EPSE_IV_J-1_TO1_PWS_-_Amendment_1.docx

Enterprise Product Support Engineering Initiatives IV

Robotic Paint Application System Effort

IDIQ GSA ITSS ID05180026001

12 June 2018

TASK ORDER: 01

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 (PM):

John Hedke, AFLCMC/EZP Phone: (937) 656-6873 E-mail: john.hedke@us.af.mil

Contractor Officer Representative (COR)/ Government Technical Point of Contact (TPOC):

Gregory Schwabacher, AFLCMC/EZPT Phone: (937) 656-7903 Fax: (937) 255-7791 E-mail: gregory.schwabacher.1@us.af.mil

General Services Administration (GSA) COR/PM:

Theresa Vollink Phone: (312) 279-8145 Fax: (312) 886-3827 E-mail: theresa.vollink@gsa.gov

1. BACKGROUND: The Air Force Life Cycle Management Center Product Support Engineering Division (AFLCMC/EZP) was established to ensure the United States Air Force (USAF) tackles product support engineering problems using an enterprise approach crossing multiple platforms and portfolios. AFLCMC/EZP’s primary customer base includes the Program Executive Offices (PEOs), System Program Offices (SPOs) – Chief Engineers, Air Force Sustainment Center (AFSC), Major Commands (MAJCOMs), as well as other center offices and headquarters. The USAF realizes that coordinated efforts progress faster and cost less in total and that moving in consistent pathways is critical to making the changes required to bend the cost curve and increase readiness.

As the USAF progresses towards a cost effective engineering mindset, opportunities to implement technologies across the USAF enterprise must be considered and evaluated to improve sustainment parts availability, reduce life cycle costs and increase weapon system readiness. AFLCMC/EZP is in the process of qualifying new materials and equipment and identifying a number of aircraft and ground support equipment parts that would benefit from application of emerging technology, equipment and processes. The focus is on identifying, qualifying and implementing the best opportunities to facilitate rapid infusion of technology across the USAF enterprise. Demonstration projects and qualification programs shall be accomplished in conjunction with this Task Order (TO 01). These efforts are focused on addressing needs across both the maintenance and sustainment (M&S) and reliability and maintainability (R&M) spectrums whose application could cross multiple weapon systems.

2. SCOPE OF WORK: The scope of this task is on efforts that will enhance quick, successful adoption of technologies within the USAF. Work under Task Order 01 will cross multiple PEOs and SPOs in an enterprise manner; the Contractor shall:

· Perform required taskings related to robotic paint application

· Accomplish tasks in coordination with Airworthiness Bulletin (AWB)-1015, Airworthiness Process for Deploying New or Substitute Materials, Processes, and Product Forms, as required

· Develop abstracts, presentations, newsletters, articles, posters showcasing technology efforts

2.1. Objective. The overall objective of this Task Order is to accomplish technical and program management planning, coordination, design, testing, evaluations including cost benefit analysis, qualification and analysis, validation and verification, demonstration plans, process orders, to transition solutions; product and/or process focused, using the new or substitute materials, processes, and product form(s) using the Air Force airworthiness approach.

3. CONTRACTOR REQUIREMENTS: Each technical activity pre-screening/qualification/demonstration project shall be funded based on the availability of resources. To execute this Task Order, both technical and program management activities shall be required, and the Contractor shall apply common technical and program management requirements and techniques. In all cases, the Contractor shall perform the appropriate level of effort in accordance with the state of the technical activity (i.e., some projects may require in-house testing, demonstration, and validation support while others will require management of sub-tier suppliers whereby planning and requirements matching to ensure sub-contractor contract deliverables are the critical activities required). For this Task Order, the Contractor shall consider, as appropriate, program management requirements, environmental, energy and safety requirements/savings, readiness factors, return on investment, and sustainment/maintenance needs. The project shall have a project plan that includes project objectives, technical approach, program schedule, and transition plan. All efforts shall include a final report that includes all design data, technical and non-technical, technical reports and safety analysis. In-process program reviews shall be conducted quarterly. Data included in the final report shall include design and test data, notebooks, pictures, analysis, test plans, verification and validation requirements, facility modification requirements as well as any data that is used to determine technical and programmatic information and decisions. The Contractor, or their subcontractor, shall propose a program manager for the design/build/test activity as well as subject matter experts, as required, to lead technical activities. The proposed program manager and all additional team members shall be identified and approved by EZP. Listed below are some of the major technical activities to be accomplished. Each activity/demonstration project must be considered a separate undertaking and deliverable if funded. Monthly reporting shall be conducted that includes status on technical performance, cost and schedule aspects as well as includes a detailed invoice for each sub-task. The Contractor shall also develop a parent-level program plan and integrated master schedule that outlines all technical activities, showing any interconnects between efforts as means to enhance efficiencies and effectiveness.

3.1 Robotic Paint Application. The Contractor shall design, build and deliver a modular, automated Robotic Coating Application System for use on the Outer Mold Line (OML) of F-16 aircraft. The Contractor shall use a spiral approach that will allow future enhancement with tool change capability. The Robotic Coating Application System shall provide opportunities to add additional capabilities. The Contractor shall clearly define, in their proposal, the capabilities the robotic system will have; both at initial delivery and at full capability.

3.1.1 Functional Requirements.

3.1.1.1 System Requirements.

3.1.1.1.1 Production Ready System. The Contractor shall develop and implement a production-ready system to perform full aircraft OML coating application process. The coating application process shall be able to support use of both standard and plural component paint spraying.

A production-ready system is defined as:

· A fully validated and installed system satisfying all established safety and performance requirements,

· Approved for use in a Class I, Div. 1, production environment,

· Using personnel who have passed all required training,

· Successfully and fully processing at least five F-16 aircraft with no unplanned maintenance or repair down-time using the primary system operator

· Operates according to applicable statutes of local, state, and federal regulation on environmental, safety, and occupational health standards

3.1.1.1.2 Coating Application. The system shall be designed to apply primer and topcoat coatings to F-16 OML (excluding air inlet). The OML is comprised of metallic and composite substrates. Coating schemes are specific to each aircraft mission design series.

3.1.1.1.2.1 The system shall satisfy operating parameters outlined in Section 3.1.4, System Specifications

3.1.1.1.2.2 The system shall include design features such as, but not limited to:

· Paint delivery system,

· Paint mixing system,

· Highest reliability of components,

· Environmental monitoring and recording capability, maintain historical database by aircraft tail number (paint configurations, paint batch numbers, tail numbers, humidity, temperature, etc.),

· Minimize manual data entry for operation of robots, robotic control systems, and other components into a seamless, user-friendly package.

3.1.1.1.2.3 The system shall be detailed in a design specification with associated drawings down to level 3 and operations detailed in a process specification.

3.1.1.1.2.4 The design of the control platform and the overall design philosophy for this robotic system shall be based on an open architecture and the design concept shall use Commercial-off-the Shelf (COTS) parts, components and software to the greatest degree possible. Unique components and proprietary software shall be clearly identified in all drawings and design documents.

3.1.1.1.2.5 The following substrates, coatings, and primers are used on the F-16 aircraft, with anticipated use in the future:

· Metallic Substrates: 2024 T3 Aluminum and 7075 T6 Aluminum all riveted and bonded core.

· Composite Substrate: Graphite Epoxy IM7/977-3.

Table 1. Coating Systems for the F-16

F-16

FMS-3600

MIL-PRF-23377 Type 1 Class N (currently not used, but anticipated for use in near term)

3.1.1.1.2.6 Coating Application and Process Test Procedures. The Contractor shall define, in their proposal, coating application and process test procedures to test suitability, efficiency and effectiveness of coatings, material, conditions, etc., of the robotic coating application system prior to robotically applying coatings to an aircraft OML.

3.1.1.1.3 Process Controls. The Contractor shall specify all process controls and sampling capabilities. As a minimum, the System shall have the following process control capabilities :

3.1.1.1.3.1 Monitor, record, display, alert, and control key system or process parameters by stopping the coating application process and/or alerting the system operator when a process or parameter are outside the control limits.

3.1.1.1.3.2 Monitor and record paint booth / hangar environmental conditions during coating application and report anomalies to system operator.

3.1.1.1.3.3 Monitor flow of exhaust system during coating application and shutdown robotic system if anomalies occur and report to system operator.

3.1.1.1.3.4 Monitor and record select safety systems information and warnings during coating application and report anomalies to system operator.

3.1.1.1.4 Safety Systems. The Contractor shall ensure sufficient safety features are built into the system to prevent injury to personnel or damage to aircraft, facility, environment, or support equipment.

3.1.1.1.4.1 The Contractor shall fully document a lock-out, tag-out process for the full system and sub-system components.

3.1.1.1.4.2 Robots will be stored when not in operation in such a way to prevent interference with movement of aircraft, support equipment, or other painting applications within the coatings application facility.

3.1.1.1.4.3 The Contractor shall ensure a visual indication to the operator that the Robotic Coating Application System is in operation by means of a light stack or other visual indicator.

3.1.1.1.4.4 The Contractor shall install an emergency stop system to safely shutdown the Robotic Coating Application System from within the operator’s control booth.

3.1.1.1.5 User Access. The Contractor shall ensure only authorized users have access to the system.

3.1.1.1.5.1 The system shall allow authorized user the ability to identify when each task was started and completed, all parameters and the operator(s) performing the work.

3.1.1.1.5.2 The system shall provide for role-based access control, documented in the Operations Manual. The Contractor shall provide an initial recommendation during the Preliminary Design Review, and, based upon customer feedback, propose a solution during the Critical Design Review.

3.1.1.1.6 Accessibility. The Contractor shall ensure ease of access to the robotic system components requiring periodic maintenance.

3.1.1.1.7 Self-cleaning. The System shall provide a self-cleaning operation as required during and at the end of each primary activity.

3.1.1.2 Software Requirements.

3.1.1.2.1 The Contractor shall use software that integrates the system’s subsystems and components to provide all the necessary functionality described above.

3.1.1.2.1.1 The Contractor shall use COTS open architecture software to the greatest extent possible.

3.1.1.2.1.2 The software shall enable system set up, simulation, testing and performance, and collection and storage of job process control data.

3.1.1.2.1.3 The user interface shall be designed to enable a person with a 2-year technical degree or equivalent to easily operate the system without aid.

3.1.1.2.1.4 The software shall be written to allow a systems engineer to install software upgrades to the system.

3.1.1.2.1.5 A system recovery feature shall be installed to provide quick recovery in the event of a system failure.

3.1.1.2.1.6 The operating system shall include a startup checklist to certify that the operator performed all the necessary activities to start the system, and to prevent start up/operation if the checklist is not completed.

3.1.1.2.1.7 Where the Contractor has access or license to distribute source or software code, the software code and documentation shall be delivered to the Air Force to maintain software configuration control.

3.1.1.2.2 The Contractor shall provide the source code for software developed under government contract. This system shall be in a standard agreed upon format that meets conventional software coding requirements. The level of code delivered for each subsystem will be determined and agreed upon before work commences.

3.1.1.2.3 The Contractor shall meet all data and software rights as defined in Defense Federal Acquisition Regulation (DFAR) 252.227.7013 (data rights) and DFAR 252.227.7014 (software rights).

3.1.1.3 Hardware: The Contractor shall incorporate COTS hardware components to the greatest extent possible to meet the system requirements defined in Section 3.1.1.1. Components shall be selected to meet or exceed the system specifications defined in Section 3.1.1.2.

3.1.1.4 Mobility: The Contractor shall incorporate a mobile platform or gantry system that supports the robot and support components to freely and safely operate around the aircraft platform and within the confines of the facility as defined in Section 3.1.2.4.

3.1.1.4.1 Only minor modifications to the hangar will be permitted, e.g. lockout / tag out features for entry / exit ways.

3.1.1.4.2 Aircraft hangar modifications will be identified in detail by the Contractor and must be mutually agreed upon as part of the Preliminary Design Review.

3.1.1.4.3 OPTIONAL: It would be advantageous to the production environment if the Robotic Coating Application System could be easily moved within the coatings application facility.

3.1.1.5 Support Equipment: The Contractor shall identify all necessary support equipment needed to keep the system operational in its specified environment for the system to operate correctly. Support equipment includes but is not limited to items needed to handle, test and maintain the system and its associated parts.

3.1.2 Support Requirements.

3.1.2.1 Phased Development: The Contractor shall pursue the development of this System in two phases:

3.1.2.1.1 Phase I, Detailed Design including Integration of Subsystems and Prototype Development (12 months) – The Contractor shall:

3.1.2.1.1.1 Provide detailed design of system and subsystems to show traceability to user requirements and initial system specification document.

3.1.2.1.1.2 Provide initial bed down drawings AND simulation to postulate what the system will look like in its operating environment.

3.1.2.1.1.3 Identify and provide a cost estimate for stocking likely spare part requirements.

3.1.2.1.1.4 Preliminary Design Review. The Contractor shall support a comprehensive Preliminary Design Review to gain an understanding of the prototype design and to provide guidance on any adjustments needed to the design.

3.1.2.1.1.4.1 Mechanical Design Review – Review of all mechanical drawings and design specifications.

3.1.2.1.1.4.2 Software Design Review – Review of all software architecture, user interface, design specifications, and proprietary software / data rights.

3.1.2.1.1.4.3 Facility Design Review – Review of all facility drawings and design specifications.

3.1.2.1.1.4.4 Safety Design Review – Review of all safety features and design specifications.

3.1.2.1.1.4.5 Process Failure Modes and Effects Criticality Analysis (P-FMECA) – List of potential process failure modes ranked by probability of occurrence, potential severity, and detectability.

3.1.2.1.1.5 The Contractor shall provide a schedule with the proposal that outlines the specific timeframe for completion of these preliminary design reviews.

3.1.2.1.1.6 Critical Design Review. The Contractor shall support a comprehensive Critical Design Review and simulation of the prototype design.

3.1.2.1.1.6.1 Critical Mechanical Design Review – Review of all finalized mechanical drawings and design specifications.

3.1.2.1.1.6.2 Critical Software Design Review – Review of all finalized software architecture, user interface, design specifications, and proprietary software / data rights.

3.1.2.1.1.6.3 Critical Facility Design Review – Review of all finalized facility drawings and design specifications.

3.1.2.1.1.6.4 Critical Safety Design Review – Review of all finalized safety features and design specifications.

3.1.2.1.1.7 The Contractor shall provide a schedule with the proposal that outlines the specific timeframe for completion of these critical design reviews.

3.1.2.1.1.8 A successful Critical Design Review is required to proceed to Prototype Development.

3.1.2.1.1.9 Prototype Development – The Contractor shall:

3.1.2.1.1.10 Build prototype robot(s) and control system at the Contractor’s facility to demonstrate proof of concept of system and receive approval to move into Phase 2, Prototype Validation and Verification and Production and System Delivery/Support.

3.1.2.1.1.11 Conduct program reviews at the 50% design of the prototype system with Government users. Perform simulation/demonstrations of the system capabilities during these reviews.

3.1.2.1.1.12 Perform a safety assessment of the system and document it in a Safety Assessment Report.

3.1.2.1.1.13 Perform a Preliminary Cost Benefit Analysis (CBA) and document it in a Preliminary CBA Report

3.1.2.1.1.14 Submit Preliminary CBA Report to the Government for review and comment. The Government will review the Preliminary CBA prior to proceeding to Phase 2, Prototype Validation and Verification and Production and System Delivery/Support.

3.1.2.1.1.15 Develop a Validation and Verification Plan to ensure the robotic system meets applicable specifications and other performance requirements. The plan shall include test procedures, system performance criteria and measurement, required testing, staff training procedures, and occupational safety and health requirements.

3.1.2.1.1.16 Submit Validation and Verification Plan to the Government for approval. The Government will review the plan to ensure it sufficiently tests and evaluates all requirements for the system. Approval of the Validation and Verification Plan is a mandatory condition to proceed to Phase 2, Prototype Validation and Verification and Production and System Delivery/Support.

3.1.2.1.2 Phase 2, Prototype Validation and Verification and Production and System Delivery/Support (12 months). The Contractor shall:

3.1.2.1.2.1 Perform the Prototype Validation and Verification at the Contractor facility on a Government-provided platform.

3.1.2.1.2.2 Conduct the prototype Validation and Verification in collaboration with the Government.

3.1.2.1.2.3 Conduct Validation and Verification of the integrated system in accordance with the Government-approved test plan for verification (Developmental Testing) and validation (Operational Testing) that system is fully functional, operational and safe. Integrated System Evaluation shall include development of a Value Stream Map of the process.

3.1.2.1.2.4 Conduct a Final Design Review after completion of the Prototype Validation and Verification to capture any required design changes.

3.1.2.1.2.5 Gain approval from the Government following a successful Final Design Review before proceeding to Production and System Delivery/Support.

3.1.2.1.3 Production and System Delivery/Support – The Contractor shall:

3.1.2.1.3.1 Produce and deliver required number of systems based on successful demonstration of performance, reliability and ability to sustain the system. The prototype system developed during Phase 1, Detailed Design including Integration of Subsystems and Prototype Development, shall be updated and converted as one of the production systems.

3.1.2.1.3.2 Conduct a Production Readiness Review at the Contractor’s facility to validate the production systems are ready to be deployed to the Government facility at Hill AFB, UT.

3.1.2.1.3.2.1 The Production Readiness Review will demonstrate the integration of multiple robots, as required, to safely operate in a production-like environment.

3.1.2.1.3.2.2 All software coding shall be completed before the system is shipped to Hill AFB, UT. Then delivered to the applicable base Software Control Centers upon acceptance by the Air Force.

3.1.2.1.3.3 Be responsible for disassembly, packing, and shipment of the system(s) to Hill AFB, UT, upon completion of the Validation and Verification Phase.

3.1.2.1.3.4 Provide on-site assembly and start-up of the system and complete final Validation and Verification of system (includes full system checkout, i.e., Acceptance Test and associated Test Readiness Review).

3.1.2.1.3.5 Provide operational support on five (5) F-16 aircraft demonstrating successful preparation, coating application and stencil application operations with no unplanned maintenance and repair down time.

3.1.2.1.3.6 The Contractor shall minimize any software changes after system deployment to Hill AFB.

3.1.2.1.3.7 Perform a Final Cost Benefit Analysis (CBA) and document it in a Final CBA Report

3.1.2.1.3.8 Submit Final CBA Report to the Government for review and comment.

3.1.2.2 Technical Data Documentation.

3.1.2.2.1 Systems Manual. The Contractor shall develop a systems manual that comprehensively describes the overall system, subsystems and components, and how they work together to achieve the desired system functionality. The document shall explain how the subsystems and components work with the software to provide an integrated capability.

3.1.2.2.2 Operations Manual. The Contractor shall develop an operations manual that comprehensively describes the details of how the system is operated. This document shall serve as the basis for operator training so the operator has formal documentation at their work station as reference material during actual system operations. This document shall contain all the necessary start up and shut down checklist and operational checklists and procedures for coating application of the aircraft, component or test coupons. The manual shall include a series of functional and/or process flow diagrams necessary to provide a complete visual representation for understanding how the system, subsystems and components work together. The manual shall also include process checklists and step-by-step procedures for how to operate the system at the various roles agreed to by the Government.

3.1.2.2.3 Maintenance Manual. The Contractor shall develop a maintenance manual that captures the organizational-level servicing, preventive maintenance and scheduled maintenance actions to maintain the system in peak operating performance. This includes all manuals associated with COTS products. This manual shall include an illustrated parts breakdown, Bill of Materials and a list of likely high failure items that need to be stocked to minimize potential down-time.

3.1.2.2.4 Drawings. The Contractor shall provide all drawings, including assembly drawings and Illustrated Parts Breakdown drawings, and any drawings associated with non-COTS products.

3.1.2.2.5 P-FMECA. The Contractor shall provide a complete P-FMECA which lists potential process failure modes ranked by probability of occurrence, potential severity, and detectability. As a general rule, the P-FMECA should contain all the standard information typically provided by industry in such documentation.

3.1.2.3 Training. The Contractor shall describe their strategy for providing all training to operate and maintain the system and all of the components as identified and defined within this Task. The Contractor shall consider in their strategy initial and continuing training over the lifecycle of the system.

3.1.2.3.1 Operator Training – The Contractor shall provide comprehensive training to identified Government personnel to safely and effectively operate the system in all its modes of operation. Comprehensive training shall include an operator’s training course, training manuals, and training simulation.

3.1.2.3.2 Supervisor Training – The Contractor shall provide comprehensive supervisory training to identified Government personnel to properly oversee the effective and efficient operation of the system.

3.1.2.3.3 Maintenance Training – The Contractor shall provide comprehensive training to identified Government personnel in order to safely and effectively maintain the system and any support equipment at an organizational-level of responsibility.

3.1.2.4 Facility.

3.1.2.4.1 Requirements.

3.1.2.4.1.1 The Contractor shall work with the Chief, Infrastructure Support Section, at the ALCs to perform minor facility modifications, at contractor’s expense, to install robotic safety features in accordance with published standards. At a minimum, these modifications include utility drops, installation of interlock doors, operator control station, observation window(s) from the operator work station, cameras to monitor operations within the coating application bay of the hangar.

3.1.2.4.1.2 The Contractor shall design a system that allows full mobility within the hangar to freely move around the outer mold line of the airframe. Detailed design specifics for Building 220 (Hill AFB) (F-16 aircraft) are located in Attachment 1. If the recommended system requires facility modifications, the Contractor shall identify and provide specifications for required facility modifications such as electrical upgrades, structural modifications, and door safety interlocks.

3.1.2.4.2 Location

3.1.2.4.2.1 For planning purposes, the Contractor will use Building 220, Hill AFB, UT as a suitable facility for installation of the Robotic Coating Application System for F-16 aircraft. The facility is currently an active coating application location with sufficient environmental controls including temperature, humidity, ventilation and heating. This facility carries a Class I, Div 1, classification.

3.1.2.4.3 Airframe Dimensions – for planning purposes, the general dimensions of the F-16A are listed below. See Attachment 2 for additional dimensions.

3.1.2.4.3.1 F-16 Dimensions

Length: 49’ 5” Wingspan: 31’ Tail Height: 16’ 10”

3.1.2.5 Scalability – The Contractor shall design the system with scalability in mind so the system can be easily reproduced with only minor modifications to support select weapons platform and other aircraft platforms where the system has been qualified and approved for use.

3.1.2.6 Interchangeability/Redundancy – The Contractor shall design a system to allow robots to be interchangeable with one another, where applicable, should one of the robots become inoperable. Further, the Contractor shall design a system to continue operating in production environment should one of the robots fail.

3.1.2.7 Supportability.

3.1.2.7.1 The Contractor shall provide full and continued support for the system until the first five sequential successful production runs are completed for F-16 aircraft.

3.1.2.7.2 The Contractor shall provide maintenance, repair and overhaul actions on the system for the first year once the system has completed requirements of Section 3.1.2.7.1. This condition is based on weapon system specific and start of production certification of specific weapon system. This includes preventive maintenance, scheduled maintenance and unscheduled maintenance activities. The Contractor shall allow the Government to shadow them during all maintenance actions.

3.1.2.7.2.1 Emergency Request – The Contractor shall respond to an emergency request within 24 hours via telephone and/or within 2 business days if travel is required. An emergency response is defined as a non-mission capable condition that interrupts production and cannot be resolved at the local level.

3.1.2.7.2.2 Routine Unscheduled Maintenance Request - The Contractor shall respond to a routine unscheduled maintenance request with 48 hours via telephone and/or within 5 business days if travel is required. A routine unscheduled maintenance request is defined as any unscheduled maintenance activity that is not an emergency and cannot be resolved at the local level.

3.1.2.7.3 The Contractor shall specify their sustainment strategy and plan, during Phase 1 – Detailed Design including Integration of Subsystems and Prototype Development, to support the system during initial Validation and Verification and during the first year of operation.

3.1.2.7.3.1 The Contractor shall produce a spares parts list that offers a breakout of system components that could reasonably be maintained by the Air Force organic depot community and what system components should remain as Contractor-repaired items.

3.1.2.7.3.2 With Government concurrence, the Contractor shall provide 1 year supply of critical spare parts to ensure no system is down for more than 48 hours.

3.1.2.7.3.3 With Government concurrence, the Contractor shall provide two spares for all long lead time items (4 months or longer).

3.1.3 Program Management – The Contractor shall identify how they plan to manage the project by laying out specific management actions they will perform to ensure the project remains within its established budget and remains on schedule as the Contractor progresses through each of the two phases of the project.

3.1.3.1 Project Management Plan. The Contractor shall:

3.1.3.1.1 Prepare and maintain a Program Management Plan (PMP) that describes the management and technical approach to controlling this task.

3.1.3.1.2 Manage all technical performance, cost, schedule, and data delivery requirements as specified in the PMP.

3.1.3.1.3 Ensure the PMP addresses/covers the project's resources and project components based upon a work breakdown structure (WBS). The WBS will serve as the basis for program and technical planning, scheduling, cost estimating, corresponding levels of effort and resource allocation, performance management, configuration management, and status reporting.

3.1.3.1.3.1 WBS – The Contractor shall develop and execute a WBS that defines specific tasks to at least the fourth level of indenture for each of the two phases of the project: Phase 1, Detailed Design including Integration of Subsystems and Prototype Development, Phase 2, Prototype Validation and Verification and Production and System Delivery/Support.

3.1.3.1.3.2 WBS Preparation – The Phase 1, Detailed Design including Integration of Subsystems and Prototype Development, Integrated Master Schedule (IMS) shall be prepared within the first 30 days after contract award.

3.1.3.1.4 Ensure that the PMP includes a detailed Gantt chart defining tasks for each component, overall program layout, schedule, project milestones, projected start and completion dates, and deliverables.

3.1.3.1.5 Include projected expenditure curves or “spend plans” for each component to help program managers determine if they are “over spent or under spent” at any time during the period-of-performance.

3.1.3.1.6 Address project management efforts within this plan, by including how Contractors will interface with this project, and how the primary Contractor shall manage the Contractors.

3.1.3.1.7 Include an organizational chart identifying the names of personnel and their expertise, plus Contractors and their involvement in the task.

3.1.3.1.8 Submit the draft PMP to the Government in electronic format using Microsoft Word. Submit the final PMP after addressing Government comments.

3.1.3.2 Project Management Review (PMR) – The Contractor shall prepare for and support quarterly PMRs with specific focus on the following:

3.1.3.2.1 Cost – Provide a snap shot of funding execution against the funds provided to support the contract.

3.1.3.2.2 Schedule – Provide a status update on progress relative to the planned schedule of events during each of the two phases of the project.

3.1.3.2.3 Performance – Provide a status update on the technical performance of the project.

3.1.3.2.4 Risk – Identify potential risk areas and recommend mitigation strategies to overcome the risk.

3.1.4 System Specifications.

3.1.4.1 System Operating Parameters.

3.1.4.1.1 Ability for both manual and automated mixing of coating material.

3.1.4.1.2 Ability to apply primer and topcoat to the OML of the F-16 aircraft (excluding air inlet).

3.1.4.1.3 Ability to minimize masking on patterned scheme overlap as specified per specific weapon system and paint scheme.

3.1.4.1.4 Ability to conduct plural component coatings application.

3.1.4.1.5 Ability to minimize paint usage using the optimal spray patterns to minimize overspray.

3.1.4.2 Key Performance Parameters (KPP).

3.1.4.2.1 Coating Application Quality.

3.1.4.2.1.1 Objective: Complete an entire coating process for a standard coating stackup with zero defects per ten coating applications. Defects include, but not limited to fish eyes, runs, orange peels (refer to TO 1-1-8 for additional defects).

3.1.4.2.1.2 Threshold: Complete an entire coating process for a standard coating stackup with one defect per ten aircraft coating applications.

3.1.4.2.1.3 Tenet: Objective of zero defects per ten aircraft coating applications < threshold of one defect per ten aircraft coating applications.

3.1.4.2.2 Coverage Area - OML.

3.1.4.2.2.1 Objective: Apply coating on 100% of the OML.

3.1.4.2.2.2 Threshold: Apply coating on no less than 98% of the OML.

3.1.4.2.2.3 Tenet: Objective of 100% > Threshold of 98%.

3.1.4.2.3 Transfer Efficiency.

3.1.4.2.3.1 Objective: Achieve a transfer efficiency of 90% during coating application.

3.1.4.2.3.2 Threshold: Achieve a transfer efficiency of 75% during coating application.

3.1.4.2.3.3 Tenet: Objective of 90% > Threshold of 75%.

3.1.4.2.4 Thickness

3.1.4.2.4.1 Primer – Apply primer in accordance to specific weapons system guidance.

3.1.4.2.4.2 Topcoat – Apply topcoat in accordance to specific weapons system guidance.

3.1.4.2.5 System availability.

3.1.4.2.5.1 Objective: Achieve a system availability rate of 98% during routine depot operational processes.

3.1.4.2.5.2 Threshold: Achieve a system availability rate of no less than 95% during routine depot operational processes.

3.1.4.2.5.3 Tenet: Objective of 98% > Threshold of 95%.

3.1.4.2.6 Mean Time Between Failures.

3.1.4.2.6.1 Objective: Achieve a mean time between failure rates of 10,000 operating hours for each of the components of the system.

3.1.4.2.6.2 Threshold: Achieve a mean time between failure rates of no less than 6,000 operating hours for each of the components of the system.

3.1.4.2.6.3 Tenet: Objective of 10,000 hours > Threshold of 6,000 hours.

4. DELIVERABLES:

Data Item Title

Description

Due Date (in calendar days where appropriate)

5. MEETING ATTENDANCE/TRAVEL: Travel to commercial vendor sites, test facilities and military installations 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. Throughout the period of performance, the Contractor shall coordinate all efforts directly with AFLCMC/EZP COR and TPOC; 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 thru travel reports to EZP COR and TPOC, as appropriate. The AFLCMC/EZP technical points of contact for this effort shall be John Hedke, Jesse Holdaway, Michael C. Jones, and Greg Schwabacher. 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 USAF sites includes, but is not limited to:

· Wright Patterson Air Force Base (AFB), Ohio

· Hill Air Force Base, Utah

· Robins Air Force Base, Georgia

5.1. Kick-Off Meeting. Within 15 business days of award, the Contractor shall coordinate an Overall Task Order 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 at the parent level as well as details for each technical activity. In addition, individual technical activity area kick-off meetings shall occur for every funded area. 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. The Contractor shall be responsible for coordinating and scheduling all meetings; however, the government PM shall maintain approval authority for date, time, and location of all meetings. The Contractor shall prepare an agenda, briefing materials, brief project status and technical data, and coordinate in advance of any meeting for government PM approval. The government 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 EQUIPMENT: None

7. PLACE OF PERFORMANCE: Demonstration shall be performed at Contractor’s facilities and/or Air Force installations (e.g. WPAFB OH, Hill AFB AZ, and Robins AFB GA).

8. SECURITY CLASSIFICATION: None

9. PERIOD OF PERFORMANCE: One (12 month) base year and two (12 month) option years.

10. SPECIAL INSTRUCTIONS: All terms listed in the base IDIQ PWS are applicable.

11. Attachments:

ATTACHMENT 1: PAINT FACILITIES

Hill AFB, Building 220, Design Specifics

Hill AFB Paint Booth Description:

Working dimensions for four (4) bays are 44'-6" wide x 22'-0" high x 70'-0" deep with the overall dimensions for four (4) bays at 48'-0" wide x 22'-0" high x 76'-0" deep. Working dimensions for one (1) bay is 65'-0" wide x 22'-0" high X 70'-0" deep with the overall dimensions for one (1) bay 69'-6" wide 22'-0 high x 76'-0" deep. A 25’ aircraft safety tow lane must be maintained at the front of the booths at all time for fire egress.

Temperature, airflow and humidity are controlled by desk-top control program based on specifications and conditions at Hill AFB, Utah. Air is pulled horizontally from the front of the booth through the working depth at minimum velocity of 75 feet per minute (fpm) while maintaining a velocity within the spray zone of 100 fpm. The intake and exhaust filter layout are designed for even air velocity throughout the working area of the booth. The supplied air filtered plenum is designed with high efficiency intake filters to remove dust and dirt before it enters the paint booth. It supplies an even amount of air through the booth. The air plenum wall has adjustable filters and blanks to balance the air flow around the aircraft. In aerospace applications using polyurethane and chromate coatings, it is necessary to install National Emissions Standards for Hazardous Air Pollutants filtration in order to comply with local environmental codes.

Voltage available is 3 phase 60 HZ 480 Volts

Personnel Access Door: four (4) each personnel access doors with panic latch (3'0"W x 7'0"H) per paint booth.

Fluorescent light fixtures, inside access 48" four (4)-tube, 265 Milliamps (mA), 54-watt T5 ballast, dual voltage-120/277 with 85 % color corrected tubes. Lights are Class I, Division 2 rated.

ATTACHMENT 2: AIRCRAFT DIMENSIONS, F-16A

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