W15QKN20R0117-0001.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT 1. Contract ID Code Page Of

2. Amendment/Modification No.

3. Effective Date

4. Requisition/Purchase Req No.

5. Project No. (If applicable)

6. Issued By Code 7. Administered By (If other than Item 6) Code

8. Name And Address Of Contractor (No., Street, City, County, State and Zip Code)

9A. Amendment Of Solicitation No.

9B. Dated (See Item 11)

10A. Modification Of Contract/Order No.

10B. Dated (See Item 13) Code Facility Code

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

The above numbered solicitation is amended as set forth in item 14. The hour and date specified for receipt of Offers is extended, is not extended.

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing items 8 and 15, and returning ____________ copies of the amendments: (b) By acknowledging receipt of this amendment on each copy of the offer submitted; or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. Accounting And Appropriation Data (If required)

13. THIS ITEM ONLY APPLIES TO MODIFICATIONS OF CONTRACTS/ORDERS

It Modifies The Contract/Order No. As Described In Item 14.

A. This Change Order is Issued Pursuant To: The Changes Set Forth In Item 14 Are Made In

The Contract/Order No. In Item 10A.

B. The Above Numbered Contract/Order Is Modified To Reflect The Administrative Changes (such as changes in paying office, appropriation data, etc.) Set

Forth In Item 14, Pursuant To The Authority of FAR 43.103(b).

C. This Supplemental Agreement Is Entered Into Pursuant To Authority Of:

D. Other (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return _______________ copies to the Issuing Office.

14. Description Of Amendment/Modification (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

Except as provided herein, all terms and conditions of the document referenced in item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. Name And Title Of Signer (Type or print)

16A. Name And Title Of Contracting Officer (Type or print)

15B. Contractor/Offeror 15C. Date Signed 16B. United States Of America 16C. Date Signed

By (Signature of person authorized to sign) (Signature of Contracting Officer)

NSN 7540-01-152-8070

PREVIOUS EDITIONS UNUSABLE

30-105-02 STANDARD FORM 30 (REV. 10-83)

Prescribed by GSA FAR (48 CFR) 53.243

SEE SCHEDULE

X

Firm Fixed Price

0001 2020AUG25

W15QKN

ARMY CONTRACTING COMMAND - NJ

PICATINNY ARSENAL, NJ 07806-5000

JONATHAN KILGORE

EMAIL: JONATHAN.M.KILGORE.CIV@MAIL.MIL

W15QKN-20-R-0117

2020AUG03

X

X 2020AUG28 03:00pm

/SIGNED/

2 signed

SEE SECOND PAGE FOR DESCRIPTION

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CONTINUATION SHEET

Reference No. of Document Being Continued Page of

Name of Offeror or Contractor:

PIIN/SIIN MOD/AMD

SECTION A - SUPPLEMENTAL INFORMATION

Buyer Name: JONATHAN KILGORE

Buyer Office Symbol/Telephone Number: CCNJ-JA/(973)724-2946

Type of Contract 1: Firm Fixed Price

Kind of Contract: Supply Contracts and Priced Orders

*** End of Narrative A0000 ***

The purpose of amendment 0001 is to extend the proposal submission date to August 28, 2020 at 3pm EST and incorporate a reference to MIL-

STD-636 in SOW 5.2.2.

*** END OF NARRATIVE A0004 ***

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W15QKN-20-R-0117

Name of Offeror or Contractor:

PIIN/SIIN MOD/AMD

SECTION C - DESCRIPTION/SPECIFICATIONS/WORK STATEMENT

STATEMENT OF WORK

FOR

CARTRIDGE INSPECTION SYSTEM (CIS)

1. Scope

The Combat Capabilities Development Command (CCDC) Armaments Center (AC) requires a Small Caliber Ammunition (SCA) Cartridge Inspection

System (CIS) capable of gauging and inspecting small caliber ammunition. The system shall detect and remove nonconforming material (NCM) which includes; visual defects, critical splits, critical perforations, dimensional nonconformities, as well as defects. The system shall be capable of feeding, handling, measuring, inspecting, accepting and rejecting 7.62mm x 51mm ammunition. The system shall also be capable of electronically storing, presenting and transmitting measurement and inspection data.

2. Background

The Combat Capabilities Development Command (CCDC) Armaments Center (AC) requires a Small Caliber Ammunition (SCA) Cartridge Inspection

System (CIS) capable of gauging and inspecting and inspecting 7.62mm x 51mm ammunition at rates of 100 Parts Per Minute (PPM) or greater. The system should be capable of gauging cartridge dimensions and inspecting cartridge visual defects. The system shall also be capable of upgrades to inspect unknown/future cartridge defects that may be produced as the result of new manufacturing processes. The system shall be constructed from new materials, not refurbished components or components removed from existing equipment.

3. Applicable Documents

29 CFR 1910 Subpart 0 - OSHA Standard, Machinery and Machine Guarding (13-Nov-18)

29 CFR 1910.147 - OSHA Standard, The Control of Hazardous Energy (Lockout/Tagout) (13-Nov-18)

29 CFR 1910.333 - OSHA Standard, Selection and use of Work Practices (13-Nov-18)

MIL-DTL-46931J Dist. D - Cartridge, 7.62 Millimeter, Ball, M80 (18-Jan-18)

13023831H Dist. A - Cartridge, 7.62 MM, Ball, M80 (2-Feb-09)

10521997AG Dist. D - Case, 7.62MM (24-Mar-16)

MIL-HDBK-419A - Grounding, Bonding, and Shielding for Electronic Equipment and Facilities (20-Feb-14)

AMC-R 385-100 - AMC Safety Manual (26-Sep-95)

DA PAM 385-64 - Ammunition and Explosives Safety Standards (10-Oct-13)

Acceptance Test Plan (ATP) - Quality and Acceptance General Terms and Conditions (15-Nov-18)

MIL-STD-636 - Visual Inspection Standards for Small Arms Ammunition through Caliber .50 (26-Mar-16)

Government Supplied Performance Specification - Quantified Visual Defect Standard for 7.62mm (10-Mar-20)

AMC-R 385-100 chapter 7 and DA PAM 385-64 - Safety Manual and Ammunition and Explosives Safety Standards (26-Sep-95, 24-May-11)

4. Period of Performance

The CIS shall be completed no later than 30 weeks after design approved by United States Government. The total Period of Performance

(PoP) of this effort shall be a base year plus three option years.

4.1 Options

4.1.2 Preventative Maintenance. The contractor shall provide annual preventative maintenance to include onsite labor, spare parts, and equipment necessary to troubleshoot and maintain the equipment for three years.

4.1.3 Emergency Repair. The contractor shall provide emergency repair the CIS for three years from the time of installation covering onsite labor, spare parts, and equipment and on site prove-out.

4.1.4 Conversion Kit. The contractor shall provide all components required to change the machine from using 7.62mm cartridges to 6.8mm cartridges, hereinafter referred to as the item in question shall from now on be called a conversion kit. Total changeover time from one cartridge to another shall take less than 4 hours or \'bd shift of a working day

5. Functional Requirements

5.1. Feeding & Handling.

5.1.1. Caliber. The system must be able to process North Atlantic Treaty Organization (NATO) 7.62mm x 51mm cartridges. The feed and material handling systems must be integrated with the inspection equipment (i.e. feed system shall not run independently of CIS).The contractor shall optimize the feed system to orientate and feed parts such that there is no degradation of inspection accuracy due to

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PIIN/SIIN MOD/AMD

orientation damage. The CIS or CIS ancillary devices shall not damage the product or create defects as a result of machine operation.

5.1.2. Capacity. The feed system shall have sufficient capacity for at least a continuous 30 minutes of run time for 7.62mm cartridges without relying on an operator to add more cartridges throughout that period. The feed system shall notify the operator when the feed system is low (described below in section 5.1.4) and shall be refillable while the machine is running.

5.1.3. Height. The inlet to load cartridges into the feed system shall not be higher than 60 inches from the floor.

5.1.4. Cartridge Feed Alerts and Stoppage. The system shall have a low level sensor that will alert the operator when there are a low number of cartridges in the feed system. The alert shall be present when the feed system is at 10% of its capacity and below

(adjustable lower limit preferred).

5.1.5. Operational Availability. The feed system shall demonstrate a minimum operational availability (OA) of 85 percent as defined in the Acceptance Test Plan (ATP).

5.1.6. Dimensional Inspection Repeatability. All dimensional measurements shall be accurate to within plus or minus 0.0001 inches at a rate of 100 ppm or greater.

5.1.7. Major Dimensional Defects. The CIS shall verify that the following dimensions are in accordance with drawings 13037149 (M80A1

Cartridge), 10521997AG (7.62MM Case), and 13037148 (Bullet Assembly, M80A1).

5.1.7.1. Overall Length. The CIS shall accept cartridges with an overall length between 2.770 - 2.800 inches. The CIS shall reject cartridges whose overall length is outside of this range.

5.1.7.2. Length-To-Shoulder. The CIS shall accept cartridges with a length-to-shoulder between 1.628 1.634 inches at the 0.400 diameter location. The CIS shall reject cartridges whose length-to-shoulder is outside of this range.

5.1.7.3. Head Thickness. The CIS shall accept cartridges with a head thickness between 0.047 0.054 inches. The CIS shall reject cartridges whose head thickness is outside of this range.

5.1.7.4. Diameter of Extractor Groove. The CIS shall accept cartridges with an extractor groove diameter of 0.409 inches or less. The

CIS shall reject cartridges as a major defect whose extractor groove diameter is greater than 0.409 inches.

5.1.7.5. Head Diameter. The CIS shall accept cartridges with a head diameter between 0.466 0.473 inches. The CIS shall reject cartridges whose head diameter is outside of this range.

5.1.7.6. Penetrator Gaps. The CIS shall reject M80A1 cartridges with axial penetrator gaps above .020 and below .010 inches and radial penetrator gaps above .010 and below .005 inches as shown in figure 1 above.

5.1.7.7. Total Cartridge Runout. The CIS shall reject cartridges which exceed the runout limit of .003 of the projectile vs the cartridge.

5.1.7.8. Penetrator Runout. The CIS shall reject cartridges which exceed the runout limit of .002 of the penetrator vs the projectile.

5.1.8. Minor Dimensional Defects. The CIS shall verify that the following dimensions are in accordance with drawings 13023831(H) (M80

Cartridge), 10521997(AG) (7.62MM Case), and 8595669(J) (Bullet Assembly, M80):

5.1.8.1. Diameter of Extractor Groove. The CIS shall accept cartridges with an extractor groove diameter of 0.402 inches or more. The

CIS shall reject cartridges as a minor defect whose extractor groove diameter is less than 0.402 inches.

5.2. Visual Defect Inspection Requirements. The CIS, at a minimum, shall be capable of detecting the following characteristics:

Splits, Perforations, Dents, Scratches, Folds, Wrinkles, Buckles, Bulges, Case Head Defects, Discolored Case, Anneal Line, External

CMWP, Tip ID, primer sealant, head stamp, case mouth crimp in cannelure, primer presence: missing, cocked, inverted primer and damaged point (bullet).

5.2.1. Contrast Variation. Visual inspections shall compensate for variations in ambient lighting and variations in surface finish.

5.2.2. Critical Visual Defects. The CIS shall be capable of identifying splits in the I, S, J, K, L, M and perforations in I, S, J, K regions per the Government Supplied Performance Specification and MIL-STD-636. The CIS shall verify that the following defects, created as per the Government Supplied Performance Specification, will be rejected and separated from conforming product.

5.2.2.1. Split in I Region. As referenced in the Government Supplied Performance Specification.

5.2.2.2. Split in S Region. As referenced in the Government Supplied Performance Specification.

5.2.2.3. Split in J Region. As referenced in the Government Supplied Performance Specification.

5.2.2.4. Split in K Region. As referenced in the Government Supplied Performance Specification.

5.2.2.5. Split in L Region. As referenced in the Government Supplied Performance Specification.

5.2.2.6. Split in M Region. As referenced in the Government Supplied Performance Specification.

5.2.2.7. Perforated Case in I Region. As referenced in the Government Supplied Performance Specification.

5.2.2.8. Perforated Case in J Region. As referenced in the Government Supplied Performance Specification.

5.2.2.9. Perforated Case in K Region. As referenced in the Government Supplied Performance Specification.

5.2.2.10. Perforated Case in S Region. As referenced in the Government Supplied Performance Specification.

5.2.2.11. Perforated Case in L Region. As referenced in the Government Supplied Performance Specification.

5.2.2.12. Perforated Case in M Region. As referenced in the Government Supplied Performance Specification.

5.2.3. Major Visual Defects. The CIS shall verify that the following defect types are not present in accordance with the Government

Supplied Performance Specification and MIL-STD-636:

5.2.3.1. Discolored, Dirty, Oily, Smeared (waterproofing) in relation to Tip ID. As referenced in No. 1 Discolored, Dirty, Oily, Smeared

(waterproofing) of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50 Combat Ammunition (Page 24).

5.2.3.2. Round Head. As referenced in the Government Supplied Performance Specification.

5.2.3.3. Dent in J Region. As referenced in the Government Supplied Performance Specification.

5.2.3.4. Dent in J/S Region. As referenced in the Government Supplied Performance Specification.

5.2.3.5. Dent in K Region. As referenced in the Government Supplied Performance Specification.

5.2.3.6. Dent in I/S Region. As referenced in the Government Supplied Performance Specification.

5.2.3.7. Dent in L Region. As referenced in the Government Supplied Performance Specification.

5.2.3.8. Dent in M Region. As referenced in the Government Supplied Performance Specification.

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5.2.3.9. Split in I/S Region. As referenced in the Government Supplied Performance Specification.

5.2.3.10. Split in J Region. As referenced in the Government Supplied Performance Specification.

5.2.3.11. Draw Scratch. As referenced in No. 8 Draw Scratch of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50 Combat

Ammunition (Page 28).

5.2.3.12. Scratch. As referenced in the Government Supplied Performance Specification.

5.2.3.13. No Chamfer on Head. As referenced in the Government Supplied Performance Specification.

5.2.3.14. Beveled Underside of Head. As referenced in the Government Supplied Performance Specification.

5.2.3.15. Defective Mouth. As referenced in the Government Supplied Performance Specification.

5.2.3.16. Corroded or Stained. As referenced in the Government Supplied Performance Specification.

5.2.3.17. Fold. As referenced in No. the Government Supplied Performance Specification.

5.2.3.18. Wrinkle. As referenced in the Government Supplied Performance Specification.

5.2.3.19. Bulge. As referenced in the Government Supplied Performance Specification.

5.2.3.20. Illegible or Missing Head Stamp. As referenced in the Government Supplied Performance Specification.

5.2.3.21. No Visible Evidence of Mouth Anneal. As referenced the Government Supplied Performance Specification.

5.2.3.22. Missing, Cocked, or Inverted Primer. As referenced in the Government Supplied Performance Specification.

5.2.3.23. Upset point (bullet). As referenced in No. 28 Upset (crooked) point of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal

.50 Combat Ammunition (page 39).

5.2.4. Minor Visual Defects. The CIS shall verify that the following minor defects are not present in accordance with the Government

Supplied Performance Specification and MIL-STD-636:

5.2.4.1. Discolored, Dirty, Oily, or Smeared Waterproofing. As referenced in the Government Supplied Performance Specification.

5.2.4.2. Dent in I S J K L M Regions. As referenced the Government Supplied Performance Specification.

5.2.4.3. Draw Scratch As referenced in No. 8 Draw Scratch of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50 Combat

Ammunition (Page 28).

5.2.4.4. Scratch. As referenced in the Government Supplied Performance Specification.

5.2.4.5. Scaly Metal. As referenced in No. 12 Scaly Metal (case) of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50 Combat

Ammunition (Page 30).

5.2.4.6. Wrinkle. As referenced in the Government Supplied Performance Specification.

5.2.4.7. Buckle. As referenced in the Government Supplied Performance Specification.

5.2.4.8. Illegible or Missing Head Stamp. As referenced the Government Supplied Performance Specification.

5.2.4.9. Defective Head. As referenced in No. 19b Defective Head of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50 Combat

Ammunition (Page 35).

5.2.4.10. Defective Mouth. As referenced in the Government Supplied Performance Specification.

5.2.4.11. Blunt Point. As referenced in No. 30 Blunt Point of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50 Combat

Ammunition (Page 39).

5.2.4.12. Fold. As referenced in No. the Government Supplied Performance Specification.

5.2.4.13. Nicked or Dented Primer. As referenced in No. 36 Nicked or Dented Primer of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50 Combat Ammunition (Page 42).

5.2.4.14. No Waterproofing Material (Primer Pocket Joint). As referenced in the Government Supplied Performance Specification.

5.2.4.15. Defective Crimp. As referenced in No. 38 Defective Crimp of MIL-STD-636 List of Defects for 5.56mm, 7.62mm, and Cal .50

Combat Ammunition (Page 42).

5.2.4.16. Case Mouth Waterproofing. As referenced in the Government Supplied Performance Specification.

5.3. Acceptance/Rejection. Parts shall be accepted or rejected based on the criteria defined in the SOW Dimensional Inspection

Requirements Addendum and paragraphs 5.1.6 and placed in its respective bins/containers.

5.4. Data Requirements

5.4.1. Data Collection. For each cartridge inspected, data shall be collected and stored for each dimension and defect listed in the SOW

Dimensional Inspection Requirements Addendum and paragraphs 5.1.6 Data shall be stored for a minimum of 150,000 cartridges.

5.4.1.1. Data Recorded Per Part. In accordance with DI-STDZ-80000C (CDRL A001), for each cartridge inspected the system shall record:

- The part nomenclature/type

- The part number

- The date and time of inspection

- The accept and reject limits and other inspection settings/parameters for each dimension and defect listed in the SOW Dimensional

Inspection Requirements Addendum and paragraphs 5.1.6

- The measured value for each dimension(s) or defect(s) listed in the SOW Dimensional Inspection Requirements Addendum shall be recorded as continuous/variable data.

- The observed value for each defect(s) listed in paragraphs 5.1.7 shall be recorded as continuous/variable data when possible. When not possible, the data shall be collected as discrete data.

- Inspection decision (i.e. accepted or rejected)

5.4.1.2. Data Recorded Per Run. For each group of cartridges inspected, the system shall analyze and record:

- Production metrics (i.e. for each dimension and defect: quantity inspected, quantity accepted, quantity rejected)

- Faults (i.e. start and stop time of fault, date and location of fault, fault cause, fault status, fault history)

5.4.2. Data Format. Data shall be formatted into file(s) that can be easily identified, imported, and processed by Microsoft Excel, such as .xls, comma-separated values (CSV), tab-separated values (TSV), etc.

5.4.3. Data Transfer. The system shall have the capability to transfer/export all data recorded. The machine shall incorporate either an SD card slot, Ethernet, USB or an eSATA port by which the electronic data can be transferred.

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5.4.4. Data Display. The Data Recorded Per Part and Data Recorded Per Run shall be clearly accessed and displayed on the HMI screen.

6. Integration Requirements

6.1. Size, Utilities, and Finish.

6.1.1. Maximum Footprint. 145 inches x 90 inches (depth x width) including feeders. In addition, the equipment must be able to pass through a doorway 67 inches wide by 82 inches high at the installation point.

6.1.2. Maximum Height. 120 inches (overall equipment clearance height at installation point). In addition, the equipment must be able to pass through a doorway 67 inches wide by 82 inches high at the installation point.

6.1.3. Electrical Power. The CIS shall be capable of full operation using at least one of these electrical powers.

- 220-volt, 3-phase, 60-hertz, 3-wire, 30-amp

- 110-volt, 1-phase, 60-hertz

6.1.4. Compressed Air. Compressed air will be available at the installation location at 15 cfm at 90 pounds per square inch (psi). The

CIS shall be capable of operating within this pressure and flow rate. The contractor shall provide filtration and drying equipment necessary to condition the incoming air to prevent damage to the CIS.

6.1.5. Protective Finish. Components of the CIS susceptible to oxidation shall be protectively coated. The color and material are at the discretion of the contractor.

6.2. Product Configuration. The CIS must be able to inspect 7.62mm x 51mm cartridges at time of delivery. All requirements shall be met with one machine/system capable of inspecting all defects. Multiple machines are not acceptable. Different feed bowls are acceptable.

6.3. Operation.

6.3.1. Fail-Safe Operation. The fail-safe condition for the CIS shall be reject. All conformance checks shall utilize fail-safe design.

The decision-making logic shall be normally in a reject mode prior to and during any test. A series of signals indicative of proper test results shall be required in a given sequence to change to the accept mode. The lack of any of these signals or an incorrect signal shall cause the system to remain in the reject mode. Parts present within the equipment during startup must be rejected since the entire testing cycle is not seen by these parts. There shall be a confirmatory signal such that any rejected unit-under-test (UUT) has in fact been cycled out of the reject device. If the confirmatory signal is not activated, the system will immediately discontinue inspection and indicate a fault. It is desirable that accept gates be located before reject gates.

6.3.2. Operating Rate. System shall function at a minimum of 100 parts per minute.

6.3.3. Operational Availability. The CIS shall demonstrate a minimum operational availability (OA) of 85 percent. OA is defined in the

Acceptance Test Plan.

6.3.4. Output Constraints.

6.3.4.1. Conforming Material. The cartridges which pass all inspections shall meet the following requirements:

6.3.4.1.1. Quantity. The quantity of parts physically accepted shall be recorded by a sensor located at the point of machine exit.

6.3.4.1.2. Drop Height. The cartridges shall be discharged at a height greater than 12 inches from the floor.

6.3.4.2. Non-Conforming Material. The quantity of parts rejected by one or more of the inspection criteria shall meet the following requirements:

6.3.4.2.1. Quantity. The quantity of parts rejected at each inspection checkpoint shall be recorded by a sensor located at the point of machine exit.

6.3.4.2.2. Drop Height. The cartridges shall be discharged at a height greater than 12 inches from the floor.

6.4. Operator.

6.4.1. Integration and Control Systems.

6.4.1.1. The Station Controller Software (SCSW) shall provide a Station Controller GUI (SCGUI) for interfacing with the operator. The

SCGUI shall be capable of configurable access control that isolates access to administrative functions from typical operator/maintainer functions. The SCGUI shall follow standard design principals and also support the characteristics identified below.

6.4.1.1.1. Intuitive. SCGUI shall be easy for users to accomplish basic tasks the first time they encounter the design.

6.4.1.1.2. Efficient. Users shall be able to quickly perform tasks once they have learned the design.

6.4.1.1.3. Knowledge Retention. Users shall be able to re-establish efficiency after a period of inactivity.

6.4.1.1.4. Usability. The SCGUI shall provide meaningful feedback to the user and error messages in plain English with suggested action or reference to on-board help resources.

6.4.1.2. Machine Controller. The system shall be a programmable logic controller (PLC) or PC based controls. The control system shall provide monitoring and alarming functions for the entire system. The system shall have emergency stop functionality.

6.4.1.3. Program Updates. The inspection system shall be adaptable to allow for multiple unique product configurations within caliber.

The software must be intuitive and flexible allowing the customer to edit the program to add or remove inspection features and/or dimensional values.

6.4.1.4. Human Machine Interface (HMI). The system shall have a Human Machine Interface (HMI) that integrates and controls the feeding and inspection operations. The HMI and software for these operations shall be documented in accordance with Software Documentation (DI-

IPSC-81756) CDRL-A002. The CIS will be used in a prototyping environment for inspection and screening of product. Therefore the software shall be user-friendly and adaptable to dimensional and visual product feature changes.

6.4.1.5. HMI Modes of Operation. Two (2) modes of operation shall be included in the HMI, Production and Maintenance modes. Each mode shall be represented by a separate screen menu. The Production mode screen shall be the default screen for system operation and shall display all the normal operating parameters. The Maintenance mode screen shall allow the mechanic to bypass certain safeguards for troubleshooting and maintenance purposes and shall be password or key-switch protected to limit access.

6.4.1.6. External Devices. No devices shall be mounted on the outside of the main enclosure other than an Emergency Stop button, stack light LED, electrical cabinet, feed hoppers, and the HMI.

6.4.1.7. Comprehensiveness. All control loops, discrete on and off control functions, system indicators, permissives to start, interlocks, alarms, and shutdowns shall be wired as inputs and outputs to the PLC and shall be incorporated into the menus and/or screens of the HMI.

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6.4.1.8. Indicators. The following is a minimum list of indicators that shall be displayed on the HMI:

- System Run Mode (i.e. Production or Maintenance)

- Common alarms (number and description)

- E-stop condition

- Permissives to Start and interlocks preventing system operation

- System operating rate displayed in parts per minute (ppm)

- Cartridge detection to detect low/no cartridges in feed system

- Parts counter for total quantity inspected, total quantity accepted, and total quantity rejected

- For each dimensional defect inspection and visual defect inspection per operating run, the HMI shall display the quantity inspected, the quantity accepted, the quantity rejected, control charts (x-bar charts, R charts, np charts, etc.), and process capability statistics (i.e. Cp, Cpk, etc.).

- Status of all alarm conditions

- Alarm/fault details and history (i.e. start date/time of faults, end date/time of faults, location and cause of faults, etc.)

- Alarms triggered by Interlocks and Shutdowns and Indicators section. The HMI alarm display shall be a graphic representation of the system depicting the location of the alarm in addition to a clear and specific description of the alarm.

6.4.1.9. Light Emitting Diode (LED) Stack. An LED-type stack light is required. Preferably, an LED-type stack light shall be mounted on top of the HMI to represent critical indicators. The stack light shall indicate:

- System Running indicated by a green LED

- Active alarm or emergency stop indicated by a red LED

- Permissive and interlocks preventing system operation indicated by a flashing red LED

- Low Material Detection indicated by a yellow LED

- Alarms triggered by Interlocks and Shutdowns Indicators section by a flashing red LED

6.4.1.10. Permissives to Start. The following permissive to start conditions shall be fulfilled in order to start operation in Auto mode:

- System emergency stop buttons in the Run position

- All access doors closed

- Adequate compressed air supply pressure and/or other required utilities

- Adequate system lubrication pressure, if applicable

- Adequate raw material supply for start-up

- All safety mechanisms functioning and in-place

6.4.1.11. Interlocks and Shutdowns. Interlocks shall be part of the Safety Control Circuit in order to ensure personnel safety and avoid equipment damage. Shutdown is intended to mean that the machine will cease operations and all moving parts and other harmful components of the system will come to an immediate stop. It is not necessary to power down and de-energize the electrical systems. The controller and other electrical systems should remain functional. The minimum interlock requirements are as follows:

- An open control panel shall disconnect the main power

- An open door shall shut down the machine. The machine shall operate in Manual and Maintenance mode with the doors open.

- The system shall shutdown if Permissives to Start are not maintained

- All other interlocks required to prevent personnel injury or equipment damage shall be provided (equipment jams, motor overloads, and low air pressure).

- Emergency stop push buttons at all operator and control station locations shall shutdown the machine.

6.4.2. Operator Safety.

6.4.2.1. Grounding. The CIS and all components shall be sufficiently grounded and bonded, in accordance with (IAW) MIL-HDK-419A

Grounding, Bonding, and Shielding for Electronic Equipment and Facilities, to prevent initiation of energetics from accidental electro-static discharge. All components of the CIS requiring grounding shall tie into a single common ground lug for connection to the building ground system.

Grounding and Bonding of all parts with a surface area of greater than 400 square inches shall be accomplished by mating a compression lug to the metal frame of the equipment in question. The lug shall be crimped onto a 6 AWG or larger wire, or multi-strand cable of equivalent wire weight with no individual conductor of the multi-strand cable measuring less than 17 AWG. The other end of the wire will be attached to the nearest point of the Static Dissipation Subsystem (SDS) for the building, again using a permanent irreversible connection as appropriate. Conductive anti-oxidant shall be used between all joints. Paint shall be removed from all mating surfaces.

1/4-20 hardware shall be the minimum size of mechanical connectors used. The manufacturer shall incorporate a ground lug in an area on the outside surface of the equipment where it would be most effective, and not interfere with the operation of the equipment and/or void the warranty, with at least a 1-1/4 inch diameter of bare metal exposed around the lug on each side. Corrosion prevention shall be accomplished through tinning of assembled bonds for copper and steel, and anodizing for aluminum. A resistance test will be performed using a DMM that can read to at least hundredths of ohms to ensure that the equipment parts will have a resistance to the SDS of less than 2 ohms.

Welds are the preferred method of joining metal components. However, if bolts are used, care shall be exercised in ensuring paint is not insulating individual metal parts from each other in the equipment design.

The facility is strictly governed by the grounding and bonding requirements laid out in AMC-R 385-100 chapter 7 and DA PAM 385-64. Both of these documents are widely available on the internet.

6.4.2.2. Control Panel Master Key. The CIS shall have a master key used for energizing and de-energizing the control panel.

6.4.2.3. Enclosure. The vendor shall ensure background lighting does not affect inspection. The CIS enclosure and access doors shall be fully interlocked with a safety circuit. The CIS enclosure shall still permit the operator to refill the raw material feeders/hoppers. This may be accomplished by locating the hoppers outside of the enclosure or through the use of special access doors to the hoppers that does not result in machine shutdown.

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6.4.2.4. Guards. Guards and enclosures shall contain all parts, debris, and shrapnel thrown, ejected, or otherwise detached from the machine in a normal operating or failure mode to prevent injury. All guards shall be compliant with current OSHA standards as outlined in OSHA Part 1910, Subpart O, Machinery and Machine Guarding. The requirement for guards is intended to protect against injury from a mechanical or optical failure, not accidental primer or cartridge initiation. Regardless, the guards requirement must be compliant with the designated OSHA specification.

6.4.2.5. Windows. The enclosure shall incorporate shatter-proof covering with view port to see components of the CIS, feeding systems, and raw material hoppers.

6.4.2.6. Access Door. The enclosure shall incorporate an access door(s) to allow the operator a wide opening(s) for access to all sensors, mechanisms, and in-process material. The machine shall have an access door(s) to conveniently access all feeders, machine controls, and maintenance points.

6.4.2.7. Access Door Closure Mechanism. Parting or sliding doors shall have positive closure mechanism to minimize or eliminate the possibility of nuisance safety trips of the door safety interlock switches due to the door(s) opening slightly.

6.4.2.8. Access Door Handles. All access doors shall be equipped with grab handles that are securely mounted for convenient and safe operation of access doors.

6.4.2.9. Lockout/Tagout. The CIS shall meet requirements contained in 29 Code of Federal Regulations (CFR) 1910.147 and 29 CFR

1910.333 for lockout/tagout.

6.4.2.10. Laser Safety. Any use of lasers shall be limited to Class I lasers only.

6.4.2.11. The CCDC AC Industrial Hygiene Office. The CCDC AC Hygiene Office may observe the installation and conduct a

Workplace Ergonomics Evaluation to assess work envelope acceptability, musculoskeletal risks, noise levels, fumes/vapors, lighting, safety features, the salience of various alerts and alarms, access to components for maintenance, the salience of data and information displayed on the HMI screen, the arrangement of controls and displays for reliable use by operators, the readability of labels and placards, Personnel Protective Equipment (PPE) requirements, etc. The FCDD-AC Laser Safety Office will evaluate the CIS for compliance with laser safety and the appropriate PPE requirements necessary to mitigate any risks posed by lasers. FCDD-AC Safety inspectors will conduct a safety inspection during equipment installation.

7. Software, Technical Documentation, and Training

7.1. Software. The CIS program shall be documented in accordance with Software Documentation DI-IPSC-81756 (CDRL-A002). A laptop PC shall be delivered that contains the CIS program along with editable templates for different products.

7.2. Operation Manual. In accordance with DI-MGMT-81580 (CDRL A003) the contractor shall submit an operations manual for operation of the machine, including troubleshooting guidelines, minimum 30 days prior to delivery of the machine. This manual shall also include the Standard Operating Procedure (SOP) for start-up operations, including all safety checks.

7.3. Maintenance and Repair Documentation. In accordance with DI-MISC-80508B (CDRL A004) a full maintenance and repair guide shall be provided for the CIS system, NLT start of Final Acceptance Prove-out. Included with the documentation shall be repair procedures, lockout/tagout procedures, electrical schematics, logic documentation, and an electronic backup of parameters.

7.4. Spare Parts List. The contractor shall provide a Spare Parts List in accordance with the Proposed Spare Parts List report DI-PSSS-80134B (CDRL-A005), NLT start of Final Acceptance Prove-out. In addition, the Spare Parts List shall include the mean-time-between-failure (MTBF) (or best estimate), price, lead time, and source. Of particular interest are consumables, wear items, and long lead items possibly prone to failure. These documents shall be provided in hardcopy and electronic Excel spreadsheet format.

7.5. Preventative/Predictive Maintenance. In accordance with DI-MISC-80508B (CDRL A006) the contractor is responsible for providing a recommended preventative annual maintenance schedule, NLT start of Final Acceptance Prove-out. The contractor shall recommend key operating measurements and parameters that can be used within the preventive maintenance program. Instruction for performing maintenance shall be included in the maintenance documentation.

7.6. Training of CCDC AC Personnel. The contractor shall provide on-site operators training at CCDC AC for six (6) CCDC AC personnel on the machine. The contractor shall develop two (2) separate courses targeted for the six (6) CCDC AC personnel for three (3) days. One course shall address operation. One course shall address maintenance. The contractor shall coordinate the training schedule with CCDC AC no later than one (1) week after delivery, start-up and commissioning, and final acceptance is approved. The training shall be scheduled no later than four (4) weeks after approval of final acceptance. This training shall consist of both classroom and hands-on training. The training duration shall be a minimum of three (3) days of training within normal business hours (8:00am to

5:00pm), Monday through Friday. The contractor shall provide training material including: Course Outline, Operating Manual, and

Maintenance Manual. The training shall include at minimum, the following topics: CIS operation and CIS Maintenance. Training materials in accordance with DI-ILSS-80872 (CDRL A007) shall be provided to the Government. The contractor shall employ training instruction

(e.g., manuals), training criteria (e.g. desired learning outcomes and performance goals), and evaluation methods and metrics to verify training effectiveness in accordance with criteria (e.g., performance measurements such as number of tasks correctly completed within a prescribed time). The contractor may use MIL-HDBK-29612-2A Department of Defense Handbook, instructional Systems Development/Systems

Approach to Training and Education (Part 2 of 5 Parts), 31 August 2001 as guidance.

7.6.1. CIS Operation. This training shall consist at a minimum of the following topics: raw material handling, feeding systems, system operation, using different modes of operation, start-up procedures, shut-down procedures, on-screen programming and communicating with the software, operating the machine, and troubleshooting.

7.6.2. CIS Maintenance. This training shall consist at a minimum of the following topics: preventative maintenance, repair procedures, lubrication, calibration, training the system for defect detection, and electronic system maintenance.

7.7. Operation & Maintenance Documentation. In accordance with DI-MISC-80508B (CDRL A008) the contractor shall submit Draft

Operation and Maintenance Documentation, IAW aforementioned paragraphs NLT 1 week prior to Pre-Delivery Prove-out. The contractor shall submit the Final Operation and Maintenance Documentation NLT at the start of Final Acceptance Prove-out. Files shall be in Portable

Document File (PDF) format. Files shall be supplied on CD or DVD.

7.8. Software Documentation. In accordance with DI-IPSC-81756 (CDRL A002), the contractor shall submit electronic back-up

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copies of all software parameters and programming files necessary to restore the machine to its as-delivered condition.

7.9. Electrical Schematic Documentation. In accordance with DI-SESS-81223A (CDRL A009) the contractor shall submit electrical schematics of the machine depicting all wiring and circuitry encompassed by the machine.

7.10. Laptop Computer with Programming Software. At the time of machine delivery, the contractor shall provide a laptop computer which includes all software packages necessary to modify all aspects of the machines software/programming. All licenses shall be valid for a minimum of 12 months from time of delivery.

7.11. Drawings. In accordance with DI-MISC-80508B (CDRL A010) within seven (7) calendar days after Government approval of the Post-Delivery Prove-Out, the contractor shall deliver layout drawings, specifications, electrical schematics, and manuals for all components and assemblies designed and built for the CIS. These drawings and other technical data will be used solely for procuring replacement parts, making repairs, or to make future equipment modifications to the CIS to meet Government inspection requirements.

8. Data Rights

The Government shall obtain Government Purposes Rights for all data used by this contract. Data shall include any software, hardware, manuals, inspection/test results, reports, and or other miscellaneous information generated under this contract. The contractor shall not invest any expenditure of internal funding if there is a possible effect on the Government receiving Government purpose rights to the technology developed under this SOW. All data and intellectual property created by the contractor, previous to this contract, is solely owned by the contractor but available for use by the USG.

9. Quality & Acceptance

9.1. Pre-Delivery Acceptance. Prior to the contractor shipping the CIS to the Government, the contractor shall demonstrate that the machine has met the criteria of the Cartridge Inspection System (CIS) Acceptance Test Plan (ATP). Two week notification of prove out date is required to facilitate USG witnessing. Dimensional features will be verified against USG acceptance gauges, accepted alternate gages, and independently certified standards.

9.1.1. Pre-Delivery Prove-Out. The contractor shall demonstrate to the Government the CIS capability to inspect 7.62mm M80 cartridges. This shall be accomplished executing the Cartridge Inspection System Acceptance Test Plan.

9.1.1.1. Dimensional and Visual Analysis of Prove-Out Cartridges. Dimensional features will be verified against USG acceptance gauges, accepted alternate gages, and independently certified standards.

9.2. Pre-Delivery Acceptance Completion. Upon satisfactory completion of pre-delivery requirements set forth in the SOW, and upon CCDC AC approval, the contractor shall package and ship the CIS. Shipment shall be FOB Destination to the specified address at

CCDC AC. The contractor shall submit a Test/Inspection Report DI-NDTI-80809B (CDRL A011) within two (2) weeks of CCDC AC approval of the pre-delivery prove-out and acceptance.

9.3. Start-Up and Commissioning. After the Government connects all necessary utilities (e.g. electric, compressed air), the contractor is responsible for powering up and fully commissioning the CIS. The start-up and commissioning will occur at the Government facility between the hours of 7:00am 4:00pm, Monday through Thursday.

9.4. Post-Delivery Acceptance. After the CIS has been shipped and all installation activities are completed IAW the requirements, the contractor shall demonstrate that the machine has met the criteria of the Cartridge Inspection System (CIS) Acceptance

Test Plan. Final acceptance shall consist of the following:

9.4.1. Post Delivery Prove-Out. The contractor shall demonstrate the CISs capability by executing the Cartridge Inspection

System Acceptance Test Plan after installation at CCDC AC, Picatinny Arsenal, NJ.

9.5. Spare Parts During Acceptance. The contractor shall be responsible for all spare parts required during development, acceptance, and training. The contractor shall provide all spare parts required during this contract, including all acceptance and training activities.

9.6. Corrective Actions. The Government will not accept the CIS if it fails to satisfy the requirements delineated in DI-

MGMT-80501 (CDRL A004) and DI-SESS-80255B (CDRL 013).

10. Materials

10.1. Government Furnished Material (GFM). GFM quantities can be found in the ATP. The Government will supply both acceptable product as well as defect standards for testing.

10.2. Contractor Furnished Material (CFM). CFM Quantities can be found in the ATP.

11. Program Management

11.1. Travel. The contractor shall travel to Picatinny Arsenal, NJ as necessary to support meetings, delivery/installation, Post-Delivery Prove-out, and Training. Additional travel to support warranty actions shall be covered under warranty. All travel shall be in accordance with Joint Federal Travel Regulations (JFTR) and FAR Cost Principle 31.205-46, Travel Cost. All travel is associated with the deliverables outlined. Contractor will cover cost of travel within the contract.

11.2. Kick-Off Meeting. Within thirty (30) calendar days after contract award, the contractor shall host the Kick-Off

Meeting at the contractors facility. The contractor shall review their proposed design, discuss their path-forward and schedule, and review the contract clauses and SOW requirements to ensure clarity.

11.3. Schedule. The contractor shall submit a Project Plan Chart DI-MGMT-80507C (CDRL A014) 30 days after contract award detailing the critical tasks and milestones necessary to deliver the CIS within the PoP. At a minimum, the Project Plan Chart shall include tasks in the following categories: Design, Build, Test, and Acceptance Activities.

11.4. Design Review Meeting. At the conclusion of the contractors design phase, the contractor shall host a Design Review

Meeting at the contractors facility. Prior to manufacturing any components or beginning any assembly, the contractor shall host a meeting to review their design with the Government and explain how each requirement will be met by the proposed design.

11.5. 50% Program Review. The contractor shall host a Program Review upon completion of 50% of the requirements where the contractor shall review the status of items in the Program Plan.

11.6. Monthly Status Updates. The contractor and the Government shall hold monthly meetings to review the status of this effort. This shall be performed via teleconference, videoconference, and/or face-to-face meetings.

11.7. Monthly Status Report. In accordance with DI-MGMT-81928 (CDRL A015) a monthly status report shall be delivered not

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more than five (5) business days after the close of each calendar month. The report shall be in Microsoft Word\'ae electronic format.

The monthly report in contractor format shall include:

A statement of the period covered (e.g., calendar month, 4-week period).

Project status summary

Tasks completed during the past month

Tasks planned for the upcoming month

Progress made compared to overall project schedule

Projected completion date

Issues

11.8. Contracting Officer Representative (COR)/ WAWF ACCEPTOR:

TBD

Agreement Officers Representative (AOR):

TBD

12. Packaging Requirements

The contractor shall use best commercial practices to package and transport the CIS to the Government.

13. Freight, Rigging, and Installation

Freight, rigging, and installation are the responsibility of the contractor. Once the contractor has placed the machine in the final location at the Governments facility, the Government will connect the utilities to the machine (i.e. electricity, compressed air, etc.).

Once the utilities are connected, it is the contractor's responsibility to start-up and commission the machine.

14. Contractor Place of Performance, Delivery & Installation Location

The CIS shall be delivered to and installed at:

Commander

U.S. Army CCDC AC

Attn: Mr. Paul Betts

Building 1301, Room 220

Picatinny Arsenal NJ 07806-5000

15. Warranty Requirements

Any express warranty submitted in accordance with FAR 52.212-1 shall include minimum warranty duration of one (1) year, providing on-site repairs due to manufacturer defects at no additional cost. Additionally, the contractor shall provide a standard warranty for the machine for a minimum of one (1) year after the base contract close-out.

16. Security. The highest level of classification is UNCLASSIFIED.

16.1. Anti-Terrorism (AT) Level I Training. All contractor employees, including subcontractor employees, requiring access to Department of Defense installations, facilities, or controlled access areas shall complete AT Level I awareness training within 45 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever applies and within 12 months prior to travel outside of the US, then annually thereafter. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee to contracting officer, if a COR is not assigned) within 14 calendar days after completion of training by all employees and subcontractor personnel. AT level I awareness training is available at:

http://jkodirect.jten.mil/

16.2. Access and General Protection/Security Policy and Procedures. This standard language text is for contractor employees with an area of performance within an Army controlled installation, facility or area. All contractor employees, including subcontractor employees, shall comply with all installation and facility access and local security policies and procedures (provided by the Government representative), and security/emergency management exercises.