or automatic electronically locking doors (so stored parts can be secured).

2.13. An emergency stop button(s) shall be provided at the operator’s station that is of the mushroom type and colored red.

2.14. An energy saving LED operator lighting system shall be provided (full width) in the access opening.

2.15. Quality and durable construction of all system components. System structural components shall be rigid and stable.

2.16. An operator interface station (controller) shall be provided on the Lift that is easy to use, to store/retrieve parts. It shall be a Firmware-based unit, with no moving parts, utilizing industrial-grade compact flash memory that is insensitive to dust, dirt, and extreme temperature ranges, to provide high data security with no need for connection to a computer. The Microprocessor control system shall be a standalone database with a full-color touch-screen control and keypad with integrated real-time data browser, providing part and description search, order details, and space utilization information. Transaction logging feature shall provide data on the date, time, processing user, transaction type, quantity transacted, and affected storage location of each pick or put-away process. Provide inventory control features as a standalone unit and can be easily interfaced with external devices such as barcode reader, ID badge readers, and printer. These interfaces/ports will be on the unit already allowing the government to simply plug in a device and have that device work. The control system shall include part number, description, and minimum inventory level, File download capability eliminating the manual entry of information. The system shall be capable of processing kitting or job requests. It shall have the capability to send information to a desktop or printer and receive information from a bar code scanner. It shall also have the capability to hook a computer to it through an Ethernet connection allowing you to work at your desk or at the Lift itself. The controller shall also provide the following functions and capacities: Job management – priority controlled processing with acknowledgement of the quantity actually withdrawn; Storage strategies such as FIFO, FIFO with re-storage, selective access to storage locations, fixed location storage and random storage; Storage location unit size; Automatic size dependent storage location search (free space search); Minimum inventory feature with low stock warning and printout of a reorder recommendation list; Quantity factor and availability check for pick lists; Order picking can be sequential or route optimized (shortest route between all of the units); Storage data retrievable via web browser, partially editable.

Controllers that require a stylus pen are unacceptable.

2.17. Each system shall have soft starts and stops.

2.18. The operator work surface height shall be approximately 35 inches, with an access opening clear height of approximately 29 inches.

2.19. The system shall utilize one Trolley cart with external shelf management to allow pans to be pulled out of the Lift for easy access and allows users to operate the Lift while a pan is out. Provide one extra pair of Trolley cart docking guides to be anchored to a workbench by the government.

2.20. The system shall have an LED light bar with 16 LED’s that indicates the positon and depth of the article on the pan for quick retrieval.

2.21. The system shall have three paper copies of the manuals.

2.22. The system shall have one desktop computer with mouse, keyboard and monitor to allow the manager to view current inventory levels and review and print reports of usage, stock quantities, etc.

2.23. The system shall have one network laser printer to print reports from the Lift database.

2.24. Operations Journal Logging – which shall allow for tracking each transaction (storage to a new location, storage to an existing location, and retrieval).

2.25. Item Pool Management – which shall allow descriptive data and reorder points to be electronically sent to the unit, rather than having to type this information at the controller. Also allows for storage of this data without having a storage location assigned within the unit.

2.26. Access Code Management – which shall provide individual username/password functionality with the ability to control shelf access to specific users.

2.27. Energy Saving System that converts the kinetic energy of the descending extractor into electrical energy and feeds it back into the electrical supply system.

2.28. Shelf Lock – Locks pan while in access so that it will not move while in use. Pan is released by the push of a button.

2.29. Electrical power – Lifts shall run on 480Volt, 3 phase

2.30. OSHA Approved - The equipment specified herein shall be in compliance with the applicable OSHA regulations and be listed by one of the OSHA accredited laboratories or approved in accordance with CFR Title 29, Chapter XVII, Part 1910 and installed in accordance with applicable NEC/NFPA requirements.

3. General Carousel Specification:

3.1. This specification covers the minimum Government requirements for one (1) “Turn-Key” Carousel Storage System.

This system shall store various types of hardware/fasteners/tools/materials. The carousels shall have the capability to store bulky, heavy and dissimilar parts, with fast storage and retrieval times. An operator shall be able to store/retrieve an item via a push button & touch screen controller, using a micro-processor controller. Carriers (that hold spare parts) shall be delivered to an operator comfortably, at an optimum ergonomic height. These Carousel Storage Systems shall be designed in accordance with requirements identified in these specifications. The contractor shall provide the following (with all dimensions being +/- 3 inches):

3.2. One (1) Rotomat Industrial Carousel Storage Systems, including the following minimum technical features: All sides of the Carousel shall be enclosed including bottom, and powder coated in light grey. The dimensions are 187.8”H x 134.7” W x 68” D and an 11.8” worktable across the front of the carousel. There are to be 19 open carriers with a clear height of 13.27”, clear depth of 24.8”, a clear width of 108.26” and a .6” front lip to keep material from sliding off the carrier. Max carrier weight of 1,300 lbs. +/- 5%. Operator access height 43”.

3.3. The system shall have the capability (and be set-up) to share one database across all three units via an Ethernet cable connection. The contractor shall provide the Ethernet cabling connection.

3.4. The system shall have a programmable energy saving feature that will power down the inactive carousel after a predetermined time of inactivity in four stages or levels. Level 1, the background lighting of the TFT display is turned off. Level 2, the components of the electrical control system are turned off. Level 3, the lighting is dimmed.

Level 4, the carousel is turned off at the main switch.

3.5. Each system shall have a status imbalance monitor. The monitor will enable the microprocessor controller to achieve optimum distribution of the storage items by making loading recommendations that keep the stored goods evenly distributed thereby saving energy. Motors that are forced to push uneven loads wear out faster and use more energy compared to motors that are moving evenly distributed loads.

3.6. An operator interface station (controller) shall be provided on each Carousel that is easy to use, to store/retrieve parts.

The controller shall be mounted on a universal arm. It shall be a Firmware-based unit, with no moving parts, utilizing industrial-grade compact flash memory that is insensitive to dust, dirt, and extreme temperature ranges, to provide high data security with no need to connect to a computer. The Microprocessor control system shall be a standalone database with a full-color touch-screen control and keypad with integrated real-time data browser, providing part and description search, order details, and space utilization information. Transaction logging feature shall provide data on the date, time, processing user, transaction type, quantity transacted, and affected storage location of each pick or put-away process. Provide inventory control features as a standalone unit and can be easily interfaced with external devices such as barcode reader, ID badge readers, and printer. These interfaces/ports will be on the unit already allowing the government to simply plug in a device and have that device work. The control system shall include part number, description, and minimum inventory level. File download capability eliminating the manual entry of information. The system shall be able to process kits or job requests. It must be able to send information to a desktop or printer and receive information from a bar code scanner. It must connect to a computer through an Ethernet connection allowing you to work at your desk or at the Lift itself. The controller must provide the following functions and capacities: Job management – priority controlled processing with acknowledgement of the quantity actually withdrawn; Storage strategies such as FIFO, FIFO with re-storage, selective access to storage locations, fixed location storage and random storage; Storage location unit size; Automatic size dependent storage location search (free space search); Minimum inventory feature with low stock warning and printout of a reorder recommendation list; Quantity factor and availability check for pick lists; Order picking can be sequential or route optimized (shortest route between all of the units); Storage data retrievable via web browser, partially editable

3.7. Each system shall have soft starts and stops. The operator work surface height shall be approximately 43” from the ground.

3.8. The carriers shall be attached to the conveyor chains and guide track with 4 carrier arms per side and attached with four bolts per carrier side thereby increasing stability. This design also eliminates the carousel downtime experienced by carousels with only two arms per side that cannot rotate if one arm breaks. With four carrier arms per side if one arm breaks, the second arm keeps the carrier rotating until a technician can replace it. Two carrier per arm systems are not acceptable.

3.9. Each carousel must have dual motors. Dual Motor Drive Technology eliminates the torque problems created by single motor drive systems providing longer service for the entire system. And in case of failure of one of the motors the second motor provides redundant power eliminating the need to hand-crank the unit.

3.10. Dual Safety Redundancy, two overrides provide complete operator safety for unit function without the need to hand crank. Emergency Safety System Bypass ensures the carousel is fully operational, even if any part of the safety system is not. The emergency safety bypass system is an immediate solution to light curtain alignment problems or other safety system failures. When in safety bypass, the unit will operate by simply closing the access door so that no personnel are hurt during rotation. Systems that allow the carousel to rotate with the doors open while the safety system is not working are unacceptable as they allow for operator injury. Microprocessor Control Override ensures that retrieval and stocking can still take place, even if the control malfunctions. Should a microprocessor failure occur, the manual override provides an immediate drive alternative.

3.11. Each carousel must be a six-sided cabinet (full top and bottom, standard) designed for cleanliness, security and maximum protection for articles being stored. The skins must have interlocking lips (male/female) for maximum structural integrity and load carrying. This feature also insures that the carousel can only be installed plumb thereby reducing the wear and tear that internal moving parts can experience if not plumb to each other.

3.12. Each carousel shall have continuous guide racks welded in place at the factory to assure proper cycling of the carriers yielding maximum uptime and eliminating the need for costly track adjustments.

3.13. Drive chains shall be installed and pre-tensioned at the factory. No field adjustment shall be required following installation ever.

3.14. The carousels must use sealed self-lubricating bearings ensuring longer life and less maintenance.

3.15. Multifunctional Positioning Sensor shall allow for multiple stopping locations for each carrier. All stopping heights shall have the capability to be different on each carrier.

3.16. The carousels shall have split, locking doors with upper and lower full length piano hinge style safety touch thresholds to ensure article security and operator safety. The threshold shall break away from the rotating carriers creating a safety gap (no pinch point in case of safety failure) for protecting personnel and stored items from any risk by bringing the carousel to an immediate stop.

3.17. The carousel must have a 25% Imbalance Drive Capacity to allow for maximum imbalance while still rotating.

3.18. Self-monitoring LVS light curtain shall be installed at the operator access opening. This shall provide safety features that protect the operator from injury when the carriers are moving. This feature shall immediately stop the carriers from moving, when an operator’s hand/arm is in danger of injury.

3.19. Lockable sliding door(s), with two keys shall be provided (so stored parts can be secured).

3.20. An emergency stop button shall be provided at the operator’s station that is of the mushroom type and colored red.

3.21. An operator lighting system shall be provided (i.e. full width LED energy saving, overhead lighting)

3.22. Quality and durable construction of all system components. System structural components shall be rigid and stable.

3.23. Operations Journal Logging – which shall allow for tracking each transaction (storage to a new location, storage to an existing location, retrieval, retrieval with deletion of a bin, cancelled part request and manual shelf call) by time, date and storage location affected. This is accessible via the integrated web interface and can be exported to other programs.

3.24. Item Pool Management – which shall allow descriptive data and reorder points to be electronically sent to the unit, rather than having to type this information at the controller. Also allows for storage of this data without having a storage location assigned within the unit.

3.25. Access Code Management – with magnetic locking doors– which shall provide username/password functionality with the ability to control shelf access to specific users. The system will only rotate when the doors are closed.

3.26. The carousel shall provide a position and depth bar, which shall have an LED Light Bar with Position and depth indicators every 6” across access opening. The carousel shall have a total of 18 lights across the front.

3.27. The systems shall have the capability (and be set-up) to share one common database across all three units via an Ethernet cable connection. The contractor shall provide the Ethernet cabling connection.

3.28. The manufacturer shall provide three paper copies of the manuals.

3.29. Electrical power - The Carousel shall operate on 208 VAC, 3 phase power.

4. Computer and Printer The contractor shall provide a stand-alone desktop computer and printer that connects to the Equipment via ethernet cable.

They shall allow an operator to conduct searches on the housed inventory and create printed reports of transactions that show date and time, quantities transacted as well as knowledge of the operator who conducted these transactions.

Provided equipment (desktop and printer) shall "not" have the capability to be connected into the government's computer network/internet. The computer shall be an Acer Aspire (or equal) AZ3-710-UR52 All in one desktop, with a keyboard and mouse; Intel Core i5-4590T Quad-core 2 Ghz Processor; 23.8” Full HD (1920 x 1080) 16:9 integrated monitor; 8 GB, DDR3L SDRAM; 1 TB HDD. The printer shall be a HP (or equal) Black & White laser printer

5. ON-SITE OPERATOR TRAINING SERVICES TO BE PROVIDED

5.1. Within five (5) working days after satisfactory completion of acceptance testing of the system, the services of a qualified representative(s) shall be provided for specialized training to familiarize receiving activity personnel with the equipment. All training shall be provided by a factory authorized distributer. Training services shall be rendered at Puget Sound Naval Shipyard and Intermediate Maintenance Facility. Training shall be scheduled by mutual agreement between the Contractor and the Receiving Activity Point of Contact. The contractor shall provide all training manuals and guides. The government shall provide classroom space in close proximity to the equipment/shop (if needed). The entire contractor cost of providing the training (including travel, per diem, etc.) shall be covered by this contract. The operator training shall be provided for personnel for up to 8 hours per machine type.

This training shall include preparation of equipment for operation and actual, safe operation of the equipment. This shall include operator programming and database training.

6. ELECTRICAL, FIRE SUPPRESSION, SEISMIC ANHORING

6.1. The Navy is responsible for installation of electrical, seismic anchoring, fire suppression and safety thru NAVFAC.

Contractor will work with NAVFAC to help coordinate these items. The Vertical Lift Storage System shall operate on 480 VAC, 3 phase power. The contractor shall install approximately 100 feet of conduit and wiring, connecting the Lift’s electrical panel to the building’s electrical power panel (where an appropriate sized breaker shall be provided by the government for each system). This includes installing conduit fasteners, etc. The contractor shall follow all applicable codes, when installing this electric service. An electrical power disconnect box for each system shall be provided and installed by the contactor in the vicinity of each storage system. Vertical Lift System must be approved by Nationally Recognized Testing Laboratory (NRTL) i.e., UL listing, etc.

7. WARRANTY

7.1. Supplies and services furnished shall be covered by warranty from defects in design, materials and workmanship.

The warranty shall be the manufacturer’s standard commercial warranty, which shall conform to all the requirements of the contract. Acceptance of the manufacturer’s standard commercial warranty shall not minimize the rights of the Government under clauses in the contract, and in any conflict that arises between the terms and conditions of the contract and manufacturer’s warranty, the terms and conditions of the contract shall take precedence. The warranty period shall commence from the date of acceptance. All warranty work shall be provided by a factory authorized distributer.