JA-SPRDL122R0065_Redacted.pdf

SPRDL1-22-R-0065 (JA-00493)

(Previous J&A SPRDL1-16-R-0033 is available.)

5. Reason for Authority Cited: A main component of the FMTV engine is the Generator, Engine Accessory P/N 12423713. This component is used on the Engine, Dressed 275/330 HP (Army drawing 12505605), the Engine, Dressed 275/330 HP (Army drawing 12423110), and the 260 Amp Alternator Installation Kit (Army drawing 12423864). The Generator, Engine Accessory is an electrical component that delivers 260 amperes of current to the FMTV and on-board electrical components. By working in tandem with the FMTV batteries and engine, the generator, engine accessory is the electrical power generator for the vehicle and a critical component in the vehicle’s electrical system.

C. E. Niehoff & Co. is the only approved source of supply for this Generator, Engine Accessory. The Government does not have a complete built-to-print Technical Data Package (TDP) nor proprietary rights that would be required to produce a competitive TDP. The only available Government controlled drawing is the top level, source controlled, Generator, Engine Accessory drawing 12423713; which is insufficient to reproduce the assembly.

C. E. Niehoff & Co. is the only qualified manufacturer of this particular Generator, Engine Accessory which was designed specifically for the FMTV. This part has tailored space claim, interfaces, and performance requirements that are unique to the FMTV.

The Generator, Engine Accessory must provide up to 260 amperes at 28 volts side and up to 140 amperes at 14 volts side. Additionally, the dual voltage control system must be capable of maintaining equalization battery charge and provide for separate voltage regulation for the batteries of each voltage system. The Generator, Engine Accessory can not exceed 80 pounds in weight. The Generator, Engine Accessory must provide peak torque at 72 +/- 5 Fahrenheit (F) ambient temperature 275 pound-inch (lb.-in) minimum at 2200 +/- 25 Revolutions Per Minute (RPM) and output of 180 ampere minimum load at 28.0 +/- 0.3 Voltage Direct current (VDC). The Generator, Engine Accessory must have fungus resistance, dust resistance, and sand resistance. The Generator, Engine Accessory must include a soft start feature which incorporates a time delay such that the output current must increase incrementally until it achieves its rated limit between four and six seconds after the energize signal is applied to the Generator, Engine Accessory and rotation is detected. Having this part made by an unqualified source would run the risk of batteries and vehicle electrical components not getting the power they need to operate. C. E. Niehoff & Co. has designed, built, and successfully completed testing of the unit to meet the performance requirements listed on drawing 12423713. C. E. Niehoff & Co. is the Original Equipment Manufacturer (OEM) for this Generator, Engine Accessory and directly coordinated with BAE Systems (FMTV OEM at that time) for design, integration, testing, and validation. C. E. Niehoff & Co. retains the technical expertise of the Generator, Engine Accessory along with a proven track record to deliver as they have been awarded at least four prior contracts for this part dating back to 2012 with quantities up to 749 each.

Due to the limited technical data available on the Generator, Engine Accessory, Reverse Engineering (RE) is the only recourse for the Government to increase competition through development of a competitive build to print TDP. A significant amount of time and money would be necessary to reverse engineer, procure and test prototypes, and release the design. The cost to Reverse Engineer the unit is estimated at $4.5M and 30 months (2.5 years) to complete.

Reverse Engineering (RE): To reverse engineer, validate the design, procure prototypes for testing, and release a competitive data package would entail a significant amount of time, facility resources, man-hours, and funding. Based on previous development experience and coordination with FMTV Engineering Subject Matter Expert (SME), the estimated cost to develop a reverse engineered, competitive product is $4.5M and 30 months (2.5 years). Required funding would include $2.5M for personnel to support RE and validation of the design, fund staff to develop the computer aided design (CAD) models and drawings, and fund staff to update and produce the associated provisioning documents. Another $2M would be required to develop prototypes, test, and finalize the product to verify that the newly created item provides equivalent performance when compared against the original. Testing would include performance requirements, durability miles, and environmental testing. To complete the RE process successfully, the Government would have to obtain a sufficient sample size of existing parts to provide a 95% probability and 90% confidence level in the actual size of the existing item to be studied. Once a large enough sample has been collected, the Government would then tear down and understand the design, conduct prototype development, and produce the final TDP and associated provisioning documents at a cost of $4.5M and 30 months (2.5 years).

The Government would not be expected to recover in a reasonable amount of time, through subsequent competition, the duplication of costs involved in reverse engineering the Generator, Engine Accessory to create a new and competitive TDP. At the current average usage rate of 1,248 units each year, a current unit cost of , and assuming 25% cost savings achieved through competition, the in annual savings would take over years to offset the estimated $4.5M in cost to RE the item and qualify another source.

If the procurement of the FMTV Generator, Engine Accessory is delayed until the TDP is developed by the Government and made suitable for a competitive procurement, the Government would experience an unacceptable delay of a minimum of 2.5 years in fulfilling this requirement. The 2.5-year delay is a result of the time required to Reverse Engineer the unit of equivalent performance explained previously in this document.

Further delay in providing this NSN will negatively impact our FMTV force readiness as without the Generator, Engine Accessory the FMTV would be unable to perform its mission in adverse battlefield demands and conditions. There is currently a stock out date of 31 May 2022. C. E. Niehoff & Co. is currently the only approved source that can meet the requirements without substantial duplication of cost and without unacceptable delay against this action. The approved source has the requisite technical and engineering expertise to perform all efforts required to provide the NSN identified in this Justification and Approval (J&A). Furthermore, if a part was used without proper testing and validation, there would be an increased risk of a premature failure of this item in the field which could result in the batteries and vehicle electrical components not getting the power they need to operate.

6. Efforts to Obtain Competition:

a. Effective competition: Due to the reasons cited in section 5 above the Government is not pursuing competition for this item.

b. Subcontracting competition: Unless the contract is awarded to a small business, the solicitation and resulting contract will include FAR clauses 52.219-8, "Utilization of Small Business Concerns"; 52.244-5, "Competition in Subcontracting"; 52.219-16, "Liquidated Damages--Subcontracting Plan";" and Defense Federal Acquisition Regulation Supplement (DFARS) 252.219-7003, "Small Business Subcontracting Plan (DoD Contracts)," to maximize small business opportunities and utilization.

SOLE SOURCE: Notices required by FAR 5.201 will be posted.

7. Actions to Increase Competition: There are no plans to increase competition for future procurements due to the reasons cited above.

Due to the limited technical data available on the Generator, Engine Accessory, RE is the only recourse for the Government to consider to increase competition through development of a competitive build to print TDP.

8. Market Research:

A Sources Sought Notice was posted to SAM.gov on 23 March 2022 and was open for 15 days. No responses were received.

In April 2022, Ground Vehicle Systems Center (GVSC) Engineering conducted a computer-based online search of known Generator, Engine Accessory suppliers looking for published material on a new built Generator, Engine Accessory.

Keyword(s): Alternator 260 Amp, Dual Voltage; FMTV alternator; Military alternator;

Heavy duty alternator.

Links used to conduct market research are listed below:

https://www.americanpowerinc.com/high-output-alternator-260-amp-12-volt-output- 6600526/ https://www.nationsstarteralternator.com/DC-Power-260-Amp-SPX-High-Amp- Alternator-p/8206-260spx.htm https://www.mechman.com/ https://rflalternators.com/alternators-military-industry/ https://www.delcoremy.com/alternators/find-by-vehicle-type/heavy-duty-on-highway-truck https://www.densoheavyduty.com/alternators/medium-heavy-duty

Findings: The results of this search did not produce any new companies that would provide a direct replacement Generator, Engine Accessory for the FMTV that is 100% new and could be installed in the FMTV without considerable time and effort to adapt the new components. Additionally, internet searches did not yield any products that meet the exact performance specs of the existing Generator, Engine Accessory. The Generator, Engine Accessory must provide up to 260 amperes at 28 volts side and up to 140 amperes at 14 volts side. Additionally, the dual voltage control system must be capable of maintaining equalization battery charge and provide for separate voltage regulation for the batteries of each voltage system. The Generator, Engine Accessory cannot exceed 80 pounds in weight. The Generator, Engine Accessory must include a soft start feature which incorporates a time delay such that the output current must increase incrementally until it achieves its rated limit between four and six seconds after the energize signal is applied to the alternator and rotation is detected. Additionally numerous internet searches led back to C. E. Niehoff & Co. or surplus suppliers selling C. E. Niehoff & Co. products.

Summary: As a result of the Market Research, it was concluded that there are no drop in replacement parts available and that extensive integration and testing would be required of any other manufacturer’s part. This Generator, Engine Accessory cannot be identified as a Commercial-Off-The-Shelf (COTS) item.

9. Interested Sources: To date no additional sources have expressed interest in this item.

10. Other Facts: Procurement History:

Contract Number: SPRDL1-16-D-0073 Award Date: 21 September 2016 Contractor: C.E. Niehoff & Co. - CAGE 76761 Contract Value: $6,559,012.66 Competitive Status: FAR 6.302-1 Only one responsible source

Contract Number: W56HZV-12-C-0246 Award Date: 25 September 2012 Contractor: C.E. Niehoff & Co. - CAGE 76761 Contract Value: $1,335,586.84 Competitive Status: unknown; buyer does not have access to PCF contract file