SOWTieExchangerRebuild.pdf

SUBJECT: Tie Inserter Rebuild for the McAlester Army Ammunition Plant

(MCAAP)

1.0 – Objective & General Background

This SOW calls for a complete frame-up overhaul/rebuild of one 1996 Fairmont model RMC305 Railroad Tie Remover/Inserter, S/N 257166. The machine has reached the end of its economic life and a complete rebuild is needed to return the machine to OEM specifications. Fairmont Railway Motors was acquired by Harsco Corporation in 1979.

As a result, the Fairmont machine is a present-day Harsco Corporation machine and Harsco Rail is the Original Equipment Manufacturer (OEM). This machine rebuild shall be executed in accordance with OEM product specifications.

Vendor facilities used to perform this SOW shall be environmentally-controlled in a manner that facilitates safe and efficient contract performance consistent with prevailing environmental and community standards for air quality and pollution control.

The delivery schedule requirement is 270 Days after Date of Contract (ADC).

The contracting office will assess the awardee’s qualifications and eligibility to receive an award under applicable laws and regulations, based upon proposed delivery, performance record, financial and ethical integrity, organization, experience, operational controls, and technical skills.

The awardee is required to finance its performance of the entire SOW. Vendor proposals that require progress payments or any other type of advance financing could be considered non-responsive and eliminated from consideration for award.

2.0 – Production Plan Requirement

Vendors are required to submit written production plans that specifically delineate the processes required to return the machine to its original operating condition as defined in this SOW, to include all applicable OEM specifications. Vendors shall also submit Gantt / milestone charts that identify process milestones as well as the overall project completion schedule. Production plans shall also include work breakdown structures that define the processes involved with each major area of repair discussed ahead.

Vendors shall also identify quality control and inspection procedures that apply for each major operation in this SOW.

Vendor production plans shall also include specific descriptions of how work would be accomplished for each major operation. The vendor shall also identify any planned equipment purchases.

With regard to subcontractors planned to conduct major operations included in this SOW, beginning with the required Mobilization, vendors shall document the subcontractor’s level of experience and skill set qualifications for each planned subcontract operation. Vendors shall also submit documentation that defines the specific experience and skill sets of in-house employees who will perform on this SOW.

3.0 – Harsco Rail Vendor Certification Program Requirement

In order to demonstrate to the Government that the machine rebuild will be executed in accordance with OEM product specifications, all vendors shall submit with their offers a copy of their binding vendor certification agreement with Harsco Rail, the OEM. Vendor participation in the OEM’s vendor certification program is required in order to ensure that the machine rebuild shall be executed IAW OEM/Harsco Rail technical and performance specifications.

The OEM’s vendor certification program lowers the level of contract risk for the Government because the rebuilder will be 100% responsible for restoring the machine IAW OEM technical specifications. When the contractor’s production processes are directly pegged to OEM technical specifications, performance risk is lowered for the Government.

4.0 – Site Visit / Sight Inspection of the Machine:

Reference Solicitation Provision 52.237-1 entitled Site Visit. The Government does not require interested vendors to attend the only sight inspection visit. However, any vendor who submits a proposal that is contingent upon sight inspection of the machine shall not be considered for award. Therefore, vendor attendance at the one and only sight inspection visit is highly recommended. There will be no other sight inspection opportunities.

Vendors are allowed to photograph the machine during the sight inspection visit.

Vendors who intend to use a camera shall request a camera pass at the MCAAP Visitor Center (Pass and Tag).

All photos are subject to review prior to departing the installation by a DA-certified OPSEC Officer. Note: The MCAAP Visitor Center (Pass and Tag) requires a minimum of 48 hours to perform background checks on anyone planning to enter the installation.

See solicitation Provision 52.237-1 for further details, including date & time of sight inspection visit and vendor contact information required for each vendor attendee.

5.0 – Major Operations / Tasks:

Mobilization:

The core machine is located at McAlester Army Ammunition Plant (MCAAP), located approximately 6 miles south of McAlester, OK.

Contractor will be responsible for all transport of machine to and from the rebuilder’s facility.

Vendor production plans shall detail how the RMC305 will be transported from the customer’s facility to the vendor’s overhaul facility, including the offloading of the unit into the overhaul facility.

The vendor’s production plan shall identify the experience level and skill set of vendor or subcontract personnel planned to perform the Mobilization.

Chassis:

Complete disassembly and inspection of machine.

All cab components shall be cleaned, inspected and categorized, then rebuilt or replaced with new, as needed.

Sandblast cab assembly and machine frame to bare metal and inspect for any damage, cracks, etc. Perform any repairs / replacements / updates as necessary.

Pre-paint entire machine before re-assembly begins and, when appropriate, decal to factory and manufacturer / FRA specs.

The frame and cab shall be sprayed with corrosion-resistant epoxy primer and the finish painted with high-gloss, fade and chalk-resistant enamel paint.

All parts in the cab will be inspected, rebuilt, or replaced with new (gauges, seat, etc.).

Insulate cab.

Rebuild air conditioning unit or install new unit with heat.

Install all new tinted glass and fire extinguisher in cab.

The vendor’s production plan shall identify the experience level and skill set of vendor or subcontract personnel planned to perform upon these chassis requirements.

Engine:

Install new 6-cylinder John Deere Tier 3 turbocharged diesel engine w/air compressor and Turbo 2000 air dryer.

The engine shall carry the full John Deere manufacturer’s warranty, parts and labor included.

Vendor submittals shall include the process plan for engine conversion / modification, to include documentation of employee qualifications to successfully execute the above.

Replace all machine drive belts and engine hoses. Inspect and rebuild pump drive.

Remove, inspect and rebuild/replace pump drive.

Remove, inspect and rebuild/replace generator Full testing shall be performed and documented for customer inspection.

The vendor’s production plan shall identify the experience levels and skill sets of vendor or subcontract personnel planned to perform upon these engine

Drivetrain:

Remove and inspect wheel bearings. Rebuild or replace with new.

Inspect rail wheels for excessive wear and repair as necessary.

Drain, open, inspect and then rebuild the rear end.

Drain, open, inspect and then rebuild the transmission.

Inspect rail wheel bearings and replace as needed.

Replace all rubber suspension pads with new.

Install all new brake canisters and brake shoes.

Replace all air lines with new DOT hose and fitting.

Full testing shall be performed and documented for customer inspection.

The vendor’s production plan shall identify the experience levels and skill sets of vendor or subcontract personnel planned to perform upon these drivetrain

Electrical Completely rewire machine. All wiring will be new.

Number new wiring per OEM specifications.

Replace / install all new work, brake, marker and travel lights.

Replace / install LED Amber Strobe and Back-Up Alarm.

All electrical controls (relays, limit switches, toggle switches, etc.) will be inspected and replaced, if found to be defective or obsolete.

Full testing shall be performed and documented for customer inspection.

The vendor’s production plan shall identify the experience levels and skill sets of vendor or subcontract personnel planned to perform upon these electrical

Hydraulic Components

Install all new hydraulic hoses and steel lines, the latter where needed.

Rebuild or replace all hydraulic pumps motors, valves, and cylinders.

Replace the hydraulic oil cooler with a new unit.

The hydraulic tank will be cleaned, inspected, repaired as needed, pressure-tested, painted and re-installed.

Disassemble, clean, inspect, repair / replace as needed, and reinstall all high-pressure filters.

Turntable will be rebuilt, tested, and installed.

All testing shall be documented for customer inspection.

The vendor’s production plan shall identify the experience levels and skill sets of vendor or subcontract personnel planned to perform these hydraulic component requirements.

Rail Clamping / Tamping Components The rail clamping and jacking system shall be updated and rebuilt with replaced with remanufactured components. This includes jack cylinder, clamp cylinder, and pins and bushings.

The final restored assembly shall be tested and testing will be documented for customer inspection.

The vendor’s production plan shall identify the experience levels and skill sets of vendor or subcontract personnel planned to perform these rail clamping / tamping requirements.

Extractor Head The tie extractor head will be updated and rebuilt. This includes the tie gripper cylinder and all related components.

The outer boom and inner tube shall be inspected for scoring and scuffing marks. If scoring and/or scuffing are present, replace the affected component.

Final testing shall be performed and documented for customer inspection.

The vendor’s production plan shall identify the experience levels and skill sets of vendor or subcontract personnel planned to perform these extractor head

Cab Components

All parts in the cab will be inspected, rebuilt, or replaced with new.

All gauges will be new.

The cab will be insulated and have a new air conditioner, new heater, new pressurizer installed.

The operator’s seat will be new.

The machine will have new decals applied per OEM specification.

The vendor’s production plan shall identify the experience levels and skill sets of vendor or subcontract personnel planned to perform these cab component

Parts, Operator and Troubleshooting Manuals

Upon delivery of the rebuilt machine, the awardee shall present three sets of parts, operator and troubleshooting manuals. The manuals shall include all applicable OEM technical updates and bulletins applicable to the characteristics of the rebuilt machine.

One copy of the manuals shall be electronic. The other two copies shall be hard-copy versions.

6.0 - Requirements for Acceptance:

Set-Up and Operation of the Rebuilt Machine

Vendor production plans shall detail how the rebuilt machine will be transported from the awardee’s facility to MCAAP, including the offloading of the machine onto the inspection site.

Vendors shall plan for two workdays in order to set-up and test the rebuilt machine at MCAAP.

The awardee will thoroughly operate and test the rebuilt machine before final Acceptance is granted.

Final Acceptance of the machine is subject to its operation and testing.

The vendor’s production plan shall identify the experience level and skill set of vendor or subcontract personnel planned to participate in the operation and testing of the rebuilt machine.

Warranty

The awardee is required to offer a warranty in order to document its ownership and/or responsibility for all work performance. All warranties are the responsibility of the Contractor. The Contractor is responsible to work any issues with its subcontracted vendors / manufacturers. The offered Warranty is subject to customer review and approval prior to award.

At a minimum, vendors shall warrant their workmanship to be free of defects and premature failure for a period of one year or one thousand hours, whichever comes first, from the date of Government Acceptance.

The offered warranty can be superseded if an OEM part/item installed on the equipment carries a warranty that is longer in duration or offers more extensive coverage. In these cases, the Government shall work directly with the said OEM vendor – with the awardee’s assistance – in resolving all warranty concerns.

The offered warranty shall specifically cover craftsmanship of work performed by the awardee’s technicians and/or premature failure of new parts installed by the awardee’s technicians.

Under the offered warranty, the awardee shall repair or replace failed parts or items of concern.

The awardee shall be responsible for the freight costs incurred to ship the replacement part or the return of said defective part to the awardee’s facility for inspection, once the in-service training/orientation requirement has been completed.

Required Forty-Hour In-Service Prior to Government Acceptance

The awardee is responsible for the complete set-up of the machine at the customer’s site. Prior to Acceptance of the rebuilt machine, the awardee shall send one of its Technicians to MCAAP to perform the following tasks:

1. Review all of the machine's daily, weekly, monthly, etc. service areas with the customer’s designated personnel.

2. If there have been operation system upgrades, the Technician shall explain in full detail the operational functions of each upgraded / new system. The technical representative shall also instruct the customer's operator, mechanic, foreman and/or any other selected customer personnel how to operate/navigate the rebuilt machine and its rehabilitated major systems.

3. The Technician shall explain and demonstrate machine operations & functions, including any upgrades made to the machine pertaining to operation and function that may be different from the machine's original operations and functions.

4. The Technician shall review the new parts, operator and troubleshooting manuals provided with the re‐manufactured machine with the customer's designated personnel.

5. The Technician shall spend sufficient time with the customer's on-site operator while that same operator is using the machine. The training objectives are to ensure proper machine use and to assist customer personnel in working through any problems that may arise during a forty-hour work week.

6. The Technician shall also instruct McAlester personnel in troubleshooting methods when the machine experiences a real-time operational problem. The objective of this instruction is to minimize equipment downtime when operating issues surface in real-time.

Note: Prior to delivery of the machine, the Contractor shall contact the Government in order to coordinate scheduling of this in-service training requirement. In turn, McAlester shall ensure that the appropriate personnel are available during the in‐service timeframe. McAlester shall be responsible for scheduling of ample track time to run the machine and maximize the 40 hours of technical instruction/guidance.

Contractor Manpower Reporting (CMR)

Reference unpriced Line Item 0004. In accordance with FAR 37.102-90, the Contractor is required to report all labor hours via the Army CMR application at http://www.ecmra.