23-30884 PLZT Modernization SOW 15 Jun 23.pdf

CUI

STATEMENT OF WORK (SOW)

FOR

POLARIZED LEAD-LANTHANUM-ZIRCONATE-TITANATE (PLZT)

NUCLEAR FLASH BLINDNESS (NFB) GOGGLES MODERNIZATION

PR Number: FD2060-23-30884

Date: 13 June 2023

Distribution Statement D – Distribution authorized to the Department of Defense (DOD) and

U.S. Contractors only for administrative or operational use; 9 January 2023. Other requests must be referred to AFLCMC/WNU, Sustainment.

Prepared By:

Department of Air Force

Warner Robins Air Logistics Complex Human Systems Division

AFLCMC/WNU, Sustainment 235 Byron Street, Suite 19A

Robins AFB GA 31098

TABLE OF CONTENTS

1. OBJECTIVE

2. BACKGROUND

3. MODERNIZATION SCOPE AND SUBCOMPONENTS

3.1 Subassembly Components

3.2 Description Of Functional Tests

4. TASK AND TECHNICAL REQUIREMENTS

4.1 Task 1. Active and Passive Elements for Optical Protection

4.2 Task 2. Power, Sensing and Control Electronics

4.3 Task 3. Thermal Protection of Exposed Areas

4.4 Task 4. Frame Design and Sealing

4.5 Task 5. Laboratory Test and Evaluation

4.6 Task 6. Modeling and Simulation Tools

4.7 Task 7. Contract Management

4.8 Service Bulletins (SB)

5. DELIVERY SUMMARY

5.1 Post Award Meeting

5.2 Technical Review Documentation

5.3 Program Management Review Support

5.4 Meeting Room

5.5 Meeting Agendas

5.6 Meeting Minutes

5.7 Technical Order (TO) Requirements Support

5.8 Government Furnished Property (GFP)

5.9 Item Unique Identification (IUID) Marking

5.10 Security Requirements

5.11 Safety and Health Plan/Program

5.12 Mishap Notification/Investigation

6. BASE SUPPORT

7. CONTRACTOR REQUIREMENTS

8. HANDLING, DESTRUCTION, DEMILITARIZATION AND RETURN OF UNSERVICEABLE ASSETS

9. ACRONYM LIST

STATEMENT OF WORK

PLZT: NUCLEAR FLASHBLINDNESS PROTECTION SYSTEMS

1. OBJECTIVE

Objective of this effort is to modernize NFB/PLZT goggles as needed for existing United States

Air Force (USAF) inventory of NFB goggle assemblies (P/N EEU-2P NSN 8475-01-017-4473 and

P/N EEU-2A/P NSN 6625-01- 099-6707) to return the assets to operational status in support of the

USAF mission requirement. The outcome of this effort will require the modernization organization to complete overhauls of all degraded components of NFB/PLZT goggles that are declared and tested to be non-satisfactory in performance based on condition and acceptance test results.

Modernization must be made in a way to provide the same form factor flash-blindness, and to design, fabricate and test a variety of subcomponents that require replacement of the USAF assets.

In additional to modernization of the NFB/PLZT goggles the Air Force (AF) requests complete modernization of the goggle storage container. Packaging will be similar to original packaging.

Our aim are to have sufficient Turn-Around Time and meet overall mission capabilities without adverse effect on readiness rates.

2. BACKGROUND

This technology is 60-year old and is experiencing obsolescence challenges. Manufacturing is no longer existent or feasible. Our focus is to provide protection to Aicrews flying nuclear mission while facing intense emissions of visible light rays (blast/detonation) that will produce temporary or permanent flash-blindness and thus pose a significant threat to AF personnel and the potential for serious mission degradation. Current protection for AF aircrews against flash-blindness utilizes technology and form factor that are unsuitable for several mission profiles. The USAF is looking to modernize current NFB with an optical system with high clear state transmission and a fast-switching shutter to a dark state presented in a mission-appropriate form factor is required for this type of protection.

3. MODERNIZATION SCOPE AND SUBCOMPONENTS

Activities under this modernization effort shall include but are not limited to integration of electronics that provides fast-switching protective materials, device design, and device fabrication, device testing, and tooling fabrication. Device configurations within the modernization effort to be investigated shall include as a minimum: lens, goggles frames, material interfaces between parts

(such as gaskets), replacement electronic control modules, and improved packing materials.

3.1 Subassembly Components. This section lists the components contained in the Black

Frame Subassembly and the White Mask Subassembly.

3.1.1 Black Frame Subassembly consists of the following new parts:

Electronics Controller Circuit Assembly

High Voltage Printed Circuit Assembly

Polycarbonate lens holder body or black frame

Photodetectors, detector mounts and corresponding wiring

High voltage electrode contacts and corresponding wiring

Torsion springs for connection to helmet 28 V power and corresponding wiring

Polycarbonate rod to hold torsion springs

Various mounting hardware (fasteners, etc.)

3.1.2 White Mask Subassembly consists of the following new parts:

Molded polycarbonate white frame

Lens gaskets (left and right)

Plastic latch housing (3 pieces)

Latch retention clip

Latch torsion spring

Push to test button

O2 mask flap

3.2 Description of Functional Tests. A total of 11 tests are conducted to produce a goggle modernized goggle. Seven of the tests are performed during the production of the new Black Frame sub assembly, which contains the new bipolar electronics controller. The remaining four tests are performed during modernization steps involving legacy materials.

3.2.1 Two types of tests are involved in the modernization processes, functional and environmental. Functional tests validate the correct behavior of a component or assembly in a benign environment. Environmental tests validate the correct behavior of a component or assembly in a simulated operational environment.

3.2.2 The PLZT lens require voltages around 1kV to operate, if a lens or controller has a defect, other “good” components could become damaged or destroyed. The objective of these tests is to screen out defective components before they are used in the next level assembly. List of tests performed to produce a Black Frame Subassembly.

3.2.3 The following tests are performed during manufacturing of the new electronics controller to validate newly produced assembly used in repair of a goggle system.

Functional test of the Electronics Controller Circuit Assembly.

Functional test of conformal coated Electronics Controller Circuit Assembly.

Functional test of the High-voltage Controller Circuit Assembly.

Functional test of conformal coated High-voltage Controller Circuit Assembly.

Environmental simulated altitude test of the High-voltage Controller Circuit Assembly.

Simulated altitude test of the Black Frame Subassembly.

Environmental thermal test of the Black Frame Subassembly.

3.2.4 List of tests performed during goggle modernization. The following tests are performed during the modernization process using the received goggles.

Functional test of the supplied PLZT lens.

Functional test the Black Frame Subassembly with lens

Simulated altitude test of the Black Frame Subassembly.

Functional test of a fully assembled Modernized PLZT goggle.

4. TASK AND TECHNICAL REQUIREMENTS

4.1 Task 1. Active and Passive Elements for Optical Protection. The contractor shall modernize goggle components as required to incorporate new optical technologies for active and passive protection. Active elements must rapidly switch from a high-transmittance clear state to a high optical density dark state. Passive elements must effectively reject all out-of-band wavelengths. These protection elements must work in coordination with one another for overall system operation and protection of aircrews.

4.2 Task 2. Power, Sensing and Control Electronics. The contractor shall modernize and provide new control electronics responsible for sensing a large change in light intensity and then triggering the active optical elements. The electronics should be hardened against electromagnetic impulse / electromagnetic pulse (EMI/EMP). Current PLZT configurations items are powered by the aircraft through the helmet top latch spring bail conductors.

4.3 Task 3. Thermal Protection of Exposed Areas. The contractor shall ensure modernization incorporates the above optical system to also incorporate protection against the thermal effects associated with intense light and heat. The protection should cover exposed areas of the face that eye protection does not cover.

4.4 Task 4. Frame Design and Sealing. The contractor shall ensure modernization and produce a frame that incorporates all optical and electronics elements with no external power requirement. The frame must include a light tight seal, be robust, and be designed to integrate with recommended current aircrew support equipment. In addition, have put in-place the necessary infrastructure, processes and procedures to produce components for and conduct the modernize of

PLZT systems. Completed the retrofit manufacturing line that will output frame holder

Subassembly that will either be delivered to AFMC/WRALC or used by manufacturer to rmodernize EEU-2A/P/EEU-2/P Nuclear Flash Blindness (NFB) PLZT systems supplied by

AFMC/WRALC. The Subassembly consists of a polycarbonate lens holder (AKA black or white frame); two lens controller Printed Card Assemblies (PCA) with polarity reversal functionality and conformal coat to prevent failure at altitude; two phototransistor detector assembly mounted to the lens holder; two torsion springs for connection to helmet 28 V power; a polycarbonate rod to hold the torsion springs; electrode contacts for PLZT lens; and various hardware (fasteners and washers). All these elements are new form, fit, and functional replacements to the legacy parts and require no scavenging from legacy EEU-2A/P/EEU-2/P goggles.

4.5 Task 5. Laboratory Test and Evaluation. The contractor shall conduct rigorous test and evaluation to ensure systems meet required parameters, including optical performance, environmental durability, resistance to EMP/EMI and transient radiation, and aircrew acceptance testing. An evaluation report of each incoming article shall be available at least monthly

AFLCMC/WNUS Engineering upon request showing all pass/fail condition of all components and system operation condition. An evaluation report of each outgoing article shall be available periodically to AFLCMC/WNUS Engineering upon request showing all pass/fail conditions for all components and validation of goggle system operation. Reports shall support trend analysis and possible scope revisions. Testing can occur at either government or contractor facilities. Other emerging issues – Investigate other emerging issues identified in the efforts above based on trend analysis and item modernization considerations as required to support this modernization effort.

Inform AF program office of emerging issues. Possible reports for after the fact by batch 1900 in the AF (380 per year) for 5 years. (A001, DI-NDTI-80809B Test/Inspection Report)

4.6 Task 6. Modeling and Simulation Tools. The contractor shall have modeling and simulation capability to provide necessary support for modernization of the goggles.

4.7 Task 7. Contract Management. The contractor shall exercise program, administrative, and financial management functions during this contract, including establishing activities and milestones; tracking performance, cost, and schedule; overseeing quality performance documentation. Performance documentation shall require briefings and support for nuclear flash blindness protection symposiums. The contractor shall assign a lead for this contract. The Lead will focus on technical execution and meet with the contractor Program Manager at and possibly more if needed to discuss the technical, schedule, and cost status.

4.8 Service Bulletins (SB). All modifications to fielded equipment shall be made only by

Government approved Service Bulletins (SBs). SBs may be proposed by an ECP or other method as directed by the PM. Any kits required to implement a SB shall be built prior to final approval of the SB. Historical record forms shall be used to record compliance with

SBs Design. (A002, DI-SESS-80639E, Engineering Change Proposal (ECP))

4.8.1 Service Bulletins Procedures. ASB approved by the Government CCB and released by

AFLCMC/WNUS is the final implementing authority for changes to end item configuration baselines associated with operational systems, hardware/software and supporting equipment. SBs are the official documents, providing service instructions concerning changes, affecting government owned equipment. Instructions] may pertain to testing, installation, modification, servicing, overhaul, repair, inspection and identification of equipment. It is very important that contractors of systems, sub-systems and support equipment work closely with AFLCMC/WNUS and the PM on any proposed changes. A coordination copy for all proposed SBs will be forwarded to AFLCMC/WNUS for review and approval. (A003, DI-MISC-81618 Service Bulletins)

4.9 Obsolete Parts and Diminishing Manufacturing Sources and Material Shortages

(DMSMS). The Contractor shall notify the Government of obsolete part conditions within five business days of identification and make recommendations including last-time repair opportunities and any redesign that may ensue. The Contractor shall identify any obsolescence and DMSMS issues that arise during the course of this contract. The Contractor shall be responsible for conducting a comprehensive DMSMS and Obsolescence program for Class II form, fit, function replacement items needed to complete repair of the asset. This program shall include identification, analysis, and resolution for Class II DMSMS and Obsolescence. If the aforementioned analysis determines that there is no feasible Class II change that will resolve the issue(s), the Contractor shall recommend a course of action. Replacement parts shall be recommended to minimize impact.

Requests for funding and all related issues will be directed through the Contracting Officer. (A004, DI-PSSS-81656B Bill of Materials (BOM), for Logistics and Supply Chain Risk

Management; A005, DI-MGMT-81948 Diminishing Manufacturing Sources and Material

Shortages (DMSMS))

4.10 Configuration Management (CM). The Government has the responsibility to ensure operating forces are provided with correctly “configured” hardware, software, and the information necessary to operate and maintain them effectively. The Government will maintain configuration management and oversight of all end items. All changes/modifications shall be authorized by the

Government Configuration Control board (CCB). Work performed shall be IAW the Contractor's engineering directives, internal drawings and procedures or Government approved Contractor verification test procedures. The Contractor shall make engineering directives, internal drawings and procedures or Government approved verification test procedures available for Government on-site review when requested by the Government. The Contractor shall track and inform the cognizant System Engineer/Program Manager of configuration changes.

4.11 Contract Data Requirements List (CDRL). The Contractor shall deliver all data/reports associated with CDRL, with no more than one rejection of any single deliverable. There shall be no more than total of one rejection(s) of deliverables per month. The Government will reject a deliverable if there are any technical errors, or six or more minor errors that are found within the deliverable. A technical error is defined as the format not being in accordance with the CDRL or the content not being accurate and complete in accordance with the CDRL, SOW or contract. A minor error is defined as a typographical or grammatical error. The rejected deliverable shall be corrected and resubmitted within 10 business days of notification of Government rejection. In accordance with the associated DD Form 1423 instructions/requirements.

4.11.1 Submission of CDRL Deliverable. The Contractor shall electronically deliver all contractual data using the Government-controlled method of delivery, Multi-user ECP Automated

Review System (MEARS), https://mears1.redstone.army.mil/mears/Default.aspx. The Contractor shall work with the government to ensure that an adequate number of Contractor personnel obtain and possess Public Key Infrastructure (PKI) certification from an accepted Government source.

The Contractor shall be receptive to the training offered by the Government on the MEARS system. The Contractor shall prepare, maintain, and track the contract data status, schedule and ensure timely data deliveries. An alternate method of delivery when MEARS is down for maintenance will be the DISA application, known as DOD SAFE, https://safe.apps.mil/. It will be available to all DOD Common Access Card (CAC) holders or Contractor personnel who possess

Public Key Infrastructure (PKI) certification from an accepted Government source. Separately priced data must also be submitted/accepted in Wide Area Workflow (WAWF) in order for the

Contractor to receive payment.

4.11.1.1 Receipt of CDRL Deliverable(s). There shall be no more than one late receipt(s) of deliverables per quarter. The Contractor shall notify the Government if the delivery of any data/document will not meet the scheduled delivery date and negotiate a revised delivery date.

The data/document shall be delivered by the revised delivery date acceptable to the Government.

4.11.1.2 Data Management/MEARS. The Contractor shall electronically deliver all contractual data using the Government-controlled method of delivery, Multi-user ECP Automated

Review System (MEARS), https://mears1.redstone.army.mil/mears/Default.aspx. The Contractor shall work with the Government to ensure that an adequate number of Contractor personnel obtain and possess Public Key Infrastructure (PKI) certification from an accepted Government source.

The Contractor shall be receptive to the training offered by the Government on the MEARS system. The Contractor shall prepare, maintain, and track the contract data status, schedule and ensure timely data deliveries. An alternate method of delivery when MEARS is down for maintenance will be the DISA application, known as DOD SAFE, https://safe.apps.mil/. It will be available to all DOD Common Access Card (CAC) holders or Contractor personnel who possess

Public Key Infrastructure (PKI) certification from an accepted Government source.

5. DELIVERY SUMMARY

5.1 Post Award Meeting. The Government will convene a post award meeting with the contractor at a location that is mutually agreeable to both parties within 30 days after contract award. The Procuring Contracting Officer (PCO) will coordinate the actual date, time, and location of the meeting with the contractor.

5.2 Technical Review Documentation. The contractor shall prepare all necessary detailed status reports for the technical review meetings, meeting agendas, and meeting minutes. The contractor shall prepare formal documentation supporting technical reviews. (A006, DI-MISC-

80508B, Technical Report – Study/Services; A007, DI-ADMN-81249C Meeting Agenda;

A008 DI-ADMN-81250C, Meeting Minutes)

5.3 Program Management Review Support. The contractor shall participate in and support all reviews, audits, and meetings as requested by the PCO or the Program team. Program

Management Reviews shall be conducted as required at a mutually agreeable location or via tele meetings.

5.4 Meeting Room. The contractor shall provide a meeting room suitable for meetings of up to ten Government representatives, plus contractor personnel, in support of scheduled meetings at the contractor’s facility.

5.5 Meeting Agendas. The contractor shall publish an agenda for all meetings. The contractor shall request input from the Government any items or issues to be discussed or presented at the meetings and shall include such items in the agenda. Agendas shall be submitted not less than 10 working days or by-weekly prior to any meeting. (A007 DI-ADMN-81249C, Meeting Agenda)

5.6 Meeting Minutes. The contractor shall provide a written record of he discussions, decisions, and action items identified at each meeting. Minutes shall include presentation material.

(A009 DI-ADMN-81373, Presentation Material)

5.7 Technical Order (TO) Requirements Support. The contractor shall work with the government to develop technical manuals in accordance with TM-86-01R and TM-86-01R, Technical Contract.

5.8 Government Furnished Property (GFP). The Government will deliver the GFP to the modernization location. The contractor shall provide a report of GFP modernization status. (A011, DI-MGMT-80441D Government Property (GP) Inventory Report)

5.9 Item Unique Identification (IUID) Marking. The Contractor’s IUID Marking Plan shall fully detail and document the strategy and scope to be used to meet MIL-STD-130, DoD Standard

Practice Identification Marking of US Military Property. All test equipment leaving contractor facility will have IUID label affix to tester. If new items are purchased, all new units will be supplied with IUID labels as Contractor has previously done. The plan must be approved by the

Government Engineering organization, prior to implementation. (A012, DI-MGMT-81803A

Item Unique Identification (IUID) Marking Plan; A013, DI-MGMT-81804A, Item Unique

Identification (IUID) Marking Activity and Verification Report)

5.10 Security Requirements. Operations Security (OPSEC). Security classification for this effort shall be up to and including SECRET. Operations Security (OPSEC): The purpose of

OPSEC is to reduce the vulnerability of USAF missions to adversary collection and exploitation of critical information. The Contractor shall comply with DoD 5205.02E and DoD Manual

5205.02-M to protect United States (U.S.) Government interests. The Contractor shall ensure

Contractor personnel who perform work on a Government facility comply with the OPSEC procedures of the facility.

5.11 Safety and Health Plan/Program. The Contractor shall establish and maintain a safety program in accordance with the Safety and Health Plan, the contract/order and all applicable

Government regulations.

5.12 Mishap Notification/Investigation. The Contractor shall report mishaps including damage to DoD property; occupational illness to DoD military or civilian personnel; injury to on-or off-duty DoD military personnel; injury to on-duty DoD civilian personnel; and damage to public or private property or injury or illness to non-DoD personnel caused by Government operations. The Contractor shall ensure the safety office and the PCO are notified of mishaps.

The Contractor shall contact the Multi-Functional Team (MFT) Contracting Officer's

Representative if available, or another MFT member) by telephone within four business hours.

The Contractor shall cooperate with Government safety investigations.

6. BASE SUPPORT

Access to Government Facility or Military Installation: The Contractor shall ensure contractor/subcontractor personnel who require access to a Government facility or military installation comply with the security requirements of the facility or installation.

7. CONTRACTOR REQUIREMENTS

The Contractor shall comply with all commercial asset visibility air force (CAVAF) requirements identified in the CDRLs and attachments to the contract. Additionally, upon completion of the modernization, the contractor is required to print the DD 1348-1 (in triplicate) from CAVAF. One copy is to be placed inside the box with the returnable repair asset, one outside the box and one copy will be electronically uploaded to wawf as part of the receiving report (DD250). Note: The assigned USAF personnel responsible for managing the item is required to track the item through the CAVAF system and notify the contracting officer if the contractor is not complying with

CAVAF requirements.

8. HANDLING, DESTRUCTION, DEMILITARIZATION (DEMIL)AND RETURN OF

UNSERVICEABLE ASSETS

Nuclear Flash Blindness assemblies are categorized as ditrobution statement D. Distribution authorized to the Department of Defense and U.S. DoD contractors only (Administrative or Opera-tional Use, Export Controlled) (17 May 2022). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFLCMC/WNU. This information is furnished upon the condition that it will not be released to another nation without the specific authorityof the Department of the Air Force of the

United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the

Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating

United States agency. Return unserviceable asset using following address:

DODDAC: SW3119

MARK FOR: FLB

DDWG SUPPLY CENTRAL RECEIVING BLDG 376

455 BYRON STREET ROBINS AFB, GA 31098

DEMIL instruction for unserviceable assemblies are as follows:

- GOGGLE, NUCLEAR FLASH BLINDNESS EEU-2/P (8475-01-017-4473): DEMIL

CODE D USML OR CCL MILITARY ITEMS - DEMIL REQUIRED. DESTROY

ITEM AND COMPONENTS TO PREVENT RESTORATION OR REPAIR TO A

USABLE CONDITION.

- GOGGLE, NUCLEAR FLASH BLINDNESS EEU-2A/P (6625-01- 099-6707): DEMIL

CODE D USML OR CCL MILITARY ITEMS - DEMIL REQUIRED. DESTROY

ITEM AND COMPONENTS TO PREVENT RESTORATION OR REPAIR TO A

USABLE CONDITION.

11. REFERENCE(S)

Publication Title of Publication Date of Publication Sections(s) that Apply

FAR and supplements

Federal Acquisition Regulation http://farsite.hill.af.mil Entire

DoD 5220.22-M

National Industrial Security Program Operating Manual (NISPOM).

February 28, 2006 Change 1 - March 28, Change 2 - May 18, 6.0

DoDD) 5205.02E

DoD Operations Security (OPSEC) Program June 20, 2012 Change 1 - May 11, 6.0

DoD Manual 5205.02-M

DoD Operations Security (OPSEC) Program Manual

November 3, 2008 Change 1 - May 11, 6.0

Public Law 91-596 as amended by Public Law 101-552

Occupational Safety and Health Act of 1970

December 29, 1970 as amended through January 1, 2004

7.0

SAE

AS5553

Counterfeit Electronics Parts; Avoidance, Detection, Mitigation, and Disposition

2019-03 3.0 and 4.0

T.O.

00-5-16

Software Manager’s Manual USAF Automated Computer Program Identification Number System (ACPINS)

September 16, 2019 4.8.1

T.O.

00-35D-54

USAF Deficiency Reporting, Investigation and Resolution

September 1, 2015 4.5 and 4.2

DAFI 61-

Management of Scientific and Technical Information (STINFO)

November 30, 2020 4.0 and 5.0

EAI 649-1

Configuration Management Requirements for Defense Contracts

January/March 2015 4.8.4

9. ACRONYM LIST.

AF Air Force

CAVAF Commercial Asset Visibility Air Force

CUI Controlled Unclassified Information

COR Contracting Officer's Representative

DEMIL Demilitarization

DMSMS Diminishing Manufacturing Sources and Material Shortages

DoD Department of Defense

EMS Environmental Management System

IUID Item Unique Identification

MEARS Multi-user ECP Automated Review System

MFT Multi-Functional Team

NISPOM National Industrial Security Program Operating Manual

OPSEC Operations Security

PCO Procuring Contracting Officer

PLZT Polarized Lead-Lanthanum-Zirconate-Titanate

SB Service Bulletins

SOW Statement of Work

USAF United States Air Force