Sample_task__2_EZP_Robotic_Paint_rev2_2014-12-18.docx

Task XX

Robotic Paint Effort

IDIQ XXXX

XXX 2015

TASK ORDER: XXXXX

Air Force Life Cycle Management Center (AFLCMC) Product Support Engineering Division (EZP) Department of the Air Force Wright-Patterson Air Force Base (WPAFB), OH

POCs:

Program Manager:

Francis Erdman, AFLCMC/EZP Phone: (937) 255-6789 E-mail: francis.erdman@us.af.mil

COTR:

Francis Erdman, AFLCMC/EZP Phone: (937) 255-6789 Fax: (937) 255-7791 E-mail: francis.erdman@us.af.mil

GSA:

Benny Reyes Phone: (937) 937-431-5530 Fax: (937) 431-0137 E-mail: benny.reyes@gsa.gov

1. BACKGROUND: The Air Force Life Cycle Management Center (AFLCMC) Product Support Engineering Division (EZP) is focused on increasing readiness while decreasing costs across both organic and contractor logistic sustainment business areas using an enterprise approach to validating and approving technologies ready for implementation and transition. The focus of this task is to improve industrial modernization thru the use of robotic painting. The task is broken into two phases. The first phase will be funded as part of this task order. The first phase is to develop first a preliminary and then a detailed design for the robotic paint system for F-16 paint operations. Phase II is to build, install, test, train, and deliver two fully functional prototype units to paint F-16s at Hill AFB, UT. The overall effort shall involve the design, manufacture, test, demonstration and implementation of commercially available robotic technologies and paint processes that may offer operational, occupational, economic, and environmental benefits associated with painting processes for weapon systems and supporting systems. Technologies and efforts that reduce Maintenance and Sustainment (M&S), reduce environmental impact and improve reliability and maintainability (R&M) processes that drive enterprise-wide impact and successes across all weapon systems are critical to the Air Force. The primary customer of this project are the Air Force Sustainment Centers, Program Executive Offices (PEOs), System Program Offices (SPOs) – Chief Engineers, Major Command (MAJCOMs), as well as other center offices and headquarters. As the AF progresses towards a cost effective engineering mindset, all operations across the AF enterprise must be considered and evaluated to reduce life cycle costs and environmental burden while also increasing worker safety and weapon system readiness.

2. SCOPE OF WORK: The overall objective of this effort is to design, develop, build, test and implement a full robotic paint system that can paint the outer mold line of an F-16 aircraft to include the air inlet. To execute this Task Order, both technical and managerial activities shall be required. The Contractor shall consider program management requirements, environmental and safety requirements/savings, readiness factors, return on investment benefits, and sustainment/maintenance needs. The Contractor shall provide program schedules, program objectives, and final design drawings. The Contractor shall propose a subject matter expert to support this task. The safety of the aircraft and personnel are always top priority and should be considered during all design/build phases.

2.1. Objective. The objective for this technical activity includes two phases; this task will only fund phase I but shall include detail development/implementation plans, schedule, and detailed cost proposal for Phase II. Cost proposals for both phases shall include as well as break out all costs including materials, labor, testing, training, and travel planned for Phase II. Phase I shall include the detail design of a complete robotic paint system capable of performing all paint operations (to include pre-cleaning, pre-coat, primer, and topcoat) on the outer mold line of an F-16 to include painting the air inlet of the F-16 at Hill AFB. The design shall include a method to fully paint the entire outer mold line of an F-16 without any possibility of damage to the aircraft. The design should incorporate the use of a plural component paint system to reduce the time required to paint the aircraft if possible. The design should include considerations of all paint process steps included in the coating system to include pre-clean, conversion coating, primer, and top coat. The system shall ensure the most efficient method of delivery is provided to minimize hazardous chemical overspray in the coating system and allow a high quality coating system application that minimizes the use of materials and reduces hazardous material usage. The detailed design must include simulation, illustrated parts breakdown drawings, design drawings, all software considerations, identify safety features that will be incorporated to ensure the weapon system is not damaged, and ensure the application is fast and efficient. The system shall include components that are all commercial-off-the-shelf (COTS) with high reliability and offer ease of maintainability from a long-term sustainability perspective. Phase II will include the manufacture, procurement, build, test, demonstration, implementation, and training of the prototype system(s). As part of this proposal, the Contractor shall provide detailed plans for the manufacture, build, test, demonstration, testing, implementation, and training required for a successfully transitioned system.

3. CONTRACTOR REQUIREMENTS: The Contractor shall provide full technical and cost proposals for both phases of this effort. Phase II shall include a detailed schedule for the manufacture, procure, install, debug, and testing of the system. All long lead items will be identified in the schedule. The proposals shall include the following:

3.1 Phase I – Robotic Paint Design

3.1.1 Preliminary Robotic Paint Design

The Contractor shall develop a preliminary semi-autonomous/fully autonomous robotic paint design maximizing commercial off-the-shelf components with high reliability and ease of maintainability. The design will include utilization of safety features to ensure the semi-autonomous/full-autonomous robotic system will not damage the aircraft. This will be proven during the evaluation testing in phase II. Safety features shall include but not limited to obstacle detection around the mobile platform along with other obstacle detection devices as required on the arm and tools. The system shall be designed to all fire/safety code requirements for Air Force paint hangers to ensure all fire explosion requirements are met. The design shall include preliminary design drawings that will identify all equipment necessary for the development of the robotic paint system as well as interface/design requirements. The preliminary design drawings will be detailed enough to allow the Government to approve the proposed design before the in-depth technical design is accomplished. Preliminary design of the system should include all paint processes to include pre-clean, pre-coat, primer, and topcoat applications where feasible. The design should include ability to paint F-16 air inlets. The design proposed should include the trade-off between using one robotic system versus two robot systems for the aircraft. Trade-off considerations should include cost, efficiency, and flow days. To maximize efficiency and reduce flow days, a plural component system should be considered for the design. The design should take into consideration maximizing efficient coating delivery systems that minimize coating overspray, provide a high quality finish, and reduce coating material usage, and minimize process times. All coatings will be AF approved coatings and the application of the coatings must meet AF coating requirements to include adhesion requirements. The preliminary design will also provide detailed safety plans to ensure semi-autonomous robots do not damage any aircraft components or injure personnel. The operator system shall also be included in the preliminary design and all functions/capabilities shall be identified in the technical proposal and clearly shown in the preliminary design concept. The system shall be designed for ease of use with the paint operators but shall include considerations for continued operational safety.

3.1.2 Robotic Simulation of Proposed Design

The Contractor shall provide the Government a live simulation of the robotic paint system design that will show all proposed paint processes, interfaces, tool changes, application efficiency and estimation of process times for each paint process. The simulation will optimize the paint delivery to ensure efficient application of coating. The simulation shall demonstrate process flows, paint application, and safety features.

3.1.3 Detailed Design Drawings and Illustrated Parts Breakdown Drawings

The Contractor shall develop detailed design drawings to included electrical schematics, mechanical design, and illustrated parts breakdown drawings after the Government approves the preliminary design and simulation of the design. The detailed drawings/design will be developed for the procurement, manufacture, and integration of components. The detailed drawings will be provided to the Government as part of the final deliverable of this task in preparation for Phase II. The drawings will show all interfaces, safety features, and proposed operations. The design drawings will include all dimensions, safety features (also identify any limitations of safety features), all required parts, and capabilities of the final system.

3.1.4 Preliminary Cost Benefit Analysis

The Contractor shall develop a preliminary cost benefit analysis of the robotic paint system. The CBA shall compare the process times, material/labor efficiency, and existing costs of the baseline system currently being utilized for the F-16 (include pre-cleaning/prep) compared to the proposed robotic system. A preliminary cost benefit analysis report shall be provided to the Government. Distribution shall be limited to Government organizations.

3.1.5 Facility Modification Requirements

The Contractor shall work with the OO-ALC personnel to review and develop any special facility requirements. If the recommended process requires facility modifications, this shall also be included. The Contractor will identify all electrical upgrades, structural modifications (including floor), operator stations, etc. This shall be accomplished within 60 days after the kick-off meeting following task order award. The Contractor shall ensure a qualified facility manager is involved with this process. The Contractor shall provide a facility modification recommendation report to the Government.

3.2 Phase II – Robotic Prototype Build Install Phase

As part of the proposal process, the Contractor shall provide the Government the proposed cost, schedule, and plan for Phase II of the effort: the procurement, manufacture, build, debug, install, and test processes that would be part of phase II. The plan should include locations for the build, debug, install, and test processes. The proposal shall address the plan for evaluation testing of the system before the Government takes ownership of the system. How debugging and testing will be accomplished. In addition, the proposal shall discuss the plan for training operators. The Contractor shall identify any unique requirements or considerations during the build/install phase. The plan should include all components necessary to deliver a fully operational system to the Government to be used on the F-16 aircraft at Hill AFB, UT.

4. DELIVERABLES

Data Item Number

Data Item Title

Description

Due Date

Monthly

Monthly

Quarterly

Invoices

5 days following the monthly financial report. Submitted to ITSS.

5. MEETING ATTENDANCE/TRAVEL. Throughout the period of performance, the Contractor shall coordinate all efforts directly with EZP personnel; this includes any travel requests and the level of effort per month that shall be allocated to this support. The Contractor shall report all findings, recommendations, and efforts to EZP personnel, as appropriate. The EZP point of contact for this effort shall be Ms. Debora Naguy. The Contractor shall participate in regular progress meetings and travel to events deemed necessary to provide support efforts described above. It is anticipated that travel to AF sites may occur, which include those locations listed below.

· Wright Patterson Air Force Base, Ohio

· Hill Air Force Base, Utah

· Robins Air Force Base, Georgia

· Tinker Air Force Base, Oklahoma

Additional travel to commercial vendor sites and test facilities is expected. Some international travel may also be required in support of technical evaluation efforts.

The Contractor shall abide by all Air Force safety and conduct policies when conducting travel. The Contractor shall coordinate with AFLCMC to ensure the proper Government documentation is in place, such as CAC cards and/or clearances pending the type of efforts and programs the Contractor is asked to support.

5.1. Kick-Off Meeting. Within 30 days of award, the Contractor shall coordinate a kickoff meeting, at which time all parties involved in the Task Order execution shall be represented and roles/responsibilities clearly outlined. During the kickoff meeting, the Contractor shall be prepared to discuss the Task Order. The intent of the technical activity area kick-off meeting is to review the sub-task schedule, objectives of each technical activity area, and review roles and responsibilities of the players.

5.2. Meetings. The Contractor shall plan to participate in monthly and quarterly progress meetings, detailing the progress, issues, needs, and/or unforeseen items that occur within each technical activity area. The Contractor shall be responsible for coordinating and scheduling all meetings; however, the PM shall maintain approval authority for date, time, and location of all meetings. The Contractor shall prepare agenda, briefing materials, brief project status and technical data, and coordinate in advance of any meeting for PM approval. The PM has authority to attend or not attend any scheduled meetings. The Contractor shall capture and track all action items, decisions, and minutes from all meetings and telecoms. A detailed review of each technical activity area shall be required.

6. GOVERNMENT FURNISHED FACILITIES AND INFORMATION: Demonstration/installation shall be performed at Hill Air Force Base.

7. PLACE OF PERFORMANCE: Contractor and DoD facilities.

8. SECURITY CLASSIFICATION: None anticipated

9. PERIOD OF PERFORMANCE: 10 Months

10. SPECIAL INSTRUCTIONS: None