Notice of Intent for Intaglio Plate Grinders

Page 1 of 20 Statement Of Work Intaglio Plate Grinder Replacement SECTION I: Background 1.1 The scope of this project is to replace the existing grinders with new grinders systems that meet operational, safety, quality, and currency production requirements. The replacements will ensure platemaking operations at the Bureau of Engraving and Printing (BEP) are maintained. The BEP currently has three (3) Rastelli plate grinders. Two (2) of the systems are located at the BEP Washington D.C. facility (DCF) and one (1) of the systems is located at the BEP Fort Worth facility (WCF). This effort supports the replacement of the Rastelli plate grinders in the Office of Engraving. Intaglio plate grinders are essential to the platemaking process and are used to grind, polish and finish plates to specification. The current fleet of grinders have exceeded their useful service life and are no longer maintainable because the original equipment manufacturer is no longer providing technical support or replacement parts Continued operation of the aging equipment increases the risk of production downtime, maintenance failures, and reduced operational reliability. To ensure uninterrupted currency production operations, the existing grinders must be replaced with new systems that provide improved performance, reliability, maintainability, and compatibility with modern production requirements. This acquisition includes the procurement, delivery, installation, integration, testing, and commissioning of replacement Intaglio Plate Grinder systems, along with associated software, hardware, training, and technical documentation necessary to support BEP operations. The replacement effort will also include replacement of obsolete components and existing system hardware and software to improve operational efficiency, safety, and long-term sustainability of the equipment. SECTION 2: Purpose 2.1 Product, Service or Outcome Needed: 2.1.1 Product Needed: The BEP is in need of four (4) Computer Numerical Controlled (CNC), fully automatic, cylindrical surface grinders. 2.1.2 Outcome Needed: • The grinding process shall be carried out automatically by control of the system. • Grinding program shall allow the progress of the process to be monitored and displayed on the Human Machine Interface (HMI). -- 1 of 20 -- Page 2 of 20 • The grinding machine shall have a simplified HMI allowing access to user adjustable parameters and data via touch screen, display any errors and warnings, and display all parameters (held in memory). • The system shall also be capable of reporting any fault/alarms directly on the screen and shall enable easy troubleshooting. • Cylinder shall hold a plate size of 880mm x 1000mm with a finished grind surface area of 860 x 850. • The cylinder shall be supported on both ends with high precision spherical bearings with a positive air pressure system to prevent coolant migration ensuring the accuracy of grinding. • Yield is 3 plates within an 8-hour shift. 2.2 Scope of the Product, Service, or Outcome. 2.2.1 To the greatest extent possible, components and configuration will first be assembled, tested, and demonstrated to the BEP at the Contractor’s site during a Factory Inspection Test (FIT). A detailed list of contractor site specific components and configurations will be mutually agreed upon by the Contractor and BEP at Design Review. 2.2.2 The FIT will be surveilled by BEP and inspected according to a systems component and configuration list. A FIT will be performed for every Intaglio Plate Grinder awarded. After BEP acceptance of the FIT, the systems components shall be delivered to the BEP DCF and WCF location. 2.2.3 The Contractor shall perform all required testing on the machine at BEP facilities both DCF and WCF. After the grinder has passed the Bureau Acceptance Testing (BAT), the Contractor shall provide on-site operator and technical training required for full production. Contract shall include delivery of grinding machine, installation, commission (BAT), delivery of any spare parts required, training, documentation, & integration into our workflow (Not Change Control Board CCB approved), and warranty. SECTION III: Technical Requirements/Tasks/Outcomes 3.1 Intaglio Plate Grinder Specifications 3.1.1 Grinder shall be capable of grinding a plate with a beginning thickness between 900 and 1100microns. 3.1.2 Wheel head, cylinder rotation, and diamond dressing all have variable speeds for operational adjustability. -- 2 of 20 -- Page 3 of 20 3.1.3 Grinder shall produce plates with a maximum tolerance of +/- 5 micron and yield a surface finish of 4 micr3on (um Rz). 3.1.4 Wheel head shall have automatic balancing capabilities. 3.1.5 A grinding wheel static balancing unit that performs preliminary balancing of the wheel before connecting to the grinding machine and all the necessary accessories shall be provided. 3.1.6 Integrated crash detection unit shall be provided on the grinder. In the event of a crash or power failure, the machine shall be stopped and retracted from the plate surface. 3.1.7 The most recent version of the grinding machine shall be offered. It should also have the infrastructure and flexibility to allow for future upgrades. 3.1.8 All electrical and electronic parts of the grinding system shall comply with the international standards (CE or other standards). The connections such as plugs, sockets shall be suitable for use in the United States of America. The system shall be operational with 220/380 Volt AC and 60 Hz (±5%) power supply. 3.1.9 The grinding machine shall not cause any significant dimensional or tolerance variation of the plates(due to high process temperature etc.) or any significant change in the hardness measurement of the plate after the grinding process. 3.1.10 The operating system shall allow us to create log files of the ground plates and to store them for a certain period. Data shall be transferable to external source. 3.1.11 There shall be hard…