Loren Data's SAM Daily™

FBO DAILY - FEDBIZOPPS ISSUE OF JUNE 18, 2015 FBO #4955
SOURCES SOUGHT

36 -- CNC Milling (engraving) Machines - (Draft)

Notice Date

6/16/2015
 

Notice Type

Sources Sought
 

NAICS

333517 — Machine Tool Manufacturing
 

Contracting Office

Department of the Treasury, United States Mint (USM), Manufacturing Procurement Branch, 801 Ninth Street, NW, Washington, District of Columbia, 20220, United States
 

ZIP Code

20220
 

Solicitation Number

USM-HQ-06162015
 

Archive Date

7/15/2015
 

Point of Contact

Jina M Jackson, Phone: 2023540123
 

E-Mail Address

jina.jackson@usmint.treas.gov
(jina.jackson@usmint.treas.gov)
 

Small Business Set-Aside

N/A
 

Description

DW-354-0000-0011 Turned Work Die DW-344-0000-0015 Final Work Die 356Turn SB Comm 355Turn Grind Gold 353Turn Grind Medal 352TurnGrind UNCIR Attachment - 351Turn grind Cir Sources Sought SECTION C - STATEMENT OF WORK (SOW) Specifications - CNC Turning Center C.1 PROJECT OVERVIEW During die manufacturing, a turned steel cylinder is impressed with the coin image, creating a hubbed die. This process mushrooms the cylinder around the image impression. The die is then turned to produce the dimensioned part: length, diameter of the body, and diameter of the neck (see the attached drawings for finish turned dimensions prior to heat treating). Dimensioning a hubbed die prior to heat treating is a major source of scrap and a timely operation in the die manufacturing process. Currently dies are loaded and unloaded manually into a stand alone lathe for each operation. Replacing the current configuration with an automated CNC Turning Center with optional robots for feeding the turning center will reduce the potential for scrap and significantly decrease the processing time. The United States Mint may order one or a combination of the following options: Option #1 - Base CNC Turning Center manually loaded and unloaded Option #2 - Turning Center with robotic system for loading and unloading dies Option #3 - A complete cell with multiple turning centers, robotics, and conveying systems. Option #4 - A combination of Options #1 - #3 All options shall include systems integration, tooling and fixturing, material handling systems, parts programming, and any other items required for safe turnkey systems. C.2 SCOPE OF WORK The CNC Turning Centers shall meet the following specification: All provided machinery and equipment shall meet all applicable federal, state, local, and United States Mint including safety and environmental standards. Each Machine Cell shall be capable of performing all turning operations on any hubbed die without removing the part from the machine. Each turning center shall have the capability to run manually, or run with the robot by automatic or teach pendent in step mode. Each turning center cell shall be capable of reliably running in an industrial setting in a 24/7 operation. The United States Mint will supply finished drawings for all turned dies, as well as, reference hubbed dies & turned dies for the small, medium and large die bodies. An electrostatic precipitator (mist collector) shall be provided and mounted to each turning center. The mist collector shall be hard-wired to the controls. Each turning center shall be equipped with a chip conveyor that does not interfere with the operation of surrounding equipment or smooth operation of the machining cell. The conveyor may extend through any safety cage provided sufficient means are in place to prevent injury to United States Mint personnel. All painted surfaces shall be painted United States Mint Blue. Any surface not painted shall be preserved in a manner acceptable to the United States Mint. Throughput shall be greater than 20 parts (hubbed dies) per hour for each turning center potentially running different die configurations with different machines. The completed System shall be capable of running with the machines (i.e., the installed lathes, robot and related equipment) in any combination of manual and/or automatic modes. Unless a tooling change is required, the system shall automatically load programs, configure the robot, and separate finished parts based on operator input (such as a scanned bar code) of incoming part type. During operation, the system shall either require no reconfiguration due to different parts in process, or change configuration on the fly, with no operator input. Operator input or action, except prior to pick up of the first part of a lot or after completion of the last part of a lot, shall not be required. Operator actions shall be required to load/unload parts manually or only to stage parts for auto-loading, input program type, remove finished parts from finished goods staging area, change work-holding devices, tools, and other part contact tooling, and resolve any alarms or malfunctions. The automated cell shall be capable of running unattended and shall continue processing parts until all lots loaded are expended or the cell is incapable of processing remaining lots (i.e., due to incorrect tooling, an alarm condition, etc). Changeover of contact tooling for the different sized hubbed dies shall take no more than ten (10) minutes. The robot (when applicable) shall place the hubbed die part in the chuck (primary or secondary) such that the die border is concentric with the turn diameter to 0.002 inches. The die face shall be perpendicular to 0.001 inch to the turn diameter centerline. Each turning center shall maintain these tolerances when transferring the workpiece between spindles. Each Machine Cell shall automatically determine whether the correct part contact tooling is installed, whether the tooling is correctly installed, and whether the part is correctly placed. A visual and audible alarm shall sound if the incorrect tooling is installed. If the incorrect tooling is installed in a turning center, any other applicable turning center operations shall not be impacted. The control system and internal gauging system for each turning center shall ensure that the first part in each lot is within tolerances (for example, by initially cutting the part oversized and then measuring and re-cutting). The die face shall be protected at all times. Any mark, mar, scratch, etc. will result in a bad part. Each turning center shall be equipped with a visual and audible alarm to alert operators of abnormal conditions. The operator may silence the audible alarm manually. The visual alarm and any on-screen warnings shall only clear when the abnormal condition is resolved. Yield shall be 99.25% or better for all combined turning operations. Yield is defined as the ratio of the number of acceptable parts produced as specified on the attached drawings to total parts produced. A factory acceptance test (FAT) shall be conducted under guidelines published in Section E.5. C.3 TRAINING The Contractor shall provide one week per shift of operator training on each of the turning centers after installation. The Contractor shall include one week per shift of Maintenance training on each of the Lathes. The Contractor shall provide system training on how to operate and maintain the equipment supplied for each Machine Cell. This program is tailored to the individual client's requirements based on personnel staffing and experience. This training shall teach experienced machine operators and technicians proper procedures for safe operation of the automation equipment supplied. It instructs personnel on proper operating procedures, troubleshooting, fault recovery procedures and basic maintenance. C.4 Issues to be covered under this solicitation. The following is a list of questions that will need to be answered in your proposal. 1) Describe the sequence of automatic operations performed by the machining cell, both external to the machine (robot) and internal (work-holding devices, etc) that will ensure the specifications of Statement of Work (SOW) are met? 2) How will the cell verify that the part is properly held, i.e. meets the requirements of SOW? 3) How will the die face be protected as required in SOW? 4) Describe the method of chip control to meet the SOW 5) Describe how parts gauging would be integrated into the process such that the quality of parts is maintained and SPC data is captured while not impacting cycle time. 6) Describe the process to verify correct tooling installation without manual intervention. 7) Describe the equipment layout that will enable personnel to perform work manually and/or automatically. 8) What components are changed during a setup or changeover from one part type to another? 9) What system integration components and software will be used to store and manage SPC data from the cell? What data and reports will be available as a result? C.5 MANUALS AND DOCUMENTATION Documentation shall be in English. A CD-ROM or DVD-ROM, readable on any PC with the Windows operating system, containing all manuals and three hardcopies of all manuals will be provided with each unit. Manuals shall include but are not limited to operations and maintenance manuals, cut-sheets, drawings, and parts lists for all installed equipment, including any components such as pumps or chucks. The manuals shall outline all equipment specifications, operating parameters, and operating procedures. This includes, but is not limited to: Safety precautions and warnings Basic operation Basic troubleshooting (where applicable) Overview of preventative and periodic maintenance (where applicable) Warranty Terms Backup copies of software and any special tools shall also be included. C.6 SERVICE DESCRIPTION OVERVIEW The contractor shall be responsible for all construction means, methods, techniques, sequences, and procedures not specified by the United States Mint and for coordinating all portions of the work with any sub-contractors and the United States Mint to accomplish this project. The contractor shall furnish all labor, materials, equipment and services to install the units and demonstrate proper operation as specified in the Statement of Work. The contractor is responsible for providing the United States Mint a list of spare parts recommended to be stocked on site. The spare parts shall cover the machine tools, robot(s), gauging station(s), control system, computer and any ancillary equipment comprising the machining cell. The contractor shall make spare parts available during warranty period for service calls, if any, to avoid downtime due to lack of spare parts. The contractor shall demonstrate operation of the installed equipment to the Contracting Officer's Representative's (COR's) or to the site manager's satisfaction. See Section E. The work shall be accomplished during regular business hours, Monday through Thursday, 7:00 a.m. through 5:30 p.m. unless otherwise directed by the Site Manager. Work may be performed on weekends at the discretion of the Site Manager so as not to interfere with United States Mint operations. Any connections requiring disabling United States Mint mechanical or electrical systems will be performed on weekends. The contractor shall ensure the work area is neat and clean at the end of each workday. Weekend work schedules should be submitted to the Site Manager by COB the preceding Wednesday. Any off-shift work should be coordinated at least the workday prior if practicable. Contractor shall submit a schedule for review and approval prior to commencement of work or ordering of long lead components. The Contracting Officer reserves the right to amend the scope of work pending comment and/or observations resulting from the joint project inspection. The contractor shall provide the Site Manager with a list of any chemicals required to perform the work or used in equipment operation or maintenance and material safety data sheets for each prior to starting the project. The Site Manager must approve the chemicals before they can be allowed into the United States Mint. For any chemicals that are flammable and have Site Manager approval, the contractor must provide fire-extinguishing media inside of the work area. The contractor shall provide to the Site Manager a list of all equipment and tools that will be used on the project and comply with the United States Mint's property management procedures. Onsite storage may be provided at the Site Manager's discretion. The contractor shall clean up any spills and dispose of them properly and report such spills to the Site Manager during the shift spill occurred. The contractor is responsible to repair any damage done to United States Mint property. Ancillary damage to equipment or any structural and/or cosmetic appurtenances, and furniture in the United States Mint caused by the contractor (to include the contractor's employees, sub-contractors, or consultants) during this project will be repaired and/or replaced. Repairs and/or replacements will be at the contractor's expense and must be accomplished before final payment is made. The contractor shall adhere to all applicable federal, state, and local regulations in the storage, removal, transportation and disposal of any hazardous and/or chemical residues, cleaning solvents, lubricants, coatings, and general solid waste. The contractor shall provide copies of all landfill/disposal manifests to the Site Manager showing proof of proper disposal within 30 days of project completion, if applicable. The contractor shall not allow any of their personnel out of the work area unless workers have removed any protective clothing. No soiled or protective (tyvek) clothing is allowed into the United States Mint's lunchroom, designated smoking areas, or bathrooms. The contractor shall ensure that workers adhere to the guidelines provided in this statement of work and that activities are conducted according to all federal, state and local requirements. C.7 EQUIPMENT DELIVERY The contractor shall assume all costs and responsibilities for the transport, removal of old equipment if applicable, delivery, onsite handling, staging and proper storage of equipment and materials related to the equipment installation. Delivery or pick up at the loading dock will be made between the hours of 7:00 AM and 2:00 PM. After hours deliveries or pickups will be coordinated with the Site Manager at least 48 hours in advance of the required time and date. Onsite parking will not be provided (equipment deliveries excepted). C.8 SAFETY AND HEALTH CONSIDERATIONS The contractor shall implement the appropriate safety and health protocols and procedures as described in 29 CFR sections 1910 and 1926. Any questions with respect to these protocols and procedures should be addressed to the United States Mint's Safety and Occupational Health Specialist. Contractors, sub-contractors, and their employees will be trained and sign an acknowledgment that they have been trained in accordance with United States Mint's safety policy on initial arrival at the United States Mint and prior to beginning work. C.9 SECURITY AND CONTRACTOR CLEARANCES Contractor shall ensure that all contractor's employees working on this contract or having access to the United States Mint and subcontractors are able to pass a background clearance check conducted by the United States Mint Police. The contractor shall coordinate all requests for clearances through the Site Manager utilizing the form provided with the Request for Proposal package. The current required lead time for clearances is approximately one week. C.10 SCHEDULE A Project Schedule complying with the requirements of the contract shall be approved by the COR or Site Manager within 45 days of notification to proceed. C.11 RELIABILITY The machining cell shall operate for a ten year period without a major overhaul provided the equipment is operated and maintained per the manufacturer's instructions outlined in the submitted manuals. Any visits by the contractor/supplier/distributer/manufacturer required for routine maintenance or other upkeep purposes in association with the warranty shall be clearly noted in submitted proposals. The United States Mint considers major overhauls as any procedure requiring replacement of parts that are not normal maintenance items or are not consumable parts as listed in the maintenance manual. C.12 LONG TERM TECHNICAL SUPPORT UP TO FIVE (5) YEARS 1. The Contractor shall provide technical support capabilities covering: any required tooling and fixtures to support the intended turning/machining applications, hardware & software malfunctions, diagnostics, replacement parts etc. and provide pricing structure for yearly technical support for five (5) years after contract award. 2. The Contractor shall also provide pricing for an annual preventative and emergency maintenance program for the life of the equipment including spare parts for repairs. 3. The Contractor shall provide specifics on out-of-warranty repair costs including travel fees. 4. The Contractor shall provide pricing per day for five (5) days of on-site applications support per year for the life of the equipment. *Days may be non-contiguous. [END OF SECTION C] SECTION E - INSPECTION AND ACCEPTANCE E.1 INSPECTION AND TESTING OF SUPPLIES (VAR) The Contractor shall be responsible for ensuring the performance of all test and inspection requirements herein, and provide only the equipment and supplies specified herein that are in conformance with the contract requirements. The presence or absence of a United States Mint inspector does not relieve the Contractor of any contract requirement, nor is the inspector authorized to change any term or condition of the specification without the Contractor Officer's written authorization. Prior to any shipments, the Contractor shall notify the United States Mint so the United States Mint can exercise its option to inspect the product at the Contractor's facility. The United States Mint has the right to inspect and test all supplies called for in the contract at all places and at all times before acceptance. The United States Mint will perform inspections and tests in a manner that will not unduly delay the work of the Contract. Final acceptance of supplies does not relieve the Contractor for latent defects, fraud, or gross mistakes amounting to fraud. Transfer of title to equipment and supplies furnished under this contract shall take place at the time of acceptance regardless of where or when physical possession by the United States Mint takes place, excepting loss or damage caused by the United States Mint. E.2 INSPECTION AND ACCEPTANCE OF EQUIPMENT (VAR) Final inspection and acceptance of the equipment shall be made in accordance with the specification requirements set forth in Section C and inspection and acceptance requirements stated below. E.3 QUALITY ASSURANCE INSPECTION AT THE CONTRACTOR'S FACILITY - CONTRACTOR RESPONSIBILITY (VAR) (a) Contractor shall be responsible for performance of all quality assurance and inspection requirements at his facility. The Contractor shall maintain complete inspection records and make them available to the Government upon request. (b) The Contractor shall provide its own quality assurance and inspection program for production, assembly, and performance testing of the equipment in accordance with E.5 below. The instruments and the programming methods used in performing the tests shall be at the option of the Contractor provided they accurately determine the operating capacity and operational sequencing of the equipment as required by this specification. (c) Contracting Officer's Representative (COR) or his designee shall witness all inspections and test required by this specification unless the Contracting Officer notifies the Contractor, in writing, that the requirement to witness the test has been waived. The Contractor shall notify the COR and Site Manager, in writing, fourteen (14) calendar days prior to testing. (d) The presence or absence of a Government inspector does not relieve the Contractor from any contract requirement, nor is the inspector authorized to change any term or condition of the specification without the Contracting Officer's written authorization. (e) If it does not meet the specification requirements, the Contractor shall correct the deficiencies within fifteen (15) calendar days of testing at no additional cost to the Government and shall re-test the equipment performance and furnish the results to the Government prior to shipment of the equipment. E.4 CERTIFICATION OF INSPECTION (VAR) Under no circumstances shall the Contractor ship the equipment to the United Sates Mint without written notice from the Contracting Officer acknowledging receipt of the written statement of the test results and approval for shipment. E.5 PERFORMANCE TESTING AT THE CONTRACTOR'S FACILITY (VAR) Satisfactory operation of each Machine Cell and demonstration of performance to the contract specifications shall be demonstrated prior to equipment delivery, and after each turning center is started up in the United States Mint. Nothing in the following procedure or any results from the tests outlined in the following shall supersede or otherwise void any provision of the contract. The Contractor shall be responsible for performing the tests and submitting a written report of the tests to the COR. 1. Operation of a single turning center and robot(s) shall be demonstrated to the satisfaction of the United States Mint prior to shipment to the United States Mint. The site may be of the contractor's choosing (i.e., at the manufacturer, an integrator's facility, etc.). Process three lots of twenty five pieces per lot through the system. Hubbed dies will be provided by the United States Mint. Lots shall be of two types and processed in an A/B/A sequence. Final part dimensions and tolerances are attached. Final parts not meeting the dimension and tolerance requirements are rejects. No tool change shall be required. No operator action is allowed except to load and unload the lots. Throughput shall be measured from the time the 6th piece is picked up by the robot until the 20th piece is placed in the finished parts staging area and shall be greater than 20 pieces per hour. Elapsed time for these 15 pieces shall be no greater than 45 minutes. Rejection Rate: The number of rejects shall be zero. The Contractor shall record all data specified in the contract. This data shall be provided to the United States Mint following the completion of the runoff. The dimensions of all finished parts shall meet the tolerances specified. Change contact tooling. Changeover time shall be 10 minutes or less. E.6 FINAL INSPECTION AND ACCEPTANCE AT THE UNITED STATES MINT The Contractor is responsible for performing the following tests and submitting a written report for each of the tests to the Site Manager. 1. After installation in the die shop at the United States Mint, the test specified in E.5 above shall be repeated with the following addition. Complete a marathon test. Run one lot of each die type (cent, nickel, dime, quarter, half, dollar, chess piece) or any combination of dies as specified by the Site Manager sequentially beginning at the start of the day. Repeat until eight hours have elapsed. Record the number of parts processed (ie, number that have been delivered to the completed part staging area after eight hours) and the United States Mint will provide SPC data for all parts. All parts must meet all criteria of Section C and the attached drawings. Rejection Rate: The rejection rate is calculated by dividing the number of rejects by the number of parts processed. The rejection rate shall be 0.25% or less. 2. If applicable, upon installation of the second Machine Cell at the United States Mint, perform the following. Process two different lots simultaneously. Measure throughput from the 6th piece picked up to the 20th. This test verifies that the addition of a second lathe and associated equipment does not impact cycle time or throughput and that the original equipment and the new equipment work as a single cell. Throughput shall be greater than 20 pieces per hour. Elapsed time for these 15 pieces shall be no greater than 45 minutes. Load and process a third lot prior to either of the initial lots completing processing. This third lot should be of a different type than the initial two. Process one lot with one Turning Center in manual and one in automatic. Switch modes halfway through the lot. Change contact tooling in one lathe while the other is processing. Rejection Rate: The number of rejects shall be zero. The Contractor shall record all data specified in the contract. This data shall be provided to the United States Mint immediately following the completion of the runoff. The dimensions of all finished parts shall meet the tolerances specified. Complete a marathon test. Run one lot of each die type (cent, nickel, dime, quarter, half, dollar, chess piece) or any combination of dies as specified by the Site Manager sequentially beginning at the start of the die shop day shift. Repeat until eight hours have elapsed. Record the number of parts processed (ie, number that have been delivered to the completed part staging area after eight hours) a the United States Mint will provide SPC data for all parts. All parts must meet all criteria of section C. Rejection Rate: 0.25% or less. 3. If applicable, upon installation of the third Machine Cell at the United States Mint, perform the following. Process three different lots simultaneously. Measure throughput from the 6th piece picked up to the 20th. This test verifies that the addition of a third Turning Center and associated equipment does not impact cycle time or throughput and that the original equipment and the new equipment work as a single cell. Throughput shall be greater than 20 pieces per hour. Elapsed time for these 15 pieces shall be no greater than 45 minutes. Rejection Rate: The number of rejects shall be zero. Process one lot with one Turning Center in manual and the remaining in automatic. Switch modes halfway through the lot. Change contact tooling in one lathe while the others are processing. The Contractor shall record all data specified in the contract. This data shall be provided to the United States Mint following the completion of the runoff. The dimensions of all finished parts shall meet the tolerances specified. Complete a marathon test. Run one lot of each die type (cent, nickel, dime, quarter, half, dollar, chess piece) or any combination of dies as specified by the Site Manager sequentially beginning at the start of the die shop day shift. Repeat until eight hours have elapsed. Record the number of parts processed (i.e., number that have been delivered to the completed part staging area after eight hours) and the United States Mint will provide SPC data for all parts. All parts must meet all criteria of Section C and the attached drawings. Rejection Rate: The rejection rate shall be 0.25% or less. E.7 NOISE LEVEL (VAR) The noise level criteria and test shall be as follows: The equipment shall be designed and constructed in such a manner that the maximum emission during all modes of operation shall not exceed 80dBA at any point, one meter from the equipment or at the position of the operators' ears, whichever is closer. Adjacent equipment will be present, but not operating at capacity. The background noise for the test shall be no greater than 76 dBA. If the background noise is greater than 76 dBA, adjacent equipment shall be shutdown or idled until the 76 dBA is reached. If the background level of 76 dBA cannot be reached. The overall sound readings shall be adjusted. The sound levels shall be monitored using the testing procedures specified in OSHA Safety and Health Standards (29 CFR 1910.95) using sound level meters that meet or exceed the type II requirements of the American National Standard Institute for sound level meters, S-1.4-1971(R 1976). All excessive noise abatement materials shall be provided to meet the sound requirements herein and shall be included in the basic price of the contract. If the design requires the equipment to be totally or partially enclosed, the equipment operating temperature shall not exceed 100 degrees F or a 10 degree temperature rise over ambient, whichever is less. [END OF SECTION E] NOTE: 1. "Please note, in accordance with 31 U.S.C. §5136, no provisions of law governing procurement or public contracts are applicable to the procurement of goods or services necessary for carrying out the United States Mint programs and operations." 2. In order for your company to be pre-qualified, vendors must submit capability statements in accordance with the listed pre-qualification criteria. Once a vendor is pre-qualified, the United States Mint will provide a copy of the full solicitation. Pre-Qualification Criteria: - Provide a Capability Statement - Must be current and active in System for Award Management (SAM - Must provide (3) Past Performance references (Point of Contact's name/title/agncey or firm name/contract number/email/telephone number). Excluding the United States Mint. Your response is due by 10:00 am Tuesday, June 30, 2015. Please email all responses to Jina Jackson at Jina.Jackson@usmint.treas.gov
 

Web Link

FBO.gov Permalink
(https://www.fbo.gov/spg/TREAS/USM/CirPr/USM-HQ-06162015/listing.html)
 

Place of Performance

Address: United States Mint, Philadelphia, Pennsylvania, 19106, United States

Zip Code: 19106
 

Record

SN03765388-W 20150618/150616234455-7e5436595fd34f6358657c1f09c5bb87 (fbodaily.com)
 

Source

FedBizOpps Link to This Notice
(may not be valid after Archive Date)

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