JA_SPRDL123R0142_Redacted.pdf

JA-00671 – SPRDL1-23-R-0142

Previous J&A: Not Available

Technical Data Package (TDP) or specifications.

The data rights for the C15 flashed ECU are owned solely by Oshkosh Defense. Only Oshkosh has the specific technical expertise and proper facilities to manufacture the ECU. Additionally, Oshkosh has the history of building ECUs that allow the PLS A1 to perform its mission. Only the OEM is familiar with the specific configuration required for this vehicle.

A replacement would not only have to meet the physical characteristics of the original part but also the software capability and compatibility. The software that differentiates a blank engine control unit from the desired ECU is the specialized Caterpillar C15 software. There is no way to qualify reverse engineered software against the proprietary Caterpillar software.

If the Government were to purchase ECUs that have not undergone proper verification, mission failures and potential loss of engine function could occur. Without this proper verification, it is likely that the ECU would not fit or function properly, which could result in failure, jeopardizing mission capability and fleet mobility.

Since the Government does not own any of the technical data, the Government would have to reverse engineer the ECU and the C15 software to identify all aspects of the part. A reverse engineering effort would include work to clarify and define an ECU with the same fit, form, and function as the original, then design the new ECU and develop the software. Next, Reliability, Availability, and Maintainability (RAM) testing would have to be completed with the ECU integrated into the engine. Testing would include accelerated life testing, cold and hot environments, and extensive software testing and debugging. To neglect testing would be a high risk as premature failures of this item in the field could result in a mobility failure which could jeopardize the Army’s mission in a potentially adverse operational environment. After the qualification, the Technical Data Package (TDP) would have to be built so the part could be competitively sourced.

The Ground Vehicle Systems Center (GVSC) Heavy Tactical Vehicle Sustainment Engineering Team has used historical data from past reverse engineering efforts on a Transmission Control Unit to estimate that Reverse Engineering the PLS A1 C15 flashed ECU would cost an estimated minimum of $3,000,000 for:

- Research and Development (R&D), including part qualification and design, software development, and prototype;

- RAM testing, design validation and vehicle integration testing, software functionality and safety testing; and

- TDP development, to procure competitively.

A detailed breakdown of cost impacts is shown below.

JA-00671 – SPRDL1-23-R-0142

Previous J&A: Not Available https://bigrigworld.com/module-23526112.html https://www.bosch-mobility.com/en/solutions/control-units/engine-control-unit/

Findings: C15 flashed ECUs offered by Detroit Diesel, Bosch, and Wolverine were reviewed. In summary, there is not enough information to determine whether these options will fit the PLS A1 in the same manner as the original equipment manufacturer (OEM) sole-source part. Due to the lack of a TDP or in-depth specifications of the sole-source part, the validity of the researched C15 flashed ECUs for this procurement is extremely difficult to ensure.

Although several manufacturers make products that appear to be similar to the ECU used on the PLS A1, the lack of a TDP or detailed drawings for the PLS A1 ECU and the C15 software prohibit the engineer from knowing the exact specifications that must be met by a potential alternative. A wide range of ECU dimensions and capabilities are available across the brands reviewed. However, the current C15 flashed ECU was designed by the OEM specifically to fit onto this vehicle, and integration/verification testing was conducted for this reason. Any other alternative would require integration and extensive testing to mitigate potential risks in the field, such as negative impacts to vehicle safety and operational readiness. Therefore, it can be concluded that this C15 flashed ECU is custom for the application and should be identified as a sole-source item.

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

10. Other Facts: Procurement History:

Contract Number: SPRDL1-20-C-0202 Award Date: 8/10/2020 Contractor: Oshkosh Defense LLC Contract Value: $136,325.00 Competitive Status: FAR 6.302-1 only one responsible source

Contract Number: SPRDL1-15-D-0011 Award Date: 12/13/2014 Contractor: Oshkosh Defense LLC Contract Value: $172,597.32 Competitive Status: FAR 6.302-1 only one responsible source

Contract Number: SPRDL1-13-D-0008 Award Date: 01/04/2013 Contractor: Oshkosh Defense LLC Contract Value: $224,969.40 Competitive Status: FAR 6.302-1 only one responsible source

11. Technical Certification: I certify that the supporting data under my cognizance which is included in the justification is accurate and complete to the best of my