BAA-RQKM-2015-0011-SOW.doc

Agile Manufacturing for ISR (Phase 1)

STATEMENT OF WORK (SOW)

7 January 2015

1.0 OBJECTIVE:

1.1 The objective is to research, develop, design and build a prototype multi-intelligence (INT), reconfigurable pod demonstrating benefits of agile manufacturing and a modular open systems approach (MOSA) to make podded intelligence, surveillance, and reconnaissance (ISR) capability more affordable and operationally flexible.

2.0 SCOPE

2.1 The contractor shall demonstrate the ability to accommodate multi-INT sensor capability in a prototype pod and demonstrate reconfigurability with different sensor suites provided as government furnished property (GFP), government furnished equipment (GFE) or government furnished information (GFI). The pod shall be able to accommodate 2 turret-mounted sensors and 1 gimbal-mounted sensor and be able to interact with palletized equipment in a C-130 cargo bay. Palletized equipment includes processing, exploitation, and dissemination (PED) communication and sensor processing equipment. (CDRL Data Item #A001, A002, A003, A004, A005, A006, A007, A008, A009, A010, A011, A012)

2.2 The contractor shall incorporate agile manufacturing technologies and capabilities necessary to produce an open architecture ISR pod in small lots rapidly and affordably. For this prototype, the objective is a total unit cost of $300K excluding sensors. (CDRL Data Item #A001, A004)

2.3 The contractor shall build a flight worthy demonstration pod and provide support for an AFRL flight demonstration. (CDRL Data Item # A001, A004, A006, A007)

2.4 The contractor shall incorporate software and hardware standards for pod internal interfaces and interfaces between pod and aircraft consistent with MOSA. Where the interface standards are lacking, the contractor shall recommend interface requirements. (CDRL Data Item # A008, A009)

2.5 The contractor shall demonstrate that the pod access doors and interfaces between the pod and the hardware architecture facilitates the ability to change sensor payload. The objective will be to reconfigure a sensor mission package and achieve a mission ready status (power-on and connectivity with palletized data processing and communication gear) within a 3 hour time period with a journeyman-level skilled technician. (CDRL Data Item # A008, A009)

2.6 The contractor shall demonstrate the ability to attach the pod to a GFE mount that will be attached to the aircraft at the door location. Investigate other platform mounting options (e.g. wing mount). Provide rough order of magnitude (ROM) cost impact to the total unit cost of the pod. (CDRL Data Item # A001, A004)

2.7 The contractor shall analyze and assess scalable pod designs that can readily accommodate different size ISR sensor mission packages that would require changing the dimensions of the pod. (CDRL Data Item # A001, A004)

3.0 BACKGROUND

3.1 Affordability and operational flexibility of next generation ISR systems is critical to successful fielding of warfighting ISR capability. As the Secretary of the Air Force (SECAF) and Chief of Staff of the Air Force (CSAF) stated in America’s Air Force: A Call to the Future, ‘maintaining the ability to provide an effective and vigilant stance through broad-area, global ISR and then rapidly transition to more focused warfighter collection requirements demands elasticity in ISR capability. ISR systems, Airmen, and the necessary intelligence community relationships all need to be developed in a way that makes ISR agile and responsive enough to support global and theater requirements in a seamless manner.’ In contrast, the proliferation of proprietary systems has resulted in ISR systems that are expensive to update and in many cases difficult to integrate across the ISR enterprise. Additionally, these systems are usually locked into certain platforms and dependent on vertical supply chains.

3.2 Consistent with this AF vision of flexible ISR, the intent of this program is to demonstrate a multi-INT pod system that is both flexible (reconfigurable) and affordable, even at low volume. This will be achieved through a focus on open systems architecture coupled with innovative manufacturing and supply base technologies that are integrated with the design process, along with the ability to quickly change sensor types and modalities within a common pod to accommodate mission requirements.

4.0 TASKS/TECHNICAL REQUIREMENTS

The contractor shall accomplish the following:

4.1 Design and Manufacture a Prototype Open System Pod Demonstrating Agile Manufacturing. Design a prototype pod incorporating agile manufacturing tenets as described below accommodating desired multi-sensor capability. The design shall reflect attributes enabling an efficient and repeatable supplier base response. Agile manufacturing concepts, such as model based engineering, digital systems integration, and virtual manufacturing, shall be used to ensure design and supplier base stability and maturity prior to pod manufacture. (CDRL Data Item # A001, A004)

4.1.1 Perform early manufacturability analysis, especially design-for-producibility simulations (“virtual manufacturing”) to proactively manage risk, eliminate quality escapes and concomitant rework cycles, and reduce the number of engineering changes needed upon commencing production. (CDRL Data Item # A001, A004)

4.1.2 Capture relevant engineering and production data to populate a “digital thread.” Define key performance parameters and associated product features and capture relevant engineering analysis results associated with those features (e.g. Finite Element Analysis (FEA), process yield simulations from 4.1.1, etc.). Capture relevant manufacturing process data (e.g. metrology or inspection data) for those features which reveals the inherent variability of those processes and enables ‘as designed’ vs ‘as built’ comparisons. Digital thread capabilities should enable traceability to key production components and the end item. (CDRL Data Item # A001, A004)

4.1.3 Implement use of robotics or other automation capabilities to reduce learning curve effects, improve first article quality, and demonstrate reduced dependence of item cost on lot size. (CDRL Data Item # A001, A004)

4.1.4 As deemed appropriate, implement automated delivery of digital work instructions to the factory floor which are derived from the digital models produced during design and manufacture engineering analysis. (CDRL Data Item # A001, A004)

4.1.5 Evaluate opportunities for additive manufacturing capabilities to produce non-flight critical components and incorporate as deemed appropriate. (CDRL Data Item # A001, A004)

4.1.6 For a hypothetical small lot production run, identify key supply chain risk elements, measurement techniques, key partners and suppliers, and management processes; define required information flows (e.g. technical data/models, inspection data, failure reporting, etc.) and capabilities for facilitating integration (e.g. web 2.0, data hub, third party service, etc.). (CDRL Data Item # A001, A004)

4.2 Small Lot Affordability. Demonstrate system affordability based on design approach of small lot sizes, less than 10. For this prototype, the objective is a total unit cost of $300K excluding sensors. (CDRL Data Item # A001, A004)

4.3 Multi-INT, Reconfigurable Capability. Demonstrate reconfigurable multi-INT capability with the podded system. Demonstrate how different gimbal-mounted and turret-mounted sensors and associated sensor mission package equipment can be reconfigured in the pod and connected to the palletized processing and communications equipment. Reconfiguration objective is pod power-on and connectivity with palletized data processing and communication gear within a 3 hour time period with a journeyman-level skilled technician. (CDRL Data Item # A001, A004, A005)

4.3.1 Sensor Types. Full Motion Video (FMV) turreted sensors, in variations of 14 and 15 inch class, Wide Area Motion Imagery (WAMI), to include potential for both gimbal and turreted solutions, and synthetic aperature radar/ground moving target indicator (SAR/GMTI) radar, to include potential for both gimbal and turreted solutions.

4.3.2. Communication Packages and Pod Antennas. Incorporate a Tactical Common Data Link (TCDL) along a UHF, VHF, omni-directional, and directional antennas into the pod. (CDRL Data Item # A001, A004, A005, A006, A007)

4.4 Aircraft interface. The pod will interface with a C-130H/J via a provided C-130 capable armature. This armature is secured inside the C-130 cargo area, extends out the aft troop door, and provides a standard Bomb Release Unit (BRU)-14 carriage rack as well as a cable conduit. The contractor will be responsible for proposing and integrating a flightworthy power and data interface between the pod and the on-board PED through the provided armature. No additional modifications to the host aircraft will be allowable under this effort. (CDRL Data Item # A001, A004, A005, A006, A007, A008)

4.5 Modular Open Systems Approach (MOSA). Describe the rationale for the modularization choices made to generate the design. The contractor’s design approach shall emphasize the selection of components that are available commercially or within the DoD, to avoid the need to redevelop products that already exist and that can be reused. The contractor’s rationale shall explicitly address any tradeoffs performed, particularly those that compromise the modular and open nature of the system. (CDRL Data Item # A001, A004)

4.5.1 Incorporate Open System Architecture (OSA) Standards. Incorporate software and hardware interface standards based upon industry best practices and emerging standards from the Sensor Open System Architecture (SOSA) Consortium. The contractor shall maintain membership in the SOSA consortium to ensure full awareness of open standards and facilitate rapid incorporation of open standards into this program. In the event the stand-up of the SOSA consortium is delayed, contractor will ensure a MOSA design is used and system interfaces are open. (CDRL Data Item # A008, A009, A010, A011)

4.5.2 The contractor shall review Society of Automotive Engineers (SAE) Sensor/Platform Interface and Engineering Standards (SPIES) standards for turret mounted interfaces and provide recommendation for applicability to this effort. If applicable contractor shall, select external interfaces from existing open or Government standards with an emphasis on interoperability. The contractor shall describe how its selection of interfaces will maximize the ability of the system to easily accommodate technology insertion (both hardware and software) and facilitate the insertion of alternative or reusable modular system elements. (CDRL Data Item # A001, A004, A008, A009, A010, A011)

4.6 Fit Check. Support Government activity to conduct a check validating the outer mold lines of mock-up sensors, interfaces and bolt patterns at contractor’s facility at approximately ten months after contract award. (CDRL Data Item # A001, A004)

4.7 Functional Check. Support Government activity to conduct a check validating pod functional capability to be conducted at a Government facility at approximately 12 months after contract award. The contractor shall provide all necessary engineering and test documentation to show compliance with the airworthiness criteria identified in the Modification Airworthiness Certification Criteria (MACC). (CDRL Data Item # A001, A004, A006, A007, A012)

4.8 Manufacturing Readiness Assessment (MRA). Conduct an initial and final MRA on the manufacturing process for the pod to identify manufacturing risks and to guide maturity of the manufacturing process. (CDRL Data Item # A001, A004, A012)

4.9 Business Case Analysis (BCA). Develop a BCA which compares unit costs of three pod versions: 1) an estimated, normalized ‘as is’ pod (i.e., non-open system architecture, non-agile manufacturing), 2) the “to be” pod prototype resulting from this SOW, and 3) the small lot production pod based on the pod prototype. The BCA shall use an adapted work breakdown structure (WBS) of similar systems cited in MIL-STD-881C and include a detailed assessment of how agile manufacturing techniques impacted the BCA results. For each WBS element, include break out of costs according to design engineering hours, manufacturing/fabrication hours, and material. (CDRL Data Item # A001, A004, A012)

4.10 Pod Scalability. Conduct an analysis to determine how best to accommodate scalability in an ISR pod. Provide recommended design considerations regarding scalable pods including expandable pod frames, flexible attachment points, and scalable sections. Focus shall be placed on expandable sections, capability of replacing windows, incorporating other sensors such as signals intelligence (SIGINT) and hyperspectral, relevant PED and other subsystems into the pod, use of conformal antenna arrays, and providing specification guidance for future physical pod/line replaceable unit (LRU) interfaces (i.e. recommendations for LRU sizing and shape to include power/bus/communications line physical interface location and means of attachment that affect the inner shell of the pod design). Identify if any of these features have been included in this pod design. Provide ROM cost impact to the total unit cost of the pod. (CDRL Data Item # A001, A004, A012)

4.11 Open System Management Plan. Develop, maintain, and use an Open System Management Plan to support this approach and demonstrate compliance with that plan in the final report. As part of an Open System Management Plan, the contractor shall identify in a listing contained in its proposal to the Government all commercial off-the-shelf (COTS)/non-developmental items (NDI) components, their functionality and proposed use in the system. Copies of license agreements related to the use of these components shall be made available upon request. The Government objective is to maximize the use of OSA in the demonstration pod. The contractor shall therefore explain the use of proprietary, vendor-unique or closed components or interfaces. If applicable, the contractor shall define its process for identifying and justifying proprietary, vendor-unique or closed interfaces, code modules, hardware, firmware, software, and manufacturing processes or components to be used. When interfaces, hardware, firmware, manufacturing procesess or modules that are proprietary or vendor-unique are required, the contractor shall demonstrate to the Government that those proprietary elements do not preclude or hinder other component, module, manufacturing developers from interfacing with or otherwise developing, replacing, or upgrading open parts of the system. (CDRL Data Item # A001, A004)

4.12 Meetings. Kickoff meeting at the contractor’s facility within 30 days of contract award. Technical Interchange Meetings (TIMs) held via telecom once a month following the kickoff meeting and a Program Management Reviews (PMR) six months after contract award. (CDRL Data Item # A004, A005)

4.13 Period of Performance (PoP). 18 months after contract award (15 months for technical effort plus 3 additional months for the final report). Demonstration pod to be delivered at 12 months after contract award.

4.14 Contract Deliverables. Deliver all reports and analysis in accordance with the Contract Data Requirements List (CDRLs) incorporated in the contract. The deliverables include equipment acquired and developed under this program.

Table 4.14-1. Deliverables

4.15 Operations Security (OPSEC) Requirements. All contractors shall participate in all activities associated with the disciplines of the organization’s OPSEC program following appropriate measures required for this particular contract. This is required in an effort to reduce program vulnerability from successful adversary collection of possible sensitive unclassified and/or proprietary information, and violations of export control requirements. The prime contractor will ensure that all subcontractors, if applicable, conform to these requirements as required by the prime contractor. Guidance can be provided by AFRL/RX Security as needed.

4.15.1 Program Protection Plan (PPP). Any potential critical program information (CPI) generated as part of this effort will be reviewed to determine the need for a PPP.