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Joint Group on Pollution Prevention

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1 Joint Group on Pollution Prevention
Chartered by Joint Logistics Commanders (JLC) Joint Group on Pollution Prevention (JG-PP): Partnering for Progress Joint Technology Exchange Group (JTEG) and Commercial Technologies for Maintenance Activities (CTMA) “Technology Transition as a Continuous Process Improvement” 24-25 July 2007 Lorraine Wass, BMC Inc. Consultant/Pollution Prevention Support to Naval Air Systems Command and the Joint Group on Pollution Prevention (207) Good Morning Thank you for the opportunity to spend a few minutes with you to tell you about JG-PP. I am a contractor supporting Mr. Nick Paraskevas (NAVAIR) and Mr. Andy Del Collo (N45) the Joint Group on Pollution Prevention

2 Overview Mission Leadership Benefits Methodology and Process
List of Projects Initiatives Contacts These are the topics that are in this presentation.

3 Mission DoD/NASA flag officer group Chartered to
Originally created in 1994 at industry request Chartered by JLC/NASA HQs Chartered to Reduce or eliminate system hazardous material requirements: Project Benefits Avoid duplication of effort: Consensus Building Reduce technical risk: Stakeholder Ownership Transfer technology: Documentation Leverage opportunities, reduce costs: Cost Control Dual focus on uniform implementation Acquisition (Contractor design) and sustainment community (Depot) needs Manufacturing and maintenance processes For those of you not familiar with the JG-PP, it is a flag officer level body from the services, NASA and DLA chartered by the Joint Logistics Commanders in 1994. As you see the charter, there is a focus on avoiding duplication of efforts in P2 projects. The JG-PP origins lay within the acquisition community, both in the program offices and the OEMs. From the P2 perspective, the aim is to harmonize processes used in the development of a weapon system with those used to sustain the system once it has been deployed.

4 Leadership JLC Principals Working Group
General Benjamin S. Griffin Commander U.S. Army Materiel Command Working Group Major General Fred D. Robinson Jr. Commander HQ, Army Research, Development and Engineering Command Ms. Maryalice Miller U.S. Army REDCOM Environmental Acquisition and Logistics Sustainment Program Vice Admiral Justin D. McCarthy Deputy Chief of Naval Operations, (Fleet Readiness and Logistics) Mr. William G. Mattheis Deputy Director, Environmental Readiness Division Chief of Naval Operations (N45) Mr. Andy Del Collo Technology Development & Implementation Action Officer Chief of Naval Operations (N451T) Major General Willie J. Williams Commanding General Marine Corps Logistics Command Mr. Michael T. Madden JG-PP Chairperson Executive Deputy Operations Marine Corps Logistics Command General Gregory S. Martin Commander Air Force Materiel Command Mr. Gary Leitner JG-PP Working Group Chair Marine Corps Logistics Command This is the leadership of the JG-PP. Brigadier General Francis M. Bruno Director of Logistics and Sustainment HQ Air Force Materiel Command Vice Admiral Keith W. Lippert Director Defense Logistics Agency Mr. Warren Assink Depot Maintenance and Logistics Office HQ, Air Force Materiel Command Ms. James Leatherwood Director, Environmental Management National Aeronautics and Space Administration Mr. David A. Amidei (Acting) Kennedy Space Center National Aeronautics and Space Administration Mr. Frederick N. Baille Executive Director, Distribution & Reutilization Policy Defense Logistics Agency Mr. Marvin Williams Regulated Programs Branch HQ Defense Logistics Agency

5 The Right Time For Decisive Action
Benefits Coordinate/facilitate projects Advocate funding Reduce individual participant’s costs Reduce alternative technical risk Assist in qualified alternative implementation Coordinate/facilitate project management Contact stakeholders Program offices, OEMS, process owners in the depots Depending upon the project the JG-PP can prepare and coordinate project documents Develop project management plans, etc Ensure stakeholder requirements are documented Advocate funding Encourage POM for start of project to implementation Facilitate/coordinate project start Sell project – get buy-in Reduce DoD costs Bring funds to the table Share costs with other stakeholders Conduct cost/benefit analyses Reduce Risk Collaborate with diverse knowledgeable personnel Assist in implementation as needed The Right People The Right Place The Right Time For Decisive Action

6 Six Phase Methodology Identify P2 Needs Stakeholder Buy-in
Joint Test Protocol Lessons Learned I. Identification Potential Alternatives Report VI. Evaluation/ Feedback II. Technical/ Business Cost-Benefit Analysis V. Implementation III. Alternatives Testing Funding Agreements JG-PP applies a Six-Phase Methodology on each project to implement material or process changes at Original Equipment Manufacturer (OEM) or depot/maintenance facilities. Methodology is flexible to account for different needs of OEMs, programs, and depots Provides technical and business support and facilitates the projects Assists in identifying resources for validation testing of alternatives Target – continuous process Inner Circle – Project Cycle Outer Circle - Products Phase 1 – Identification Products: Joint 1-N needs list - Participants select target hazardous material(s) - Obtain contractor/program managers agreement to participate Phase 2 – Technical/Business Products: JTP, Stakeholder Buy-in, PAR, CBA - Define performance requirements Joint Test Protocol (JTP) report; Identify alternatives to hazardous material(s) usage; Obtain consensus among stakeholders - Determine who benefits from the project; Identify sources of funding; Develop plan to satisfy project expenses Phase 3 - Alternatives Testing Products: JTR - Validate alternative(s) (lab testing/field demonstration ) Phase 4 - Process Change/Authorization Products: Authorization Letter, Manual/Spec Changes For industry, changes not required if material/process change satisfies performance requirements specified in contract; DCMS Single Process Initiative can execute a change modification (block change) for changes to single/multiple contracts as required. Each Program Office/Depot process owner is responsible for issuing approval for change to material and application within their respective manufacturing and maintenance processes Process Change Authorization - OEMs will utilize the Single Process Initiative (SPI) block change process or performance based specifications to modify contracts for implementation across all affected systems and components. Depots will utilize their respective service/agency change mechanism for implementation. Phase 5 - Implement alternative(s) Product: Technology Transfer Implementation plan, follow-up on transition for success stories/issues/concerns Phase 6 – Evaluation/Feedback - Review effectiveness and inefficiencies of process and identify new areas for improvements Implementation Plan IV. Process Change Authorization Joint Test Report Block Change or Approval Letters

7 JG-PP Project Development Process
Within Agency Needs Identification Joint Needs Identification and Prioritization CONOPS Specifies Criteria Used to Develop 1-N List Joint Project Development Schedule Revised to Match Funding Opportunities Ground Vehicle and Aircraft Working Groups Resource Identification and Pursuit Agency Funding and In-Kind Support JG-PP Support Contract ESTCP Program NDCEE Congressional Adds NCMS/CTMA Program Within Agency Needs Identification - Each services reviews their high priority needs and determine which have joint service partnership potential Joint Needs Identification and Prioritization Project Sub-committee reviews all needs submitted by Services/NASA and ranks them – average is the final JG-PP 1-N list ranking/prioritization Joint Project Development Timeline developed to ID each Service/NASA funding opportunities as well as others such as ESTCP to enhance funding opportunities for timely preparation for proposal and submissions Resources Leverage Agency funding and in-kind support JG-PP Contract Support (CTC) Working relationship with ESTCP Program Managers, Chuck Pellerin/Bruce Sartwell and Jeff Marqisee Leveraging NDCEE Congressional Adds Recently, a Letter was sent to Mr. Chuck Ryan, NCMS Vice President, Technology to establish a partnership in the near future

8 Strengths and Challenges
Improves communication Facilitates partnerships Identifies shared opportunities Reduces duplication Reduces risk Leverages funding resources Challenges Obtaining agreement and buy-in from Stakeholders Engaging Acquisition and OEM Communities Decreasing R&D budgets Improved communication – Cross feeding of efforts across DoD/NASA ensures all potential solutions are identified and all concerns are voiced by collaborating together ideas and test results of similar test efforts reduces duplication of effort in performing common tests across DoD/NASA/Industry Reduced Technical Risk - Through the collaboration/coordination with a diverse experienced knowledge base of personnel consisting of laboratory, engineering, field level personnel, management, and industrial hygienist, to name a few. Leverage Funding Resources Through established partnerships/collaboration, limited funds/resources go a bit further with cost sharing between DoD and Industry Challenges Getting stakeholder buy-in upfront – identifying appropriate personnel and getting them involved early in the project engaging Acquisition and OEM community (working with AT&L, AIA, DMCA) the continuing decrease in R&D budget to work on new technology/processes and most importantly – getting them implemented.

9 Each Project Becomes a Journey
OSD SERDP OSD ESTCP NDCEE JSI Navy Dem/Val Army JS3WG Implement Solutions JG-PP Coordination Each project becomes a journey – here is an example of the JS3WG journey Illustrates the extent of collaboration involved JS3 WG initially consisted of Army/Navy/AF Through JG-PP Coordination, now includes NASA, DLA, MC, and potentially OEM/Suppliers JG-PP coordination enabled the leveraging of funding from NDCEE, ODS, JSI for joint solutions to common problems. Air Force NASA DLA USMC OEM Joint Service Solvent Substitution Working Group’s Journey

10 Completed Projects Low- VOC Identification Marking
POC: Andy Del Collo, Navy (703) Low-VOC Topcoats and Primers POC: Warren Assink, AF (937) Non Chrome Primer for Aircraft Exteriors Moldlines POC: Warren Assink, AF (937) Solventless Seawater Ballast Tank Coating Systems POC: Andy Del Collo, Navy (703) The next few slides is complete list of projects (completed, in transition, ongoing and new starts). For more details – go to JG-PP website ( Most common Categories/Process: Painting, Depainting, Plating, Surface Treatment Targeted HAZMAT: Chromium VI, Cadmium, VOCs I will only highlight several projects - Low-VOC ID Markings – Lockheed Martin 2 alternative inks were qualified and various label systems – reduced labor costs since no masking, unmasking and cleaning was required Low-VOC Topcoats and Primers – Raytheon 3-commercially available paint systems met the system critical performance requirements and approved for use Raytheon instituted two SPI/Block changes, changing all their affected drawings to allow use of qualified low-VOC primers and topcoats SPI allows OEMs to make modifications to several contracts at one time and reduced the process time by as much as three hours piece part. Lead-Free Surface Finish and Low-VOC Conformal Coating (CCAMTF) POC: Dave Amidei, NASA (202)

11 Completed Projects (cont’d)
Chromium - Free Primer for Inserts and Fasteners POC: Warren Assink, AF (937) Chrome-Free Conversion Coatings POC: Maryalice Miller, Army (410) Alternatives to Electrodeposited Cadmium for Corrosion Protection and Threaded Part Lubricity Applications POC: Andy Del Collo, Navy (703) Chromium-Free Primers and Threaded Fasteners (Pratt & Whitney) Two alternatives validated as acceptable alternatives to Zinc Chromate primers for galvanic corrosion protection in aircraft engine manufacturing by Pratt and Whitney – United Technologies Corporation Chrome Free Conversion Coatings – (Hughes Missile Systems Co./NCMS) Although no alternative technology was implemented, the project's screening test results and JTP have since been used by other commercial and governmental organizations to evaluate new chemical conversion coatings. Alternatives to Electrodeposited Cadmium (BOEING) two viable (Zinc Nickel and IVD Aluminum) alternatives qualified for use on low strength (> 200ksi) stainless steel, aluminum, copper alloys Lead-Free Dry Film Lubricants Partnering with PEWG POC: Mary Swinford, PEWG (937)

12 Completed Projects (cont’d)
Space Initiative Low Emission Depainting POC: Dave Amidei, NASA (202) Lead Free Solder – more of a logistics issue than P2 (NASA, JCAA, OEMs) JG-PP assisted the OEMs and Joint Council on Aging Aircraft to study the effects of environmental testing on relative reliability of lead-free and tin-lead solder joints and provide baseline data from the evaluation lead-free solders and finishes. the tests generated critical reliability data follow-up efforts under new project title NASA DoD Lead Free Electronics Phase II is underway. Lead-Free Solder (Reliability Study) POC: Dave Amidei, NASA (202)

13 Completed Projects (cont’d)
Non-ODC Oxygen Line Cleaning POC: Warren Assink, AF (937) Low/No-VOC and Nonchromate Coating System for Support Equipment POC: Warren Assink, AF (937) Portable Laser Coating Removal System - Services Qualified a portable hand-held Nd:YAG laser system that does not significantly affect the substrate materials and considered an effective versatile tool that can be used for coating removal applications in small areas Being implemented within various AF and Army maintenance facilities Additional technology transfer is being pursued. Follow-on Robotic Laser Coating Removing System underway. Portable Laser Coating Removal System Partnering with ESTCP POC: Warren Assink, AF (937)

14 Completed Projects (continued)
Chromium Electroplating Alternatives Partnering with HCAT and ESTCP HVOF Thermal Spray Coatings Technology on Landing gear POC: Warren Assink, AF (937) Prop Hubs POC: Andy Del Collo, Navy (703) HVOF – HCAT/ESTCP High Thermal Oxygen Fuel (HVOF) Thermal Spray technology has been evaluated for use on external components such as Landing Gear, Propeller Hubs, Actuators. HVOF coatings has proven to be better than Hard Chrome Plating and is also more wear resistant, thus extending the life cycle of the components, reducing maintenance hours, and most importantly, more environmentally friendly alternative that reduces the risk to maintenance workers. Actuators POC: Warren Assink, AF (937)

15 Transitioning Project
Nonchromate Aluminum Pretreatments POC: Andy Del Collo, Navy (703) Joint Service Initiative Corn Hybrid Polymer (CHP) Coating Removal on Delicate Substrates POC: Andy Del Collo, Navy (703) These projects have completed all testing/field demonstrations and final reports are being prepared: NCAP – Tri-Valent Chromium (TCP) has been qualified for use - being implemented across DoD maintenance facilities CHP – proven very effective in coating removal on delicate substrates such as radomes. Being implemented across Navy and Air Force - Plans are to transition further where practical. Space Initiative Alternative to Aliphatic Isocyanate Urethane (Space) POC: Dave Amidei, NASA (202)

16 On-going Projects Cadmium Replacements for DoD
and NASA Applications POC: Andy Del Collo, Navy (703) Low Temperature Cure Powder Coating – POC: Warren Assink, AF (937) These project are Ongoing - in various testing phases Cadmium Replacements for DoD and NASA Applications High Strength Steel Structural components and Landing Gear is main focus at this time – Other potential areas include HSS Fasteners, electrical connectors, springs Phase II testing is underway and some test results are being evaluated Low temperature Cure Powder Coating some lab tests are complete, and looks very promising for aluminum substrates – but not for steel substrates. low temperature will enable use of powder coatings on more components HVOF on Dyn Components - This is the last HVOF technology dem/val on Helo Dyn Components. - All Lab testing is completed – NAVAIR is continuing the field evaluations and hopes to complete by end of FY09. Chromium Electroplating Alternatives Partnering with HCAT and ESTCP HVOF Thermal Spray Coatings on Helicopter Dynamic Components POC: Andy Del Collo, Navy (703)

17 On-going Projects (continued)
Solvent Substitution Alternatives Partnering with JS3WG POC: Andy Del Collo, Navy (703) Non-Chromate Primer for Military Applications Partnering with AERMIP POC: Andy Del Collo, Navy (703) JG-PP partnered with the Joint Service Solvent Substitution Working group (comprised of DoD services/NASA/DLA/OEM/Suppliers) – addresses solvent substitution alternatives JG-PP assists in implementing the framework that support coordination and open communication Methodology identifies tasks to ensure full implementation (id of stakeholders, acceptance criteria/test protocols, field demo and execution strategy. JS3 Database is a tool to store and disseminate info on DoD/NASA efforts. MFG are encouraged to enter their HAP free cleaners to increase visibility of their products within DoD and NASA JS3 website lists project efforts underway. Non-Chromate Primer for Military Applications for a total Non-Chromate Coating System, a non-chromate primer is the key component still being investigated. NAVY aircraft has worst environmental exposure and corrosion is still a factor deterring a total non-chromate system Biodiesel Used in DoD Tactical Vehicles another example of collaborative efforts - Stakeholders include NAVY, AF, ARMY, USMC, JTP being developed, If results are satisfactory, plans are to implement through a policy letter by direction of ASN. Biodiesel Used in DoD Tactical Vehicles (Non-Deployable) POC: Andy Del Collo, Navy (703)

18 New Projects Bio-based Hydraulic Fluids Partnering with DLA
POC: Marvin Williams, DLA (703) NASA DoD Lead Free Solder Electronics Phase II Partnering with Industry POC: David Amidei, NASA (202) New Start include: Bio-based Hydraulic Fluids for machine tools approached by DLA to partner and ensure requirements for Military applications are met Stakeholders (NASA, AF, MC, NAVY, DLA) are evaluating current specification requirements and identifying any new requirements to be incorporated into a JTP NASA/DoD Lead Free Electronics Phase II Follow-on to initial LFS efforts (reliability study) Building on results and focusing on the rework of Tin-Lead and LF solder alloys (to include mixing of tin-lead and LF solder alloys) to generate reliability data for circuit cards manufactured and reworked and subjected to rigorous environmental exposure conditions. Purpose: Provide baseline data for aerospace and defense high performance applications – JTP being developed

19 Potential New Projects
High Strength Steel Fasteners Cadmium and Hexavalent Chromium Coating Replacements for DoD Applications Non-Chromate Coating System Corn Hybrid Polymer – Follow-on These are potential new starts in the near future HSS Fasteners - Prepoposal did not make ESTCP Phase II review – reviewing other sources of funding available Some discussion with Automotive Industry on the alternatives they implemented Non-Chromate Coating System – Much work has been done – some services have accomplished total NCCS, however NAVY has worst corrosion environment and still requires chromates in coating system (pretreat or primer). Non-Chromate Primer is key to total NCCS and being pursued by NAVAIR CHP – Follow-on Preproposal did not make ESTCPH Phase II review Seeking funding to further transition this technology. Three ESTCP Preproposals that did make ESTCP Phase II review and JG-PP assisting as needed in developing full proposals. Ultraviolet Curable Powder Coating Electrostatic Precipitator (ESP) Modification for Fume Control during Welding and Cutting Disposable Dual-Component Aerosol Technology (DCAT) Demonstration/Validation

20 Initiatives Strengthen acquisition community ties Improve funding
Improve collaboration Strengthen process project selection through execution and implementation JG-PP Initiatives are to: Strength acquisition communities ties to help eliminate use of hazmats early in the design process (JSF is good example of cooperative efforts in doing just that) Establish partnerships/cooperation that will improve funding and collaboration with other government agencies and - - ESTCP/HCAT/PEWG/JCAT/JDMAG/NDCEE and hopefully CTMA/NCMS in the near future - avoid duplication of efforts, minimize costs, reduce technical risks Leverage knowledgable expertise with diverse experience base consisting of laboratories, engineers, management Strengthen process for project selection through execution and implementation - Ensure stakeholder/process owner buy-in up front for successful transition to the OEM/Maintenance facilities.

21 Working Group Core Members
Contacts Working Group Core Members Ms. Maryalice Miller HQ REDCOM, (410) Mr. Andy Del Collo CNO (N451), (703) Mr. Gary Leitner USMC, (229) Mr. Warren Assink HQ AFMC/LGPE, (937) Mr. David Amidei (Acting) NASA-KSC, (202) Mr. Marvin Williams DLA, (703) Visit our website -

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