DRAFT-~1.DOC

AUTOMATED STORAGE RETRIEVAL SYSTEM (ASRS) REBUILD

GENERAL SYSTEM DESCRIPTION

Rock Island Arsenal Joint Manufacturing Technology Center (RIA-JMTC) has been utilizing an Interlake ASRS system that was initially installed by Interlake in 1984. A portion of the system was upgraded by Retrotech in 2005. Areas upgraded included portions of the conveyor equipment as well as system controls. Due to the age and condition of the system, it has been deemed necessary for a full system rebuild to be executed. The contractor shall provide all labor and materials needed to satisfy the requirements described within this purchase description to rebuild the existing ASRS along with all necessary components and labor (listed or not) to provide an efficient fully functional and safe system.

STANDARDS AND PUBLICATIONS

Clarification Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the offeror in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF THE SOLICIATION/receipt of proposal. Submission of a proposal or quote shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

National Standards and Specifications The following specifications in effect on the Date of Invitation for Quotes/Request for Proposal form a part of this purchase description. The contractor shall perform the work stated in this purchase description while complying with the following statutes, regulations, and standards. In the case of conflicting requirements, the more stringent shall apply.

Occupational Safety and Health Act of 1970 (OSHA).

American Society of Testing and Materials (ASTM).

American Society of Mechanical Engineers (ASME).

American National Standards Institute (ANSI).

National Electrical Manufacturers Association Standards (NEMA).

Electronic Industries Association (EIA).

Institute of Electrical and Electronics Engineers (IEEE).

American Welding Society (AWS).

American Institute of Steel Construction (AISC) American Gear Manufacturers Association (AGMA).

National Fire Protection Association (NFPA).

1.1.1.1 NFPA-70 National Electrical Code

1.1.1.2 NFPA-79 Electrical Standard for Industrial Machinery.

International Standards Organization (ISO).

DESIGN

Ownership This ASRS is a custom designed system and is to be designed for use by the Rock Island Arsenal by the supplier. Components installed as part of the ASRS rebuild may be designed by others in which case ownership of design data for those components or items remains with the contractor.

General Design Standards DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve requirements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a 10-hp motor would not be acceptable.

UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, and drawings shall be in the English-US system or both the English-US and the metric systems, unless otherwise specified in this document.

ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable): Manufacturer Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine Weight. This information is necessary for compliance with the governments Unique Identification Program (UID).

DATA PLATES: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID 2-D matrix may be included on the ID Data Plate outlined in paragraph 2.2.4.

UTILITY CONNECTION: The ASRS has previously been designed with utilities feeding into one single distribution point, or main feed. Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc… This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc… Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection for any new utility feed systems provided by this ASRS rebuild. The contractor will be responsible for all connections beyond the point of first connection for each utility.

UTILITIES AVAILABLE: If new connections to RIA utilities are required as part of this ASRS rebuild, Rock Island Arsenal shall be responsible for providing the following:

1.1.1.3 Connection of 460-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

1.1.1.4 Connection of approximately 80-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

1.1.1.5 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced, by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

COMPONENT ENVIRONMENT: The ASRS is a material storage system installed in a factory environment. Under no circumstances shall a component provided by the contractor be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading etc.

REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine.

1.1.1.6 The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be English and the units shall be English standard (i.e. pints, quarts, and gallons)

1.1.1.7 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

1.1.1.7.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

1.1.1.7.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

1.1.1.7.3 All filters shall be either cleanable or replaceable.

1.1.1.7.4 All pumps shall be self-priming.

FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections.

1.1.1.8 Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

1.1.1.9 Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load.

HYDRAULICS: The machine will be equipped with a hydraulic system and the system shall be complete with, but not limited to, pump, valves, piping, cylinders, pressure controls, filter, and reservoir. All components necessary to make the system completely functional shall be provided. Removal and disposal of any existing hydraulic equipment including tanks and fluid shall be the responsibility of the contractor.

1.1.1.10 If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable air-cooled heat exchanger shall be provided to maintain fluid temperature at or below that temperature. The exchanger shall be equipped with changeable fiberglass filter(s), unless permanent type filters are supplied.

1.1.1.11 The system shall have adequate capacity to provide sufficient pressure and flow to perform all hydraulic operations under all normal machine operating conditions.

1.1.1.12 Protection shall be provided to prevent damage to components.

1.1.1.13 Safeguards shall be provided to alert the operator of temperatures and pressures above/below design limits. If safe limits (within design limits) are exceeded, the system shall automatically shut down.

1.1.1.14 Anti-surge devices or circuits shall be incorporated to ensure uniformity of motion under varying loads.

1.1.1.15 The hydraulic reservoir shall be provided with means for draining and cleaning.

1.1.1.16 Means shall be provided to enable the operator to determine fluid level.

1.1.1.17 Each hydraulic system shall include a filter, which shall be either cleanable or replaceable.

1.1.1.18 All pumps shall be self-priming.

MOTORS:

1.1.1.19 All motors shall be rated for continuous duty.

1.1.1.20 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

1.1.1.21 Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

1.1.1.22 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

1.1.1.23 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

FOUNDATION: The rebuild of mast and rail systems may be included in this project. The requirement for a separate foundation is permissible, if necessary to meet the specified alignment tolerances, to provide isolation, or to conform to a standard system configuration. The contractor shall describe the foundation requirements at the time of proposal/quote. RIA-JMTC shall be responsible for installation of the foundation based upon the drawings and specifications provided by the offeror.

Safety, Security and Environmental SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

1.1.1.24 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

1.1.1.24.1 Access to RIA: Contractor and all subcontractor employees performing work at RIA shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The COR shall provide guidance to complete the Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

1.1.1.24.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti-Terrorism Training.

1.1.1.24.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

1.1.1.24.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR, or paced in a drop box at a RIA-JMTC access point.

1.1.1.25 Security Training: The contractor shall complete the following training:

1.1.1.25.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The COR will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center (RIA-JMTC) AT Level I Awareness Training and assure that the training is complete. The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

1.1.1.25.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

FIRE PREVENTION AND PROTECTION: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the Contracting Officer. A written fire permit shall be obtained from the installation Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there is no other red buttons of any type.

CONTROL GUARDS: Controls shall be guarded against accidental operation.

OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed 85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

Responsibilities SITE INSPECTION: A site inspection to observe the current conditions of the ASRS is recommended prior to submitting a proposal/quote. It is not possible to responsibly provide a proposal/quote on this turn-key project without first examining the existing equipment and determining the existence of other potential obstacles. All site inspections and/or measurements, which must be taken in order to perform a visual inspection of the ASRS, are the sole responsibility of the contractor. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance in this inspection process SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system. Examples would include, but are not limited to, buried sewer lines, standing water, and so forth. The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to low hanging electrical lines which are clearly visible, encountering rock during excavation, inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

PHASE 1: Network Communication and Floor Rail Grinding

Ethernet-to-Serial Terminal Servers:

The contractor will transfer the current serial connection into Ethernet. The current Lantronix terminal server will be replaced in the process of transferring the communication lines. A new Warehouse Control System (WCS) will be implemented that can still support the existing Warehouse Management System-Programmable Logic Controller (WMS-PLC) equipment interface protocols and messaging. Messaging will be transmitted to/from the WMS over an Ethernet network and connect to a new single-port Perle Terminal Server, or equivalent, located at the end of aisle for the systems as well as the control enclosure for the conveyor, the two Unit Load weigh scales and printer(s). The Perle Terminal Servers convert Ethernet to RS232 messaging. These will need to be configured to be compatible with our existing components. The contractor will be responsible for the software engineering, procurement, providing and installing Perle terminal server components, setting configuration/setup, shipping, on-site installation and commissioning support and anything else necessary to make the system fully and safely operational. The awardee will also be responsible for the termination and disposal of cabling no longer needed.

ETHERNET COMMUNICATION INFRASTRUCTURE: The contractor will supply a wiring diagram for all Ethernet communication infrastructure. The Government will install and configure all Ethernet communication infrastructure.

EXISTING INTERFACE: The existing Host interface protocol will NOT change.

Floor Rail Grinding:

The contractor will provide floor rail grinding services to smooth out any irregularities present from wheel wear. The rails will be evaluated and profile grinding will take place where there are any irregularities along the length of the rails for all five (5) crane aisles.

PHASE 2: Conveyor controls and Software Upgrade Conveyor Control System Upgrades PLC: The current Allen Bradley SLC 504 PLC will be replaced with an Allen Bradley ControlLogix PLC (1756-L71) or equivalent and be installed with an appropriate program logic.

INPUT/OUTPUT: The contractor will replace the current 1771 I/O with 1756 conversion racks.

NETWORK: The contractor shall replace the current DH+ PLC network communication with Ethernet.

HUMAN MACHINE INTERFACE: The contractor shall replace the current PanelView 600 HMI will be replaced with an Ethernet PanelView Plus v7 700, or equivalent, and installed with proper displays/diagnostics.

POINT I/O: The contractor shall install a new Point I/O module to support the existing interface with the legacy WMS host. When the equipment management system is ready to be implemented, the PLC host interface program can then be switched over to support the Ethernet EIIP interface protocol.

DEVICENET: The contractor will provide and install a new DeviceNet card to provide communication with the following drives and I/O components:

· 15- ArmorStart Drives

· 2- MicroLogix 1200 PLCs for sizing on Aisle #2 and Aisle #5 systems

· 2- MicroLogix 1200 PLCs for running the pallet accumulators/dispensers on Aisle #2 and Aisle #5

· 2- Turck Interlink BT FDN20-16XSG I/O Block on Aisle #2 and #5 Computer System Upgrade (replace the legacy WMS):

The contractor will implement a new system software application to perform the ASRS inventory management and equipment control operations to replace the current obsolete software. The software implementation must support the current logistics modernization program (LMP) host which is a SAP ERP system. The software implementation must support equipment control interfaces with both the existing Legacy RS232 Serial system interfaces as well as a new upgraded conveyor PLC Ethernet EIIP interface protocol. The software must also provide for future Ethernet EIIP interface that will be switched on upon completion of each aisle upgrade/install. The system server computer will have an interface to the host logistics modernization program (LMP). The software system will also have interface connections to the aisle controls and to the PLCs. The system will contain user interface screens that will provide the user the ability to see the status and operation of the system. Equipment status will also be provided to the user.

FUNCTIONAL OPERATIONS OVERVIEW: The software system is responsible for accepting expected receipts, pick and part ownership transfer requests from LMP. The requests will include fields of information such as the SKU, WBS, transfer order number and quantity among others. Some functions of the software are to accept incoming pallet loads at an operator’s direction, selecting rack storage locations for new pallets, maintaining a home position for pans in the mini-load aisles and directing a crane to store the loads in selected/ dedicated locations. The operator will select a put-away to work on and will call for a pallet, pan, or introduce a new pallet. For Picks, the system will select loads to satisfy the request, and then direct the equipment to deliver the selected loads to an output station where the operator will conduct and confirm the pick. The software will respond to the host with the appropriate message related to the request type.

1.1.1.26 System Layout: There are currently 5 aisles consisting of one (1) Large Load, Double-deep aisle (#1), two (2) Unit Load, Double-deep aisle, and two (2) Mini-Load aisle. The unit load and large load aisles use slave pallets for storage. Each workstation has a pallet collector/distributor and each workstation is allowed to have only one pallet being picked or deposited into at any one time.

1.1.1.27 Receiving: After parts are entered into LMP, a ticket is printed to have the system store the parts into the racking. Each transaction from LMP has an internally generated transfer order number. The operator chooses which aisle the parts will be stored based on size or weight constraints.

1.1.1.28 Pallet/Pan: After releasing an empty pallet/pan, the operator will sign on using their Controlled Access Card and initiate the store request. When the load is released for storage, ASRS’s software will communicate with the Conveyor PLC to bring the material to the size and weigh station where if it passes, the load will then be put in a location selected by the software. If the load fails the size and weigh constraints, then the load will be returned to the operator workstation. A location is selected based on

· A near position that already has the same product

· A correct sized empty location when there are none that match

· The next size larger location

· A near position that has a different product

1.1.1.29 Inventory Management: The ASRS’s software system is responsible for maintaining a Load ID Number, SKU, WBS Number, condition code, quantity, rack location, expiration date, transfer request number etc.

1.1.1.30 Picking: Pick requests are received from LMP and picks are done at the operator workstation where the system will tell the operator how many parts to pick. In the case where there is not enough inventory to cover the pick or the pick was cancelled, then the system will send a Denial message to LMP.

1.1.1.31 Cycle Counts: In the case that the operator feels that there is an inventory counting error, they can call out pallets or pans to be brought down and counted. Any adjustments made to the inventory count have to be manually entered into LMP at this point.

1.1.1.32 Empty Pallets: Once empty pallets have accumulated, the operator will have the ability to store a stack of empty pallets into the racking system. The stack of pallets will still be constrained by the size and weight constraints of any other load.

1.1.1.33 Crane: The new software provided by the contractor will communicate with the contractor provided and installed onboard controllers for the cranes by Ethernet to a Perle terminal server which utilizes a serial connection to the end of aisle modems. The software will be responsible for issuing load movement commands.

1.1.1.34 Conveyor: The software will interface with a new, contractor provided and installed Allen Bradley CompactLogix PLC to track and direct load movement on the conveyor. The weigh scale and sizing data will be processed through the PLCs and then communicated to the system software.

USER INTERFACES:

The contactor shall provide and install each storage aisle with its own workstation, located at the front of each aisle with additional workstations in the office area. The ASRS’s software will provide the user interfaces necessary to operate and monitor the system which include:

1.1.1.35 User Functions:

1.1.1.35.1 Graphical Overview: The ASRS software will provide real-time viewing of load movement, equipment status, and situations needing manual support.

1.1.1.35.2 Devices: The software will show the status of all devices included within the system as well as any errors or alarm conditions.

1.1.1.35.3 Alarms: The software will provide some way to view a logging of system alarms recorded within the ASRS software system.

1.1.1.35.4 Alarm Configuration: The software shall provide the ability to view alarm configurations and the ability to choose which alarms are sent to the database.

1.1.1.35.5 User Configuration: The software will provide for the authorizing of users and viewing all authorized users within the system.

1.1.1.35.6 System Startup and Shutdown: The software will provide authorized users the ability to startup and shutdown system applications.

1.1.1.35.7 System Status Bar: The software will provide information for any device, system, or alarm.

1.1.1.35.8 System Parameters: The software will allow for viewing and modification of values that control system operations, perform calculations, or change decisions.

1.1.1.35.9 Watch Bar: The software will provide a specialized viewing pane enabling the operator to monitor items of interest.

1.1.1.35.10 Conveyor Management: The software will provide for the viewing, enabling, or disabling of conveyor regions.

1.1.1.35.11 Crane Management: The software will provide for viewing of the current status and pending commands for cranes. The function shall provide the operators to allow or prevent inventory allocation to the cranes, allow or prevent storage or retrieval for the cranes, and execute semi-automatic commands to cranes.

1.1.1.35.12 Load Management: The software will control all loads in the system and include common operations such as modifying the availability, or identify the location of container inventory. The load management component of the software will provide for editing the destination location for load moves in progress.

1.1.1.35.13 ASRS Locations: The software will provide for the viewing of the information for locations in the system software. The function will allow the operator to control storage and retrieval for rack locations, and the ability to change the status of rack locations and the change storage classes for rack locations.

1.1.1.35.14 ASRS Storage Classes: The software will provide the ability to view information on ASRS storage classes in the system software. It will enable the operator to assign and rank storage classes to ASRS locations.

1.1.1.35.15 Non-Rack Locations: The software will provide for the viewing of storage locations for areas not in ASRS, enabling the operator to change the statuses for them.

1.1.1.35.16 Order Management: The software will be able to identify orders both completed and in progress orders and have the ability to cancel and change order priorities.

1.1.1.35.17 Transaction Monitor: The software will provide historical information on events that are occurring.

1.1.1.35.18 Containers: The software will provide for the viewing of all containers, and any information regarding the container’s activity, current location, or past location.

1.1.1.35.19 Count Material: The software will have the ability to retrieve material, or a storage location for counting by the operator. The software will prompt the operator to enter a value into a field that will send messaging to update LMPs count.

1.1.1.35.20 Count Frequency: The software will record how often a bin/ location has been counted to ensure accuracy.

1.1.1.35.21 Count Empty Locations: The software will provide and display statistics, and define available locations for receiving material. This will include partial and empty locations.

1.1.1.35.22 Pick Material: The software will have ability to execute an LMP pick request.

1.1.1.35.23 Receive Material: The software will have the ability to execute an LMP store request.

1.1.1.35.24 Release Pallet/Pan: The software control system will be able to return a pan or a pallet that is currently at the operator work station back to storage. If the pallet is empty, the operator will be notified.

1.1.1.35.25 Retrieve Empty Pan: The software will be able to select a pan to be retrieved and display free space in the mini-load aisles.

1.1.1.35.26 Store a Stack of Empty Boards: The software will be able to store a stack of empty pallets while coordinating with the Conveyor PLC for completion.

1.1.1.35.27 View/Inspect Material: The software will log an event that the material was viewed or inspected.

1.1.1.35.28 Re-print Ticket: The software will allow an authorized operator to receive another print out of a ticket at the work station.

1.1.1.36 Reports: The system shall include a reporting function to track historical system performance and troubleshooting. The report functions will include:

· Alarm report

· Downtime report

· Crane fault downtime report

· Crane statistics report

· Bin location utilization- (overall and by aisle)

· Inventory quantity- (System and by aisle)

· Storage Class Rank

· Station Activity

· Host Log

· Users

· Crane Fault List

· Crane Fault Occurrence

· Pallet reject report

· Offline Locations report

· Expiration Date report

· Issue Request report

Host Computer Interface INTERFACE: The ASRS system shall provide and receive information regarding certain processes associated with the pick, issue, and put away functions. Data will need to be exchanged with the Logistics Modernization Program (LMP). LMP is a Systems Applications Products (SAP) based solution which utilizes SAP ECC (ERP Central Component), Extended Warehouse Management (EWM), WM, and Complex Assembly Manufacturing Solution (CAMS) as part of its support to the Army Material Command industrial sites. LMP does not track material to individual ASRS storage locations for selecting material to satisfy a pick Transfer Order. Bin numbers should be SAP/LMP compatible. A list of potential outbound transactions (information data elements for LMP) are shown below. Determination will be made by the government following award as to the transactions that will need to be supported.

TABLE 1: Outbound Transactions (Defines requests by LMP to initiate a move by the ASRS or request information from the ASRS):

The ASRS software must provide certain specified transaction data to LMP. This data must be provided in either an SAP IDoc (Intermediate Document) format or in an agreed upon flat file format to LMP. LMP will convert the flat file to an inbound IDoc file for processing. Transactions needed to be provided to LMP are listed in Table 2. Determination as to any exceptions to Transactions to be required will be determined during the detailed design phase of the implementation.

TABLE 2: Inbound Transactions (All move or data updates initiated by the ASRS, requiring data input or updates into LMP):

LMP INTERFACE COMMUNICATION:

1.1.1.37 The ASRS system will use the Army NIPR network

1.1.1.38 Data will be sent from LMP to the ASRS. The software will need to be able to receive data in an SAP IDoc or agreed upon flat file format for receipt and processing by the ASRS.

1.1.1.39 The ASRS system shall provide a Send and Receive Socket pair be used for communication. LMP connects to the ASRS receive socket when transactions are available to send. LMP sends all transactions it has in its queue, followed by an end of transmission; the ASRS must acknowledge this end of transmission. LMP may establish multiple concurrent connections.

1.1.1.40 LMP connects to the ASRS send socket periodically to receive transactions in the ASRS send queue, followed by an end of transmission. LMP acknowledges this end of transmission, and disconnects from the socket.

1.1.1.41 The data passed between the ASRS system and LMP must be encrypted.

LMP INTERFACE TESTING: The contractor will be responsible for unit testing of interface transactions. Interface testing will be done using a live test LMP instance that mirrors the production LMP system. Interface test cases and transactions will be provided by the Government.

ROUTINES: The contractor will provide descriptions of Order and Material software functions available for storage and retrieval. Required routines will be determined during the design phase of implementation. The contractor will include descriptions of system functions for segregation of material by WBS (Project/Work Breakdown Structure), material selection to satisfy pick requests (i.e. First In First Out, material batch, expiration/shelf life dates, etc.), material storage, and cycle counting retrieval.

SERIALIZATION: Material stored in the ASRS can be identified with Serial Number identifiers for tracking. The new ASRS software must support tracking of Serial Number data with material records. The ASRS system must also support picking, reporting, and searching material by Serial Number.

MATERIAL IDENTIFICATION: Material Identification tags must be printed for each material/storage location in the material receipt process. Material Move Tags will be printed for each pick. Required formats will be determined during the detailed design phase of implementation.

DATA CONVERSION: The contractor will convert the data and load the materials stored in the existing RIA-JMTC ASRS. Data will be provided in an agreed upon format (Excel spreadsheet, CSV file, or flat file). The required data record format will be determined during the detailed design phase of implementation.

1.1.1.42 The Offeror shall execute data migration trial loads, and provide in validation of trial loads, and support JMTC in resolution of trial load issues.

DOCUMENTATION: The contractor will document and provide the Government with the ASRS application database design, and data structures.

USERS: The ASRS system and database shall allow Government administrative users to create reports and perform ad hoc queries against the ASRS database.

SUPPORT: The contractor shall also maintain a log of all helpdesk tickets, and resolutions for issues reported by RIA-JMTC.

Computer Hardware and Software ACQUISITION PROCESS: For all computing/communication infrastructure (both hardware and software) provided by the contractor, herein after referred to as Offeror Components, the awardee will follow these guidelines to minimize the non-refundable cost of Offeror Components which do not meet NECRIA approval requirements. Implementation of Offeror Components will be contingent on successful review of NECRIA’s Change Control Board (CCB). To facilitate NECRIA’s CCB process, the contractor shall supply a list of all Offeror Components to JMTC 180 days before the start of the project.

END USER COMPUTING AND SERVER HARDWARE: The contractor will supply the Government with the minimum system requirements for computing hardware. The Government will provide all computing hardware which meets or exceeds the specified minimum requirements.

END USER AND SERVER SOFTWARE: The contractor will supply the software and any licensing, and documentation detailing the installation, configuration, and administration of the software. The Government will perform installation, configuration, and administration of the software based on the provided documentation. The contractor shall be available to JMTC during this installation process.

DATABASE SOFTWARE: The database product must be either: Microsoft SQL Server 2016 Enterprise Edition, Oracle Database 12c, or Oracle Database 12c r2. The Government will host and administer the database environment.

SOFTWARE AND SYSTEM UPDATES: The contractor will supply patches and fixes to address issues with stability, security, and compatibility in line with the industry standard known as Patch Tuesday.

DOCUMENTATION: All documentation must include step by step graphics of the task to be performed.

PHASE 3: Large Load asrs Aisle Upgrade Large Load Aisle #1 Crane Control/Drive System Upgrades and Shuttle Replacement PLC: The contractor will replace the current SLC 5/04 PLC with an Allen-Bradley Compact Logix PLC, or equivalent.

MODEM: The current SICK communication modems will be replaced with Lueze Ethernet, or…