Corrosion Ambassador Briefing March 2007

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DoD Corrosion Prevention and Control Corrosion Ambassador Briefing March 2007

Problems with Corrosion: 

Problems with Corrosion • Treatment often inadequate  Significant maintenance required! • Materials vulnerable • Inspection not always revealing

Traditional Response to Vehicle Corrosion: 

Traditional Response to Vehicle Corrosion ….Peel Repair Paint Wash…

Traditional Response to Aircraft Corrosion: 

Traditional Response to Aircraft Corrosion ….Strip Repair Paint Wash…

Traditional Response to Naval Corrosion: 

….Chip Scrape Paint Wash… Traditional Response to Naval Corrosion

Topic Overview: 

Topic Overview Congressional mandate Keys to transcending traditional corrosion control Response to Congressional mandate DoD Corrosion Organization DoD Long Term Strategy Summary of accomplishments Future plans

The War on Corrosion: 

The War on Corrosion

The Law: 

DoD designate a responsible official or organization DoD develop a long-term corrosion strategy to include Expansion of emphasis on corrosion prevention & mitigation Uniform application of requirements and criteria for the testing and certification of new corrosion prevention technologies within common materiel, infrastructure, or operational groupings Implementation of programs to collect and share information on corrosion within the DoD Establishment of a coordinated R&D program with transition plans Strategy to include policy guidance & assessment of funding and personnel resources required The Law Public Law 107-314 Sec: 1067 [portions codified in 10 U.S.C. 2228]: Prevention and mitigation of corrosion of military infrastructure and equipment requires that:

Keys to Transcending Traditional Corrosion Control: 

Keys to Transcending Traditional Corrosion Control Transcend* – go beyond the limits of – triumph over negative aspects of DoD Corrosion Prevention and Mitigation Program transcends: Traditional organizational “stovepipe” boundaries Traditional corrosion control participants Traditional corrosion policies and strategies Traditional corrosion control technologies and processes Traditional funding approaches * Merriam-Webster Collegiate Dictionary

DoD Corrosion Organization: 

DoD Corrosion Organization

IPT Structure: 

Working IPTs (WIPTs) Policy and requirements Impact, metrics and sustainment Science and Technology Communication and outreach Training and Doctrine Facilities Specifications and standards IPT Structure Corrosion Prevention and Control IPT (CPCIPT) Provide strategic review and advice Develop and recommend policy guidance

Transcending the Traditional Organization: 

Transcending the Traditional Organization DoD Corrosion Prevention and Control (CPC) organization unique in terms of: Composition DoD Leadership with AT&L organizational support Five services plus NASA, DLA, NACE, industry, academia Equipment and Facilities equally represented Approach Anything can be done and will be done – “Skunk Works” Total cooperation – continuous coordination – unselfish give and take Sentient task groups with shared experience and information Expectations - Top-level DoD acceptance of recommendations and buy-in to planned approach Continued high-level visibility and protection from bureaucratic obstacles Results – unparalleled in terms of accomplishments: quantity, quality, rapidity Loyalty – unprecedented depth toward leadership and co-participants Dedication – extraordinary efforts to participate, cooperate, contribute and support Competence Top level people in terms of position and experience True subject matter experts from all participating organizations Visibility Access to and support of DoD Corrosion Official Recognition by Congress/DoD organization/Service components Glue – motivation, positive vision, cohesion and clear guidance

DoD Long Term Strategy: 

DoD Long Term Strategy Reflecting the requirements of the Law Expanded emphasis on corrosion prevention and mitigation Improved, standard application of specifications, standards and qualification processes Increased focus on collecting and sharing information Coordinated R&D program emphasizing transitions

Strategic Plan: 

Strategic Plan Roadmap to Transcend Traditional Corrosion Control Provides Strategic Direction – vision, mission, policy, strategies and objectives Articulates Management Strategy Roles and responsibilities Planning requirements Planning process Includes Appendices Action plans and roadmaps for each WIPT Project selection and management guidance Reference information on the law, policies, metrics and IPT Charter

DoD Long Term Strategy1. Expanded Emphasis on Corrosion Prevention and Mitigation: 

DoD Long Term Strategy 1. Expanded Emphasis on Corrosion Prevention and Mitigation Transcend traditional corrosion control by Investing in up-front prevention technologies, materials, and processes to leverage downstream savings in corrosion maintenance and repair Developing corrosion mitigation technologies and processes that reduce insidious effects and impact of corrosion on safety, cost and readiness and extend service life Improving predictive and prognostic techniques to eliminate unseen failure and reduce unnecessary maintenance and repair costs

Corrosion Prevention and Mitigation Policies: 

Corrosion Prevention and Mitigation Policies Revitalize approach by implementing best practices and best value decisions Objectively evaluate methods to prevent or mitigate corrosion through objective trade-offs Evaluate response to corrosion control requirements – early in review process by decision authorities at every level Include planning guidance in guidebooks and other appropriate documents

Corrosion Prevention and Mitigation Strategies: 

Corrosion Prevention and Mitigation Strategies Rapidly replace aging assets and close marginal facilities Implement web-based communication and sharing of best practices Include corrosion control planning as part of performance-based acquisition and logistics Establish formal acquisition review structure up through DAB Form Corrosion Prevention and Control Teams Include Integrating and Overarching IPTs in structure Streamline specifications, standards and qualification processes Review and update acquisition-related directives to reflect corrosion policies and requirements Develop DoD Instruction for implementing program

Corrosion Prevention & Mitigation Accomplishments: 

Corrosion Prevention & Mitigation Accomplishments CPC part of Performance Based Acquisition and Logistics DoD Instruction under development Training CPC Training Plan and Curriculum Corrosion “101” – elective course for 135,000 AT&L workforce Defense Acquisition University courses and video Corrosion Official Training Video NACE involvement Corrosion Policy in DoD 5000 Guidebook – part of Systems Engineering Guidebook for Designing and Assessing Supportability in DoD Weapon Systems CPC Requirements included in Initial Capabilities Documents (ICDs) and Capabilities Development Documents (CDDs) DoDI 5000.2 DFARS – corrosion planning required

DFARS RulingAcquisition Plans – Corrosion Protection and Mitigation: 

DFARS Ruling Acquisition Plans – Corrosion Protection and Mitigation Notice of change states that ruling adds corrosion prevention and mitigation to the areas that agencies must address in acquisition plans.  This change implements Section 1067 of the National Defense Authorization Act for Fiscal Year 2003, which requires DoD to prevent and mitigate corrosion during the design, acquisition, and maintenance of military equipment. DFARS 207.105(b)(13)(ii) states that logistics considerations in the plan of action portion of every acquisition plan will “[also discuss corrosion prevention and mitigation plans]”

Published Spiral 2: 

Published Spiral 2 Download from www.DoDcorrosionexchange.org Changes featured in Spiral 2 More comprehensive coverage of requirements and processes Improved process flow illustrations Unique system and facility processes delineated Specific aerospace applications included CPC Planning Guidebook

DoD Long Term Strategy2. Improved, standard application of specifications, standards and qualification processes: 

DoD Long Term Strategy 2. Improved, standard application of specifications, standards and qualification processes Transcend traditional corrosion control by: Integrating the best industry, association and DoD corrosion specifications, standards and qualification processes Developing standardized, consistent selection, application and updating of corrosion specifications and standards across the DoD community Establishing an effective, standard, DoD-wide qualification process to effectively introduce products into the DoD corrosion prevention and control system

Improved Specifications, Standards and Qualification Process Accomplishments: 

Improved Specifications, Standards and Qualification Process Accomplishments Reviewed thousands of military and commercial specifications and standards Developed a standard specs and standards application matrix Created a standardized qualification process roadmap

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path forward based upon Supplier’s Search Link to Product Information Sheet and Specification Search Tool. Qualification Process Flow

SSQP PHASE III Flow Diagram: 

SSQP PHASE III Flow Diagram

DoD Long Term Strategy 3. Increased focus on collecting and sharing information: 

DoD Long Term Strategy 3. Increased focus on collecting and sharing information Transcend traditional corrosion control by: Assembling the best available people at all levels to resolve problems and sharing solutions and results in real-time during Corrosion Fora Using modern, web-based methods to collect and disseminate information by taking advantage of existing web-sites and developing corrosion-specific web sites Using every available opportunity and medium to publicize the existence, purpose, structure and accomplishments of the CPC organization

Collecting and Sharing Information Accomplishments: 

Fourteen Corrosion Fora (and counting) Numerous Speeches and Briefings at Conferences, Meetings and Academic Events Focused Communication and Outreach Efforts AMPTIAC Quarterly Issue on Corrosion AMPTIAC White Paper to National Academy of Sciences – include corrosion at undergraduate level AT&L Magazine feature Acquisition website features corrosion control training Corrosion Website Working Groups – WGs www.acq.osd.mil Collecting and Sharing Information Accomplishments www.DoDcorrosionexchange.org

DoD Long Term Strategy 4. Coordinated R&D program emphasizing transitions: 

DoD Long Term Strategy 4. Coordinated R&D program emphasizing transitions Transcend traditional corrosion control by: Selecting projects that have joint application to multiple services/ organizations/weapon systems Selecting affordable projects that have significant long-term return on investment and savings potential Ensuring adequate project funding over multiple fiscal years to support a long-term corrosion prevention and mitigation program

Coordinated R&D Program Accomplishments: 

Identified and implemented equipment and facility “Quick Hit” projects for FY04 Selected Corrosion Prevention and Mitigation Projects for FY05 and FY06 Identified long-term resource and funding requirements Sources of funding (PEs) for FY05-FY13 Distribution of funds via MIPR or contract Articulating process via PDUSD memo Generated Statements of Work and Funding Requirements for all WIPTs Coordinated R&D Program Accomplishments

FY05 Project Selection: 

FY05 Project Selection 66 Projects Submitted – 29 Projects Selected Projects selected based on established criteria Joint emphasis Less than two year performance period New technology Matching/complementary funds ROI based on OMB guidelines $27M funded $17.4M for 26 projects $9.6M for CPC activities in Specs & Standards, Training, and Policy Implementation

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FY05 Projects and Activities

FY 06 Project Selection: 

FY 06 Project Selection Weapon Systems: 14 Projects OSD $4.1M and Service $3.7M Facilities: 15 Projects OSD $5.7M and Service $6.8M Categories: Coatings & Corrosion Prevention Compounds (13 projects) 45% Non-Destructive Inspection (2) 7% Diagnostics, Prognostics, and Monitoring (2) 7% Prediction, Modeling, and Supporting technologies (1) 3% Maintenance Technologies and Practices (11) 38%

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FY06 Projects and Activities

Projected Savings from FY05 & FY06 Projects: 

Projected Savings from FY05 & FY06 Projects Year Army Navy Air Force Total

Highlights of FY 07 Projects/Activities: 

Highlights of FY 07 Projects/Activities Weapon Systems: 34 Projects submitted – 13 selected OSD $3.6M and Service $3.3M Facilities: 35 Projects submitted – 12 selected OSD $4.5M and Service $5.2M Average ROI: 52 to 1 Total Life Cycle Savings: $868M Activities: Cost of Corrosion Baseline Study continues – finish FY2008 New Executive Agent for National Research Council Study New Migration of WebSite to executive branch host New development of “201” continuous learning module course Activities funded at $4.2M

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FY07 Projects and Activities

Three Year Project and Activity Status: 

Three Year Project and Activity Status 212 project plans submitted over three year period 82 projects selected for funding $89 million spent on projects and activities Service project funding - $36.5 million OSD project funding - $34.8 million Activities funding - $17.7 million

Summary of Accomplishments and Future Plans: 

Summary of Accomplishments and Future Plans

Summary of Important Accomplishments: 

Summary of Important Accomplishments Report to Congress submitted in December 2003 Follow-on Report submitted in February 2005 DoD Strategic Plan for Corrosion Prevention and Mitigation completed Corrosion Policy featured in : DoD 5000 Guidebook – part of Systems Engineering Designing and Assessing Supportability in DoD Weapon Systems ICD/CDD – must address CPC requirements DFARS – corrosion planning required in all acquisition plans CPC Planning Guidebook published – Spiral 2 Training Underway CPC Training Plan and Curriculum Corrosion “101” & Defense Acquisition University courses and video FY05, FY06 and FY07 Project Selection Completed Specifications and Standards Process In Development Matrix QPL Screening Process Successful Tri-Service Corrosion Conference in November 2005 National Research Council (NRC) briefed on CPC Program March 2006 NRC Study on corrosion education launched in March 2007

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Download from www.DoDcorrosionexchange.org

Future Activities: 

Future Activities Update the Strategic Plan periodically Continue WIPT efforts and complete roadmap milestones Perform Cost-of-Corrosion Studies Publish future CPC Guidebook Spirals Develop and approve service project plans for FY08+ Complete and Implement CPC Training Plan – “Corrosion 101+” courses Execute a FACA Charter with NACE Continue communication and outreach 2007 Tri-Service Corrosion Conference Improve corrosion website Participate in NRC study Cooperate with the GAO Complete DoD Instruction Submit Follow-on Report to Congress in April 2007

Summary: 

Summary We are successfully transcending traditional corrosion control! We have excellent inter-service, inter-agency and military-civilian cooperation! We are getting wide-spread support for our WAR ON CORROSION