Attachment_6_Turnkey_Management_Plan_Rev__A.doc

FISCAL YEAR (FY) 10 AND FOLLOW

AEGIS DESTROYER

DDG 51 CLASS

TURNKEY MANAGEMENT PLAN

REVISION A

25 SEP 13

Distribution is authorized to the DoD and DoD contractors only for administrative or operational use. Further dissemination shall be only as directed by the DDG 51 Program Manager, PMS 400D. Any questions or comments concerning this document may be referred to the DDG 51 Program Office Engineering & Material Services Branch Head (PMS 400D7).

Revision History

10 Jun 09

25 Sep 13

Executive Summary

The Turnkey approach continues to provide the Navy with great design flexibility. Turnkey enables the Navy to deliver “just in time” Government Furnished Equipment (GFE) and Government Furnished Information (GFI) to support detailed design, installation, and test of Radio Communication Suite (RCS) and Ship Signal Exploitation Space (SSES) equipment. Conceived in late 1991 by the Program Executive Office, Command, Control, Communication, Computers, and Intelligence (PEO C4I), then the Space and Naval Warfare Systems Command (SPAWAR), Turnkey continues to realize its goal of providing the fleet, at ship delivery, the most technologically advanced RCS, SSES, and C4I equipment available. Moreover, it has done so without incurring a significant increase in shipbuilding costs associated with design changes.

The Turnkey approach was initially implemented for RCS on DDG 73, the first of four AEGIS destroyers authorized in Fiscal Year 1993 (FY 93). With DDG 79, Turnkey expanded to include SSES. The Cabinet Level Turnkey approach was implemented with DDG 89 for PEO C4I/PMW 760 Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance (C4ISR) systems external to the RCS and SSES spaces.

The following stakeholders all have key roles in the Turnkey process, as described in Chapter Two: Program Executive Office, Ships (PMS 400D, PEO Ships Acquisition Management (AM)); Program Executive Office, Integrated Warfare Systems (PEO IWS); Program Executive Office, C4I (Program Manager Warfare (PMW) 760, PMW 120); Surface Training Systems Program Office (PMS 339); Naval Air Systems Command (NAVAIR); the Supervisors of Shipbuilding, Bath, ME, and Gulf Coast, MS (SSBA and SSGC); Lead Yard Services (LYS); Follow Yard Services (FYS); and the shipbuilders. The Turnkey Implementation Working Group (TIWG) is the focal point for the concurrent engineering that is the cornerstone of the Turnkey process.

The technical approach to Turnkey, discussed in Chapter Three, is divided into four phases: (1) initial exchange of engineering data; (2) ship construction until RCS/SSES loadout; (3) loadout prior to AEGIS Light Off; and (4) testing, maintenance, and trial support. A notional Turnkey GFI schedule is depicted in Figure 3-1. The TIWG shall continue to pursue Computer-Aided Design (CAD) to the maximum extent feasible.

The Turnkey process works in conjunction with a strict Configuration Management process from contract award through ship delivery, as discussed in Chapter Four. Nothing contained in this Turnkey Management Plan shall be interpreted as contradicting or superseding the established PEO Ships Configuration Management process.

As the Participating Acquisition Resource Manager (PARM) for RCS and SSES, PEO C4I/PMW 760 is primarily responsible to PEO Ships AM for identifying and tracking GFE and to PMS 400D7 for GFI. PEO C4I/PMW 760 also provides delivery status at the TIWG meetings. This enables the TIWG to generate a recommended solution in the event of a late or missed delivery.

Additionally, PEO C4I/PMW 760 continues to perform complete Integrated Logistics Support (ILS) planning and documentation for all RCS and SSES equipment, as was accomplished for pre-Turnkey ships. The DDG 51 New Construction Acquisition Logistics Branch Head (PMS 400D1) and New Construction Manpower, Personnel, and Training Program Manager (PMS 339), as members of the Turnkey Steering Group and TIWG, communicate logistics and lifecycle support concerns.

TURNKEY MANAGEMENT PLAN

FOR DDG 51 CLASS DESTROYERS

Table of Contents

IIRevision History

Executive Summary

III

Table of Contents V List of Figures

VII

1.0

INTRODUCTION

1.1 Background 1.2 The Turnkey Concept 2.0

ORGANIZATION AND RESPONSIBILITIES

2.1 Program Executive Office, Ships (PEO Ships) 2.2 Program Executive Office, Command, Control, Communication, Computers, and Intelligence (PEO C4I) 2.2.1

PEO C4I/PMW 760

2.2.2

PEO C4I/PMW 120

2.2.3 Naval Air Systems Command (NAVAIR), St. Inigoes, MD 2.3 Program Executive Office Ships, Acquisition Management (PEO Ships AM) 2.4 Program Executive Office, Integrated Warfare Systems (PEO IWS) 2.5 Surface Training Systems (PMS 339) 2.6 Lead Yard Services (LYS) and Follow Yard Services (FYS) 2.7 Supervisors of Shipbuilding 2.8 Shipbuilders 2.9 The Turnkey Steering Group 2.10 The Turnkey Implementation Working Group (TIWG) 3.0

TECHNICAL APPROACH

3.1 Phases of the Milestone and Design Schedule 3.2 Notional Deliverable Schedule 3.2.1 Preliminary Data 3.2.2 Final GFI 3.2.3 Turnkey GFI and Shipyard Preferred Dates (SYPDs) 3.3 Turnkey GFI Delivery 3.3.1 Turnkey Preliminary Data Delivery 3.3.2 Turnkey Final GFI Delivery 3.3.2.1 Delivery of Phased GFI with Change Sheets 3.3.2.2 DDG 114-115 and DDG 119-125 Phased GFI Final Delivery Change Sheets 3.3.2.3 Electronic Delivery of GFI 3.4

TEMPEST

3.5 Cabinet Level Turnkey 3.5.1 Cabinet Level Turnkey Applicability 3.5.2 Cabinet Level Turnkey Change Process 4.0

CONFIGURATION MANAGEMENT

4.1 Overview 4.2 Configuration Change Procedures 4.2.1 Ship Design Changes 4.2.2 Turnkey Space Design Changes 4.2.3 Implementation of Changes into Future GFI 4.3 Configuration Identification Drawings and Documentation 4.3.1 RCS/SSES Design Configuration 5.0

TURNKEY GFI TRACKING

5.1 The Need For Tracking 5.2 Reporting Procedures 6.0

INTEGRATED LOGISTICS SUPPORT (ILS)

6.1 Overview 6.1.1 ILS Management 6.1.2 Equipment Identification Numbers (EINs) 6.2 Supply Support 6.3 Maintenance Planning 6.3.1 Organizational and Intermediate Maintenance/Depots 6.3.2 Planned Maintenance System (PMS) 6.4 Support and Test Equipment (S&TE) Planning 6.4.1 General Purpose Electronic Test Equipment (GPETE) 6.4.2 Special Purpose Electronic Test Equipment (SPETE) 6.4.3 Automated Test Equipment (ATE) 6.5 Packaging, Handling, Storage, and Transportation (PHS&T) 6.5.1 Preservation-Packaging 6.6 Technical Manuals 6.7 Manpower and Personnel 6.8 Training 6.9 Reliability, Maintainability, and Availability (RM&A) 6.9.1 Reliability 6.9.2 Maintainability 6.9.3 Availability

APPENDIX A - PROCESS FOR FORMATTING, DELIVERY, AND USE OF MINIMUM DATA SET FILES

A-1

APPENDIX B - CABLE ROUTING MINIMUM DATA SET FIELD DEFINITIONS

B-1

APPENDIX C - TERMS, PHRASES, AND ACRONYMS

C-1

APPENDIX D - REFERENCES

D-1

List of Figures

11Figure 3-1 Notional Turnkey GFI Delivery Schedule

17Figure 4-1 Changes That Breach Turnkey Parameters

18Figure 4-2 Changes That Do Not Breach Turnkey Parameters

20Figure 4-3 Request for Advanced Implementation Authority (RAIA) Form

TURNKEY MANAGEMENT PLAN

FOR DDG 51 CLASS DESTROYERS

1.0

INTRODUCTION

The primary goal of the Turnkey process is to provide the fleet with the most technologically advanced RCS and SSES equipment available, without incurring a significant increase in shipbuilding costs due to design changes.

The purpose of this document is to provide the DDG 51 community with the Program Manager’s guidelines for the management and implementation of the RCS and SSES equipment envelope and C4I Cabinet Level Turnkey approach.

This plan establishes roles and responsibilities within the DDG 51 Program for managing the Turnkey process and institutes milestones for meeting DDG 51 Class Destroyer shipbuilding program requirements.

1.1 Background

In late 1991, SPAWAR (now PEO C4I/PMW 760) introduced “Turnkey” as a solution for providing greater flexibility to class design and integration of the AEGIS Destroyer RCS. Until that time, the design, acquisition, and integration of the RCS had been burdened with constraints, including an early configuration definition of GFE, which inhibited the installation of rapidly changing technologies in new construction ships prior to delivery. The Turnkey approach, on the other hand, provided a great degree of design flexibility by allowing the Navy to deliver GFI “just in time” to support detail design.

By December 1991, a Turnkey working group was established, with representation from PMS 400D, PMS 400B (now PEO IWS), SPAWAR, NAVAIR, the Supervisors of Shipbuilding, LYS, FYS, Bath Iron Works (BIW), and Ingalls Shipbuilding, Inc. (Ingalls) (now Huntington Ingalls Industries (HII/Ingalls)). This group was chartered to facilitate the coordination and exchange of data between the Navy, LYS, and the shipbuilders during the ship design and construction process.

Initial Review Board (IRB) item 0925R1, AEGIS RCS Turnkey Implementation, was approved for inclusion in the FY 93 Request for Proposal (RFP) package on 3 November 1992 as Engineering Change Proposal (ECP) 51-1052. The Turnkey Steering Group, chaired by the AEGIS Destroyer Combat Systems & Test Branch Head (PMS 400D5), was also formed during this timeframe to address Turnkey programmatic issues. The AEGIS Destroyer FY 93 shipbuilding contract was awarded to BIW and Ingalls on 19 January and 21 January 1993, respectively.

On 21 September1993, PMS 400 and PMW 178 (Naval Electronic Combat Surveillance Systems) agreed to implement the Turnkey approach for installation of the SSES systems in DDG 80 and Follow. PMS 400D later approved IRB 1158R3, SSES Turnkey, for DDG 79 and Follow at a Special Configuration Control Board (CCB) on 6 July 1994. With the approval of the FY 98 Baseline on 6 March 1998, ECP 51-1396 initiated Cabinet Level Turnkey for DDG 89 and Follow.

The objective of the FY 93 Turnkey initiative was to establish among PMS 400, PMS 400B, SPAWAR, NAVAIR, LYS, and FYS the necessary program management, design processes and products, and liaison to support the Navy's Turnkey implementation plans (IRB 0925R1 and 1158R3) fully.

This management plan is not intended to serve as a contractual document. It is provided as a summary of the management approach to be used to execute the Turnkey process.

1.2 The Turnkey Concept

Rather than propose a classical Turnkey approach, this management plan describes a modified approach geared specifically toward minimizing impacts to shipbuilding operations. An example of this modified approach can be illustrated by examining the space turnover phase. In other programs, the Turnkey plan calls for the shipbuilder to prepare a space for an outside activity to load out and test the equipment. The DDG 51 Program Manager recognizes the potential impact this would have on the shipbuilders’ industrial base, so this Turnkey approach allows the shipbuilder to retain responsibility for loadout of the Turnkey equipment, as well as for completing the Turnkey space.

The Turnkey process establishes envelopes and budget parameters, defining the not-to-exceed (NTE) weight, power requirements, heat loads, and cable quantities for the RCS and SSES. As construction of the ship progresses, the details of the composition for each envelope are provided to the shipbuilder, in accordance with a carefully planned phased GFI delivery schedule. The concept of Cabinet Level Turnkey, introduced for the FY 98 ships, allows the Navy the maximum opportunity to integrate advanced technology in those C4I systems located external to the RCS and SSES. PEO C4I/PMW 760 acquisition managers and programs of record may refresh system technology on an FY basis, as long as parameters related to installation and checkout remain constant.

The Turnkey process was integrated into the shipbuilding contract. Beginning with the DDG 73/74/75/76 FY 93 Construction Contract, Turnkey provisions were included to ensure minimal impact to the shipbuilders. In short, as long as the Navy stays within the prescribed envelopes and budget parameters, no ECP is required. The specific words governing this process and included in the shipbuilding contract are as follows:

[T]he Navy may make alterations, additions, revisions, and deletions in the RCS Turnkey Drawings. If such alterations, additions, revisions, and deletions are made and remain within the equipment envelopes and budget parameters identified on the drawings, the Contractor will not be entitled to any adjustment in the price structure or delivery schedule of the contract.

If the Navy exceeds the envelopes or budget parameters, an ECP, at cost to the Navy, will be required. The specific words governing this process, and included in the shipbuilding contract, are as follows:

[T]he Navy may make alterations, additions, revisions, and deletions in the RCS Turnkey Drawings that exceed the identified parameters and equipment envelopes. If such alterations, additions, revisions, and deletions are made and cause an increase or decrease in the Contractor's cost of performance of the contract, the Contractor or the Government, as appropriate, shall be entitled to an equitable adjustment in the price structure of the contract but not to the delivery schedule.

Finally, if PEO C4I/PMW 760 does not deliver a Turnkey drawing in accordance with the Schedule “C” requirements, the shipbuilder may proceed in accordance with the latest contractual revision to the drawing in the shipbuilders' possession. The specific words governing this process, and included in the shipbuilding contract, are as follows:

[F]or any RCS or SSES Turnkey Drawing which is not released to the Contractor on or before the date set forth in Schedule “C,” the contractor may proceed with the performance of the contract as if the Turnkey Drawing was released, without any alteration, addition, revision, or deletion to the budgeted parameters identified.

2.0 ORGANIZATION AND RESPONSIBILITIES

2.1 Program Executive Office, Ships (PEO Ships)

PEO Ships manages acquisition for all current and future non-nuclear U.S. Navy surface ships. Within PEO Ships, the DDG 51 Program Office (PMS 400D) manages acquisition of the DDG 51 Class Destroyers and oversees the cost, schedule, and technical performance of the Turnkey process.

PMS 400D1, the Acquisition Logistics Branch Head, is responsible for ensuring the DDG 51 Class Destroyers receive full logistics and lifecycle support. PMS 400D1 serves as an advisory for ILS issues at meetings of the Turnkey Steering Group and TIWG.

PMS 400D5, the Combat Systems & Test Branch Head, co-chairs the Turnkey Steering Group. PMS 400D5 is responsible for scheduling and publishing the agenda and minutes for the Turnkey Steering Group and for briefing PMS 400D at each BIW and HII/Ingalls Incentive Evaluation Board (IEB). PMS 400D51, the Combat System Engineer, serves as Co-Chair for the TIWG.

PMS 400D7, the Engineering & Material Services Branch Head, oversees cost as it pertains to LYS and FYS. PMS 400D7 maintains the Turnkey Management Plan for DDG 51 Class Destroyers and a website, https://navsea-ide.nmci.navy.mil, that provides Configuration and Data Management information relating to Turnkey. In addition, PMS 400D7 endorses all preliminary Turnkey GFI deliveries to SSBA, SSGC, LYS, and FYS via Services Pre-Turnkey Data Transmittals and provides the official GFI deliveries to the shipyards, in accordance with Schedule “C” requirements.

2.2 Program Executive Office, Command, Control, Communication, Computers, and Intelligence (PEO C4I) 2.2.1

PEO C4I/PMW 760

PEO C4I/PMW 760 is responsible for ensuring the acquisition, integration, testing, checkout, and delivery of the RCS and SSES suites. PMW 760 also ensures PARMs provide ILS and meet Information Assurance (IA) requirements for the systems that comprise the RCS and SSES. In addition, PMW 760 develops the RCS and SSES equipment drawings. These drawings are, in turn, delivered to PMS 400D7 in accordance with an agreed-to schedule and are then forwarded to LYS, FYS, and the shipbuilders as shown in Figure 3-1. PMW 760 procures and delivers the RCS to the shipbuilders as determined by its Ship Project Directive (SPD) Part III.

The PMW 760 Ship Construction, Navy (SCN) DDG 51 Platform C4I Lead Engineer serves as Co-Chair for the Turnkey Steering Group and TIWG.

2.2.2

PEO C4I/PMW 120

PMW 120 supplies the Ship Signal Exploitation Equipment (SSEE) directly to the shipbuilders, in accordance with Schedule “A” requirements, and has tasked NAVAIR to design and integrate the Special Intelligence Communications (SI Comms) equipment in parallel with the RCS. All NAVAIR SI Comms GFI is approved by PMW 120 prior to delivery to PMW 760 and subsequent delivery to PMS 400D7.

2.2.3 Naval Air Systems Command (NAVAIR), St. Inigoes, MD

NAVAIR 4.5.10 is the PMW 760 and PMW 120 integration agent for the RCS, SSES/SI Comms, and Cabinet Level Turnkey equipment on DDG 51 Class ships. NAVAIR receives GFI from PMW 760 and PMW 120 for the individual C4I systems and incorporates this into the RCS and SSES FY GFI. This GFI is provided to PMW 760 and PMS 400D7 to meet Schedule “C” delivery to the shipyards, as shown in Figure 3-1. NAVAIR is also responsible for reviewing proposed changes to Cabinet Level Turnkey systems and initiating the appropriate change documents for implementation. Most RCS and SSES (SI Comms only) equipment is delivered to NAVAIR and installed on a ship-specific test bed. The RCS suite and the SI Comms component of SSES are fully assembled on the test bed, and Stage 1-4 testing is completed. (Note: Stage 5 is not applicable and Stages 6 and 7 are performed following shipboard installation.) Government furnished cables are also assembled and tested prior to delivery. The entire integrated suite is then delivered to the shipbuilder in accordance with the SPD Part III.

2.3 Program Executive Office Ships, Acquisition Management (PEO Ships AM)

PEO Ships AM, the Acquisition Management Program Director, through PEO Ships AM4, the Assistant Program Manager, Combat System/GFE Acquisition, manages the acquisition of Turnkey equipment. PEO Ships AM ensures that all GFE is delivered to the shipyards on time and within budget. PEO Ships AM4 is responsible for the acquisition of Turnkey material and interfaces with the PARM, who meets the SPD requirements. In addition, PEO Ships AM4 coordinates Shipyard Preferred Dates (SYPDs) for equipment delivery to ensure efficient ship construction. PEO Ships AM4 is also responsible for providing GFI to PMW 760 in time to meet the development schedule.

2.4 Program Executive Office, Integrated Warfare Systems (PEO IWS)

PEO IWS has overall responsibility for fleet combat systems performance, planning, design management, engineering, integration, installation, test, maintenance, and disposal. Within PEO IWS, the Integrated Combat Systems Directorate (PEO IWS 1.0) manages the design, integration, and testing of the AEGIS Combat System (ACS). Among other responsibilities, PEO IWS 1.0 develops top level engineering requirements for the ACS and systems engineering of interfaces from the RCS and SSES suites to the ACS, engineers baselines for planned upgrades to the ACS, manages the integration of combat system equipment into AEGIS ships, and develops changes necessary to integrate equipment and ship design modifications into established combat system and ship baselines. In addition, PEO IWS 1.0 oversees the AEGIS Test Teams (ATTs) in the installation and test of the ACS and its upgrades for new construction and in-services availability. Representatives from PEO IWS 1.0 attend meetings of the Turnkey Steering Group and TIWG to address issues relating to combat systems integration.

2.5 Surface Training Systems (PMS 339)

The Surface Training Systems Program Office (PMS 339) is the single point of contact for all existing and future Navy surface ship training management. A representative from PMS 339 attends meetings of the Turnkey Steering Group and TIWG and advises on training issues.

2.6 Lead Yard Services (LYS) and Follow Yard Services (FYS)

LYS is responsible for developing the detail design for ship support services necessary to provide electrical power; cooling water; and Heating, Ventilation, and Air Conditioning (HVAC) to the RCS and SSES. LYS personnel also develop room arrangements and drawing schedules, locate cableways, hold design reviews, and co-chair the TIWG. LYS and FYS review preliminary Turnkey data and provide comments to PMW 760 in accordance with an agreed-to timeline.

2.7 Supervisors of Shipbuilding

SSBA and SSGC are responsible for monitoring the delivery of design products from PMS 400D7 to the shipbuilders and for ensuring that GFE is received. The Supervisors receive deliverables from LYS, in the form of detail design products. They also forward the PMS 400D7 Services Pre-Turnkey Data Transmittals and GFI delivery letters to the shipbuilders. Comments generated by the shipbuilders against preliminary data or final GFI are provided to the Supervisors, who in turn forward them to PMS 400D7. The Supervisors are responsible for monitoring the RCS and SSES spaces to meet scheduled loadout. They monitor production schedules and milestones, perform inspections, and receive and inspect Turnkey GFE. In addition, the Supervisors witness Stage 2 testing, as applicable, and ensure that adequate Installation and Checkout (INCO) spares are available to support testing. The Supervisors chair readiness meetings, review and deliver the necessary government furnished test outlines and procedures, and provide the appropriate test team personnel for assisting in equipment installation and testing.

2.8 Shipbuilders

The shipbuilders are responsible for defining SYPDs for GFE, meeting all production milestones, and installing the RCS and SSES. Installation of working suites includes building the spaces; providing services such as cooling water, HVAC, and power to the spaces; installing foundations; loading out and energizing equipment; following the Navy's procedures to test the equipment; and assisting the Supervisors of Shipbuilding and ATTs in grooming the equipment. These responsibilities remain the same with Turnkey implementation.

2.9 The Turnkey Steering Group

The Turnkey Steering Group, co-chaired by PMS 400D5 and the PMW 760 SCN DDG 51 Platform C4I Lead Engineer, resolves Turnkey programmatic issues. Members of the Steering Group include PMS 400D1; PMS 400D7; PEO Ships AM4; and representatives from PEO IWS 1.0, PMS 339, SSBA, SSGC, LYS, FYS, BIW, and HII/Ingalls. The group meets at the request of the TIWG. Steering Group meetings may be held concurrently with TIWG meetings. PMS 400D5 is responsible for scheduling and publishing the agenda and minutes for the Turnkey Steering Group.

2.10 The Turnkey Implementation Working Group (TIWG)

The TIWG, co-chaired by PMS 400D51, the PMW 760 SCN DDG 51 Platform C4I Lead Engineer, and a representative from LYS, implements the Turnkey program. Members of the TIWG include PMS 400D1; PMS 400D7; PEO Ships AM41; and representatives from PEO IWS 1.0, PMS 339, SSBA, SSGC, FYS, BIW, and HII/Ingalls. The group meets quarterly or as required. PMS 400D51 documents TIWG meeting minutes and newly assigned action items and coordinates electronic meeting access, as needed. The PMW 760 SCN DDG 51 Platform C4I Lead Engineer develops TIWG agendas and tracks the status of action items. Any additional local support is provided by the stakeholder hosting the meeting.

3.0

TECHNICAL APPROACH

3.1 Phases of the Milestone and Design Schedule

The Turnkey milestone and design schedule is divided into four phases. Phase I of the ship construction schedule encompasses functions for all work, commencing from ship contract award, roughly 54 months before [ship] delivery (MBD), to the completion of the RCS and SSES compartments, roughly 28 MBD. During this phase, the Navy, LYS, and FYS will coordinate and exchange engineering data for the development of GFI necessary for LYS to complete the initial design phase supporting the fabrication of standard foundations and the pre-outfitting of the RCS and SSES compartments.

Phase II covers the ship construction phase from the completion of the RCS and SSES compartments to loadout of the Turnkey equipment by the shipbuilder, typically at 16 MBD, with the exception of SSEE, which is loaded out at 5 MBD. During this phase, the Navy, LYS, and FYS will continue to coordinate and exchange engineering data for the development of additional GFI and commence the delivery of cables, connectors, and backshells necessary for the shipbuilder to complete the preparation of the Turnkey spaces and all remote RCS and SSES equipment.

Phase III covers those functions from RCS and SSES SI Comms suite loadout to the start of AEGIS Light Off (ALO). Task functions during this phase include installation of the RCS and SSES SI Comms suite equipment, completion of cable pulling, and termination of the unconnectorized end of the RCS or SSES cables by the shipbuilder prior to the commencement of ALO.

Phase IV encompasses testing, maintenance, and ship's trial support from the start of ALO through Ship Custody Transfer (SCT).

3.2 Notional Deliverable Schedule

A notional Turnkey GFI Delivery Schedule is shown in Figure 3-1. Delivery of this material is made in two, distinct categories: Preliminary (non-contractual) and Final (contractual). The RCS/SSES Phased GFI to be delivered is defined as follows:

Phased GFI Deliverables:

Outline and Mounting of Method Mounted Equipment: Provides the installation data for non-hull foundations and defines the installation requirements for individually mounted equipment weighing less than 75 lbs. The TIWG uses the concurrent engineering process to determine if individually mounted pieces of equipment exceeding 75 pounds should be identified in the Outline and Mounting of Method Mounted Equipment drawing or the Cabinet Foundation Outline and Mounting drawing. This deliverable also provides bonding and grounding requirements.

Cabinet Foundation Outline and Mounting Drawing: Defines the installation requirements, including TEMPEST, for all cabinets mounted in Turnkey equipment envelopes. It also identifies the number of cabinets and is used for sequencing cabinet loadout. Cabinet Outline and Installation drawings for newly installed systems or modified systems will be delivered at this time for reference.

60/400Hz One Line Diagram: Depicts connectivity to the ship’s power distribution systems, power panel circuit designations, load and circuit breaker values, power cable applicability, and terminations.

Main Cable Routing: Defines the termination plan for all RCS and SSES related cables in the Turnkey spaces; the cable routing plan is coordinated with LYS, validated at the Satellite Production Test Center (SPTC), and provided for reference only.

Installation Aid Fixture (IAF) Backplane Assembly Drawing: Identifies backplane locations (horizontal, vertical, depth attachment) and geometric configurations to be used with universal IAFs provided as GFE to the shipbuilders.

Intra-Compartment Cable Block Diagram/Inter-Cabinet: Defines the single-line cable connections between cabinets and individually mounted pieces of equipment within the space, including cables connecting RCS, SSES, and non-RCS and non-SSES mounted equipment. It also depicts the RCS and SSES portions of inter-compartment cable run sheets.

Intra-Compartment Cable Running Sheets/Inter-Cabinet: Define the pinout data for cables depicted in the inter-cabinet cable block diagrams and provide cable, connector, and backshell part numbers.

TEMPEST List: Defines equipment and cabling that must be installed in accordance with policies and procedures required to process secure or classified information. This is a non-SPD Schedule “C” deliverable.

Equipment Identification Numbering (EIN) Listing: Defines the non-contractual six digit tracking number for equipment residing within the RCS/SSES Turnkey equipment envelopes. This is a non-SPD Schedule “C” deliverable.

Space Arrangement Drawings: Depict the front and top views of RCS and SSES equipment and provide final design data on HVAC requirements. These drawings also depict access and maintenance requirements.

Intra-Compartment Cable Block Diagram/Intra-Cabinet: Depicts the single-line connections for equipment mounted within NAVAIR populated cabinets.

Intra-Compartment Cable Running Sheets/Intra-Cabinet: Depict the pinout data for equipment mounted within NAVAIR populated cabinets and provide cable, connector, and backshell part numbers.

3.2.1 Preliminary Data

As noted in Figure 3-1, certain Turnkey products are delivered to LYS and FYS as preliminary data for review approximately two months prior to their contractual due dates.

3.2.2 Final GFI

Final GFI is delivered to the shipbuilders in accordance with Schedule “C” requirements.

3.2.3 Turnkey GFI and Shipyard Preferred Dates (SYPDs)

SYPDs for GFE shall not precede any Schedule “C” date by 45 days. Requests for exceptions, accompanied by clear and acceptable justification, shall be addressed to PEO Ships AM4 and PMS 400D7.

3.3 Turnkey GFI Delivery

3.3.1 Turnkey Preliminary Data Delivery

As stated in Section 3.2.1, PMW 760 provides preliminary versions of certain Turnkey products for review by LYS and FYS. These preliminary data deliveries allow a “concurrent engineering” process between PMW 760 and LYS, whereby a constant dialogue is maintained during the development of both final GFI and Class Design. Certain elements of the data can be loaded immediately into a preliminary LYS Class Design product, benefiting the process in two ways. First, LYS design engineers can quickly identify “won’t work” situations and liaise with PMW 760 to correct defects prior to contractual GFI delivery. Second, level-loading of the LYS design process is assisted, in that a major portion of Class Design work is already completed upon GFI delivery.

Preliminary data are transmitted electronically via the PMS 400 Digital Data Transfer Homepage (https://km3.alionscience.com/sites/set2), a secure Internet file transfer protocol site. Once the data are loaded to the site, NAVAIR provides an e-mail notification to PMS 400D7 that delivery has taken place. PMS 400D7 then notifies SSBA, SSGC, LYS, and FYS that the products are available, via a Services Pre-Turnkey Data Transmittal Form.

Figure 3-1 Notional Turnkey GFI Delivery Schedule

RFP

33 MBD*

25 MBD*

23 MBD*

20 MBD*

19 MBD*

16 MBD*

10 MBD*

Ship’s Spec

Space Arrangement Drawings (Envelopes)

Schedule A (Reduced)

Schedule C (Reduced)

Cable Block Diagram Outline and

Mounting of Method Mounted Equipment

150.000.023

260.000.041

Cabinet

Foundation

Outline

And Mounting

Drawing

150.000.022

260.000.040

60/400Hz** One Line Power Diagrams

150.000.026

260.000.043

Main Cable Routing**

150.000.041, 150.000.043-050 260.000.052-054, 260.000.056-058, 260.000.060-061 Installation

Aid Fixture

Backplane

Assembly

Drawing

150.000.025

260.000.042

Intra-compt, Inter-cabinet Cable

Running

Sheets** 150.000.013-021, 150.000.039 260.000.011-012, 260.000.015-021, Intra-compt, Inter-cabinet

Cable Block Diagram** 150.000.029

260.000.046

TEMPEST List Equipment Identification Numbering Listing

Technical Manuals

Space Arrangement

Drawings

150.000.028

260.000.045

Intra-compt, Intra-cabinet Cable

Running

Sheets

150.000.031, 150.000.033-038, 150.000.040 260.000.026-027, 260.000.031-034 Intra-compt, Intra-cabinet

Cable Block Diagram

150.000.030

260.000.047

*Months Before [Ship] Delivery

**Preliminary review copy provided approximately two months before final contractual due date

3.3.2 Turnkey Final GFI Delivery Final Turnkey GFI delivered to the shipbuilders is transmitted electronically via the PMS 400 Digital Data Transfer Homepage. NAVAIR provides an e-mail notification to all parties when GFI is posted to the site. A Portable Document Format (PDF) version is also placed on the PEO Ships website (https://navsea-ide.nmci.navy.mil). PMS 400D7 posts formal delivery letters addressed to the shipbuilders via the Supervisors of Shipbuilding in the same location and notifies SSBA and SSGC via e-mail. SSBA and SSGC inform the shipbuilders that the delivery is available.

3.3.2.1 Delivery of Phased GFI with Change Sheets

For DDG 113-125, the deliveries for DDG 113, DDG 116, and DDG 117-118 will consist of new drawings. For the interim and remaining hulls, the existing drawings will be extended using change sheets as follows:

New Drawing

Change Pages Only

DDG 113

DDG 114-115

DDG 116

N/A

DDG 117-118

DDG 119-125

In order to meet the contractual delivery dates for DDG 114-115 and DDG 119-125 phased GFI, the delivery letter from PMS 400D7 will direct the shipbuilders to utilize the DDG 113 phased GFI to design DDG 114-115 and the DDG 117-118 phased GFI to design DDG 119-125, while incorporating the provided change sheets into the existing DDG 113 and DDG 117-118 drawings.

3.3.2.2 DDG 114-115 and DDG 119-125 Phased GFI Final Delivery Change Sheets

As noted in the previous section, for DDG 114-115 and DDG 119-125, change sheets are to be delivered in lieu of the entire drawing. Change sheets shall include the following:

a) Existing sheet(s) with changes to the added hulls incorporated

b) New sheet(s) added to the drawing

c) Drawing title sheet incorporating the following:

· Updated Title Block reflecting the new hull effectivity

· Updated Revision Status Block outlining the latest revision for each sheet in the drawing

· Updated Revision Description listing all changes made to the drawing

3.3.2.3 Electronic Delivery of GFI

The following data are exchanged:

a) 2-D CAD, for arrangement drawings, interface checking, cabinet foundation outline and mounting, design control, cable block diagrams, one-line power diagrams, and installation backplane drawings.

b) Minimum Data Set (MDS), in accordance with Memorandum of Agreement (MOA) for MDS Files (provided in Appendix A), for wire connection lists.

c) MDS, in accordance with Appendix B, for main cable routing sheets.

3.4

TEMPEST

The shipbuilders are required to issue, update and maintain listings of TEMPEST related spaces, equipment and cables by individual hulls. These lists are utilized first to ensure that all TEMPEST related material is installed in accordance with Ship Specification Section 402 and, ultimately, to provide certification to the Navy that Ship Specification Section 402 was adhered to during the installation of all “red” equipment.

A TEMPEST listing of cabinets and cables will be delivered at 19 MBD. This list will be provided via letter as a non-SPD Schedule “C” deliverable or by a Services Pre-Turnkey Data Transmittal Form, as done for preliminary Turnkey data.

3.5 Cabinet Level Turnkey

3.5.1 Cabinet Level Turnkey Applicability

Cabinet Level Turnkey extends the principles of Turnkey outside of the RCS and SSES spaces for applicable systems. These systems are normally comprised of Commercial-Off-The-Shelf (COTS) components, which frequently change configuration or rapidly reach their End-Of-Life. To avoid change documentation and allow the PARM to insert the latest technology, the enclosures or cabinets housing these components become Turnkey envelopes and are managed by the process outlined below.

3.5.2 Cabinet Level Turnkey Change Process

Cabinet Level Turnkey Equipment is implemented into the DDG 51 Class SCN design and installed via the DDG 51 Shipbuilding Change Control process, with the following caveats:

Nomenclatures

Cabinet Level Turnkey equipment has generic “noun name” nomenclatures in the Schedule “A,” contract drawings, and other contract documentation. For example, an “OJ-685(V)7/USQ-155, GCCS-M File Server” would be referred to as a “File Server.” The equipment is also given an envelope number for tracking purposes. This way, internal component changes that affect nomenclature but not the external parameters of the equipment can be implemented without shipbuilder impact. NAVAIR is responsible for assigning and maintaining Cabinet Level Turnkey envelope designations.

GFI

Outline and Installation GFI for Cabinet Level Turnkey Equipment contains the minimum amount of information required by the shipbuilder to install the equipment. Internal components that do not impact the external parameters of the rack will not be depicted in Cabinet Level Turnkey GFI. This GFI establishes the Cabinet Level Turnkey envelope. Any subsequent changes to the equipment that alter the information within the Cabinet Level Turnkey envelope will be considered transparent to the shipbuilder and can be implemented without a ship integration ECP. However, if changes cause any deviation outside the Cabinet Level Turnkey envelope, a ship integration ECP must be written and new GFI provided.

4.0

CONFIGURATION MANAGEMENT

4.1 Overview

The Turnkey approach is intended to relieve some of the design changes and costs inherent to the shipbuilding configuration control process. The objective of the process is to advance the introduction of new technology into the DDG 51 Class Destroyers without affecting ship construction schedules and without incurring significant costs. The Turnkey team must reach this goal without sacrificing strict configuration control through ship delivery.

4.2 Configuration Change Procedures

Changes to equipment nomenclature, quantities, or any other factor affecting ship design are processed through procedures described in Section 4.2.1 and shown in Figure 4-1. Changes that do not breach established parameters and are located within Turnkey spaces are processed as stated in Section 4.2.2 and shown in Figure 4-2.

PMW 760 continues to exercise technical management over RCS equipment definition and integration in fulfillment of Top Level Requirements. PEO C4I/PMW 120 exercises similar authority over SSES equipment.

4.2.1 Ship Design Changes

A ship integration ECP must be provided for ship design changes affecting areas outside of the Turnkey envelopes or exceeding Turnkey parameters, as depicted in Figure 4-1. In most cases, these changes are submitted initially as Ship Change Documents (SCDs) through the PEO IWS Enterprise Change Control Board (IWS ECCB). They include the following:

a) Changes that impact shipbuilder design outside the RCS or SSES spaces. For example, all topside changes, remote equipment substitutions not covered by Cabinet Level Turnkey, and inter-compartment cable changes fall into this category.

b) Changes within the RCS or SSES spaces that exceed established envelopes or design budgets for weight, power, or cooling.

c) Changes within the RCS or SSES spaces altering equipment installation designs after their configuration has been established through phased release of GFI. For example, changes to established foundations, cableways, and lighting would be included.

d) Changes that alter electromagnetic effects (EMX) outside the Turnkey spaces.

e) Modifications to RCS or SSES interfaces to the ACS.

Upon approval from PEO IWS 1.0, the changes are then submitted to the PMS 400D Pre-Initial Change Proposal (Pre-ICP) Board in accordance with the DDG 51 Shipbuilding Division Change Control Process.

Changes with shipbuilder impact but no effect on the combat system (e.g., an Installation Control Drawing (ICD) is updated to revise bolt hole requirements) do not require submittal through the IWS ECCB and may be submitted directly as a Pre-ICP.

In order to accelerate product development, PMW 760 has been granted authority to implement ship design changes listed in the PMS 400D7 monthly preliminary implementation directive into subsequent Turnkey Phased GFI deliveries. This authority is predicated on changes receiving approval via the current configuration control process, as depicted in Figure 4-1. Turnkey Phased GFI should include all ship integration ECPs listed in monthly preliminary implementation directives received up to 20 business days prior to the scheduled GFI delivery date. Changes received within the 20 business days prior to the scheduled GFI delivery date may be included, when feasible.

These changes will eventually be included in the final implementation directive. The directive remains the authority to distribute Configuration Control Baseline (CCBL) documents.

4.2.2 Turnkey Space Design Changes

Turnkey space design changes are those having no impact to the shipbuilding contract baseline. These changes can be made for each fiscal year set of ships prior to delivery of any phased Turnkey GFI that may be impacted in that fiscal year’s delivery. Examples of changes in this category include the following:

a) System upgrades

b) Equipment substitutions, additions, or deletions

c) Equipment nomenclature changes

d) Relocation of existing equipment within and between established Turnkey envelopes Changes submitted to the PMS 400D Pre-ICP Board in accordance with the DDG 51 Shipbuilding Division Change Control Process and deemed by PMW 760 to meet the criteria of a Turnkey space design change must receive concurrence from PEO IWS 1.0 prior to implementation of the change. Upon approval of the Pre-ICP by PMS 400D, PMW 760 will request that PEO IWS 1.0 review the change to ensure there are no combat system or shipbuilder impacts. Upon receipt of concurrence from PEO IWS that the change meets the Turnkey space design change criteria, PMS 400D7 will authorize PMW 760 to implement the change into the Turnkey design. This process is depicted in Figure 4-2.

Figure 4-1 Changes That Breach Turnkey Parameters

Figure 4-2 Changes That Do Not Breach Turnkey Parameters

4.2.3 Implementation of Changes into Future GFI Due to the time between the approval of a Technical Data Package (TDP) and implementation of the subsequent ECP, phased GFI could be delivered without the required changes or intent of the ECP incorporated, which would result in the need for a “cleanup” package. To alleviate this possibility, each TDP submitted to PMS 400D7 for ICP development that impacts future phased Turnkey GFI deliveries will include the following items:

a) “IS/WAS” sheets of all impacted future phased Turnkey GFI scheduled to be delivered within 90 business days of the TDP posting. These “IS/WAS” sheets will not be incorporated into any phased GFI deliveries, but will be implemented when the TDP is approved and included in a PMS 400D7 implementation directive.

b) A Request for Advance Implementation Authority (RAIA) form (Figure 4-3), listing any additional impacted future phased Turnkey GFI scheduled to be delivered 90 business days after the TDP posting.

Upon approval of the ICP for ECP development, PMS 400D will determine, based on risk of approval of the final ECP, whether to authorize PMW 760 to incorporate the intent of the change into the future phased Turnkey GFI listed on the RAIA.

If authority is not provided by PMS 400D, PMW 760 must request authorization to incorporate the intent of the change from PMS 400D7 60 days prior to each scheduled delivery, as listed on the RAIA.

Figure 4-3 Request for Advanced Implementation Authority (RAIA) Form

4.3 Configuration Identification Drawings and Documentation

4.3.1 RCS/SSES Design Configuration

Drawings under the cognizance of PMW 760 depict two levels of detail, depending on whether the portion of the RCS/SSES is within or outside the Turnkey envelope. Areas outside the Turnkey envelope show the traditional level of detail, including equipment nomenclatures, circuit designations, and data, traceable to cable and connector types shown on GFI. Areas inside the Turnkey envelope normally provide NTE data used for detail design, but do not depict the traditional level of detail associated with nomenclatures and quantities.

The difference in level of detail shown provides the Navy with a measure of flexibility in the final RCS/SSES configuration. The details of equipment nomenclatures, quantities, and rack configuration can change, provided that NTE design parameters are not breached or GFI data are not changed to the point of affecting detail design.

5.0

TURNKEY GFI TRACKING

5.1 The Need For Tracking

One of the inherent advantages of the Turnkey approach is that the phased delivery of GFI accommodates the master ship construction schedules of each shipbuilder without adversely impacting the goals of the Turnkey approach. With “just in time” delivery of Turnkey GFI, however, comes a greater responsibility to ensure on-time delivery of GFI to LYS, FYS, and the shipbuilders. As in the past, punctual delivery of GFI is critical in preventing delay and disruption at the shipyards.

5.2 Reporting Procedures

Both development and delivery of RCS and SSES Turnkey GFI are continuously tracked by PMW 760. PMW 760 provides a status of Turnkey GFI deliveries at PARM reviews and at TIWG meetings, addressing GFI under development, review, or in the delivery process. When necessary, the TIWG generates workarounds for high-risk GFE/GFI schedule items.

6.0

INTEGRATED LOGISTICS SUPPORT (ILS)

6.1 Overview

ILS requirements and responsibilities for the DDG 51 Class RCS and SSES suites remain unchanged under the Turnkey approach. As PARM for the RCS and SSES suites, PMW 760 is responsible for complete ILS planning and associated technical documentation for all RCS and SSES equipment. In particular, PMW 760 is responsible for adhering to all ILS requirements, in accordance with Naval Sea Systems Command (NAVSEA) ILSP-416-P. Logistic support requirements are documented in the SPD coordinated among PMS 400D, PEO Ships AM, and PMW 760.

6.1.1 ILS Management

The following is a list of ILS products and requirements required of the PARM:

a) Designate ILS Manager

b) Designate Supply System Point of Contact

c) Submit New Equipment Brief Sheets

d) Provide Integrated Logistics Support Plan (ILSP)/User's Logistics Support Summary (ULSS)

e) Provide Operation and Maintenance Manuals

f) Provide Technical Manuals

g) Develop/Update Navy Training Systems Plan (NTSP)

h) Provide Program Support Data (PSD)/Provisioning Technical Documentation (PTD) Information

i) Provide PTD Summary Status Reports

j) Provide Operating Space Items (OSI) Installation Drawings

k) Provide an INCO Configuration List/Update

l) Establish/Maintain an INCO Repair Contract

m) Deliver INCO Kit/Planned Replenishment

n) Determine Interim Repair Part (IRP) Configuration/Best Estimated Delivery Date (BEDD)

o) Determine Maintenance Assist Module (MAM) Configuration/BEDD

p) Identify Allowance Equipage Lists (AELs)

q) Identify Support and Test Equipment (S&TE)/BEDD

r) Provide Maintenance Index Pages (MIPs)/Maintenance Requirement Cards (MRCs)

s) Perform ILS Certification

6.1.2 Equipment Identification Numbers (EINs)

Equipment previously located in RCS and SSES envelopes was deleted from Schedule “A” by ECPs 51-1052 and 51-1250R2C1. EINs are provided to the shipbuilders in place of Schedule “A” for Turnkey GFE. The EINs are provided to PEO Ships AM4 and PMS 400D 60 days prior to Bulk and Early Install deliveries in the SPTC Invoice and Inventory Receipt Form (SIIRF) cards. EINs include the location of the equipment racks, provide equipment nomenclatures/descriptions, and are used to update both the Configuration Data Managers Database - Open Architecture (CDMD-OA) and Real-Time Outfitting Management Information System - Material Management System (ROMIS-MMS) databases maintained by PMS 400D and the shipyards.

6.2 Supply Support

Requirements for provisioning are based on Logistics Management Information (LMI) MIL-PRF-49506, superseding DoD Military Standards MIL-STD-1561B, MIL-STD-1388 and MIL-STD-1552. Though these former standards may still be referenced in active contracts, MIL-PRF-49506 includes the latest provisioning guidance. Further DoD guidance is available in the DoD Material Management Regulation (DoD 4140.1-R) and the Acquisition Logistics Handbook (MIL-HDBK-502). Present NAVSEA guidance on provisioning is contained in the Program Management Guide for Provisioning, which includes the Provisioning Statement of Work (SOW), Provisioning Contract Data Requirements Lists (CDRLs) and Provisioning Data Item Descriptions (DIDs). PMW 760 is responsible for tailoring provisioning requirements and submitting PSD and Provisioning Technical Documentation to the Naval Supply Systems Command Weapon Systems Support (NAVSUP WSS), in accordance with the applicable DoD and NAVSEA processes highlighted above.

PMW 760 continues to provide interim support for equipment that has not reached its Material Support Date (MSD). PMW 760 also manages life cycle support and costs. PMW 760 analyzes each RCS/SSES design change for potential impact to supply support requirements and takes necessary action.

6.3 Maintenance Planning

6.3.1 Organizational and Intermediate Maintenance/Depots

PMW 760 continues to identify and support required levels of maintenance.

6.3.2 Planned Maintenance System (PMS)

The planned maintenance organization and program is based on the requirements of OPNAVINST 4790.4. PEO Ships requirements should be determined in accordance with Reliability-Centered Maintenance (RCM) methodology. PMW 760 is responsible for ensuring the PARMs update PMS requirements.

6.4 Support and Test Equipment (S&TE) Planning

S&TE planning is consistent with the policy and responsibilities for life cycle management of portable test, measuring, and diagnostic equipment…