**1/28/05**

**Documentation for FDCA**

**Summary of Integration and Kitting Requirements**

Attached below are the detail plans for integration and kitting of the
2006 Census Test HHC equipment. Since this is a contract with an outide
vendor, some of the detail as to "how" the vendor achieved the results
(integration of the Secure Digital Cards and HHC) is not specified in
this document.

Since this is the case, pages of this document will outline the
technical process used for the integration of the 2004 Census Test HHCs
and what is known to date about the 2006 Census Test HHC integration.
Also not included are the requirements for the kit box. The Kit
container that we used for the 2004 Census Test was a true example of
what we "do not want" in the future. The 2006 HHC Kit container is
currently being designed, so the size of this container is not specified
here.

**HHC Software Integration Process:**

# 2004 Census Test HHC Integration

Detail:

The BOC provided **two** 2004 Census Test software images to the
integrator. One image included the map files for the New York site, and
the other included the map files for the Atlanta site (NOTE: the
integrator was given several test images prior to the final images being
handed over on which to develop the final integration process). In all
other ways, the images were identical.

The 2004 Census Test HHC Software Integration process was conducted in
two phases. First, using BOC provided counts of cards required for each
site, the 2004 Census Test image was copied onto the individual Secure
Digital (SD) cards. This was done by placing the image on a desktop
using Sprite Clone and then doing a physical copy to SD cards inserted
in a multi-SD card reader.

The cards were labelled with a thumbnail size label that had the
Regional Office Alpha code on the label (NY or AT). Each card was
checked to make sure the image was on the card and the file was the
correct size.

The card was then inserted in the device. When the card was installed,
the image "exploded" onto the device. After the device was imaged, the
vendor verified that the image was complete and that the map files on
the device were the map files for the RO on the SD card label.

The BOC conducted a 10% Quality Control check on the devices and kits
after integration and before shipping to the LCOs.

# 

# 

# 2006 Census Test HHC Integration

We expect that the 2006 Census test software integration will be similar
manner as the 2004 software integration.

**[Kit Box Specifications:]{.underline}**

The Statement of Need for both procurements stated that a kit box had to
be developed that would hold all the accessories the Enumerator needed
to conduct their work. It had to 1) be secure, 2) withstand 4 shipments
and 3) be as small as possible and still meet the first two
requirements.

The 2004 Census Test kit box met these requirements, but was larger than
the FLD Space and Logisitics staff had expected, so it caused a problem.
The 2004 Census Test kit box measurements were 5 1/2\" H x 12 1/2\" W x
16 ½"L. We expect the 2006 Census Test Kit box to be more compact and
may, if cost effecitve, include a plastic handle (enumerators carry the
kit home with them from training, the handle will assist with this).

**Overview: 2006 Census Test Service Requirements**

The work for this project is projected to be performed in (6) phases.
The phases of this project include:

Phase I. Equipment receipt, functional testing and acceptance, develop
kit box prototype and storage:

> **January, 2005 -- April 22, 2005**

Phase II. Test, Integrate, Kit and Ship up to 510 devices to the LCOs
for the Address Canvass Census Operation.

**February 15, 2005 -- May 15, 2005**

Phase III. Kit and Ship Spare Parts for the Address Canvass Operation to
the LCOs:

> **May 1, 2005 -- May 15,2005**

Phase IV. Receive, Verify functionality and clean up approximately 510
devices and parts for the

Address Canvass Census Operation***:* September 1, 2005 -- October 30,
2005**

Phase V. Test, Integrate, Kit and Ship up to **1427** PDA Kits to the
LCOs for the Non-Response Follow-Up Operation: **December 15, 2005 --
February, 7, 2006**

Phase VI. Kit and Ship Spare Parts for Non-Response Follow-up

> Operations to the LCOs for the Non-Response Follow-Up Operation:
>
> **January 15, 2006 -- February 7, 2006**

**PHASE I. REQUIREMENTS:**

Phase I: To be conducted between equipment arrival at vendor site and
April 22, 2005 (Order has been submitted to Dell).

-   Receive, inspect (ensure that unit is not physically broken), and
    verify quantity of PDAs and accessories against packing slip
    information provided by OEM and store.

    -   The equipment being delivered to WWT by Dell includes:

> ITEM Quantity

Axim X50 520 MHZ Unit with Cradle/AC Adapter/Standard

Battery/Standard Case: 1427

2200 MAH Extended Batteries: 3016

Pocket Map CF GPS Receiver: 1589

Socket 56KBPS CF Modem: 1589

Axim 12-Volt Auto Adapter: 1589

Ultra Scan 512 MB Secure Digital Cards 1589

3 Pack Styluses 1589

Axim X50 Cradle with AC Adapter 212

Axim AC Adapter/Power Cord 162

Axim Charger Adapters 200

1\. BOC expects full asset tracking of equipment and will require
documentation of receipt and counts at various times through out the
project.

TASKS:

-   Barcode PDAs with BOC GFE Asset tags

    -   The Barcode label must be placed in a specific location on the
        device. See

> Attachment 1

-   Scan OEM Service Tag Number and Census Barcode and provide an Excel
    file of these serial numbers/barcodes to BOC. The spreadsheet should
    include Receipt Date, Service Tag and CD barcode.

    -   Timing is no later than 2 weeks after receipt at WWT (in order
        to facilitate payment to Dell)

-   Identify and resolve missing component issues with DELL

> Must be completed by June, 2005

-   Remove and Package for Return to BOC:

    -   Manuals

    -   Standard Battery and Standard Battery Plastic Battery Port Cover

    -   Any other items in the PDA box that are not described in the
        above item list

-   Conduct functional test on each of the following:

    -   PDA

        -   Burn-In: **Every** PDA must be exercised for 2 hours. BOC
            will provide a Read/Write Looping Program that should be
            used to exercise the unit. The unit should be in the cradle
            during this test (not running off battery power).

            -   If any unit fails during this test it must be replaced.

            -   The cradle should be tested during this test. If any
                cradle fails during this test it must be replaced.

            -   The AC Adapter/Power Cord should be tested during this
                test. If any AC Adapters/Power cords fail during this
                test, they must be replaced.

        -   The BIOS rev must be verified during this process. The
            expected BIOS is A01 (10130400) Any units identified that
            have a BIOS other than A01 (10130400) need to be set aside
            for later operations.

> If we have fewer than 510 units that are running rev A01 (10130400)
> than enough units to get to this number need to be flashed to match
> this rev.

-   2 Extended Batteries

    -   Fully charge **each** battery and monitor draining of each
        battery for 4 hours

-   Auto Adapter

    -   Attach to 12V Power Source and PDA with Battery. Verify that
        unit begins to Charge.

-   56K Modem:

    -   Randomly select 5 modems from each shipment of modems received
        from Dell. If fewer than 35 modems have been selected when the
        last shipment is received, pull more modems from the last
        shipment to make 35.

    -   Track the shipment (date received, shipment #) that each modem
        selected came from in case we find problems.

    -   Attach modem to PDA using supplied Modem Cable. Dial out and
        connect to a server. Verify that:

        -   The modem light on the right front of the modem blinks green
            when first attached to the PDA

        -   The modem light on the left front of the modem turns solid
            green when the modem is connected to the server.

        -   If any modem fails, pull another 5 modems from the shipment
            of modems that that modem came from and test those. If any
            of those fail, test the entire shipment.

CF GPS**:**

-   Verify the Firmware version of each GPS receiver. Provide counts of
    receivers by firmware type in a file to BOC.

    -   BOC will provide a utility on the first SW image provided to WWT
        that can be used to verify the Firmware. The process to verify
        the firmware is:

> a\. The user attaches the GPS receiver into the CF slot of the device

b\. A file will be created in the root of the device called
GPSVERSION.TXT

> c\. The user can use \'file explorer\' to navigate to the root of the
> device

d\. The user can tap on the gpsversion.txt file to get the firmware
version. (The current version that we have on the Space machines is
231.000.000ES)

> e\. Close the file

-   If it is determined that the firmware version varies between units
    the BOC will determine which firmware rev to standardize on and WWT
    will need to update the firmware on the receivers that do not match
    this rev. SIRF provides a tool called SiRFFlash free of charge that
    will update the firmware rev. Details of how this is used will have
    to be worked out.

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-   Test the Accuracy of a Sample of GPS Receivers (BOC will actually
    conduct this testing at the WWT site).

    -   WWT should randomly select 5 GPS receivers from each shipment of
        receivers received from Dell. If by the last shipment 35
        receivers have not been selected, WWT will pull more receivers
        from the last shipment to get a total of 35 receivers.

    -   WWT must track the shipment (date received, shipment #) that
        each receiver selected came from in case we find problems.

    -   BOC will provide a test image to WWT that includes ESRI ArcPad
        and corrected map files created from GPS points taken when BOC
        attended the Contract kick-off meeting on January 13^th^.

    -   Once all of the GPS receivers have been received and the
        selected receivers are available, WWT will notify BOC so they
        can send staff out to test the receivers.

    -   WWT will image two PDAs using the test image provided and will
        assist BOC staff at the GPS test location.

    -   Using the two PDAs, BOC staff will verify that each of the
        selected receivers collects GPS points within the map circle. If
        a receiver does not collect good points, more receivers from
        that shipment need to be pulled and verified. WWT staff will be
        needed to assist with this.

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-   Store all devices and parts in secure, conditioned space until they
    are shipped to the Census offices.

-   Work with Census to develop a prototype kit box for the PDA unit and
    parts.

    -   The kit will include:

        -   PDA with Charged Auxillary Battery attached

        -   Cradle w/ tag attached to USB cord

        -   Imaged and Labelled 512 SD Card (inserted in device)

        -   AC Adapter/Power Cord

        -   Charger Adapter

        -   One additional Auxillary Battery

        -   Auto Adapter

        -   CF Modem w/ modem phone cord

        -   CF GPS

        -   Case

        -   3 Pack Stylus

Phase II. **Test, Integrate, Kit and Ship up to 510 devices to the LCOs
for the Address Canvass (AC) Census Operation**.

February 15, 2005 -- May 15, 2005

> **BOC would like designated technical staff at WWT to work with during
> this development process.**
>
> **BOC expects to review process plans for this phase to ensure that
> all requirements are addressed.**

**Assumptions entering this phase:**

1.  **The BIOS rev on 510 devices matches the BOC image rev by April 15,
    2005**

2.  **The firmware version on 570 GPS receivers matches the BOC required
    version by April 15, 2005**

> **3. All other Phase 1 activities have been completed by April 15,
> 2005.**

# Tasks:

-   Develop an imaging process to place the BOC image onto the Secure
    Digital Cards and replicate onto the device. It is expected that WWT
    and Dell personnel will work closely with BOC during this process.

-   Receive test images from the BOC to test the imaging/replication
    process prior to production.

-   Receive a final image from the BOC for the Denver and Dallas sites.

-   Complete a test of the production imaging, integration, QA and QC
    process with the BOC (BOC will need to sign off on the image before
    production begins).

-   Charge 1020 batteries (2 per kit) to OEM recommended levels to
    sustain charge the longest while in shipping and storage.

-   Replicate BOC provided software image onto the SD cards and label
    each card by region DN for Denver, DA for Dallas.

-   QA each SD card after imaging to ensure that the card was good and
    that the image was complete.

-   Replicate software image onto the device (via the SD card that will
    be used with that device). The units for each region must be kept
    separate at this point.

-   QA each of the devices to ensure they replicated properly (QA plan
    to be developed later)

-   Label each kit box with the OEM service tag number, Census Barcode
    number, and Region.

-   Place a BOC produced kit picture and repacking instructions in each
    kit box.

-   Attach a colored "Warning Label" (provided by BOC) to each CradleUSB
    Cord.

-   Pack and QA the kits to ensure all parts are included (assumes kit
    boxes for 510 units are ready and available).

-   Provide space for BOC to conduct a QC of the vendors work (prior to
    shipping).

Ship BOC provided quantities of kits to the Census sites. The kits
should be palletized and shrink-wrapped. The vendor is responsible for
the safe delivery of the equipment, inside delivery and removel of all
shipping pallets and trash, and all costs incurred.

**Phase III.** Kit and Ship Spare Parts for the Address Canvass
Operation to the LCOs:

> **May 1, 2005 -- May 15,2005**

The BOC has a requirement to have spare parts securely packed in
oversized boxes and shipped to the Census locations in quantities
specified by the BOC. The spare parts would have been functionally
tested during Phase 1. Extra imaged/labelled Secure Digital cards will
be included in these sets of spare parts. The BOC will provide WWT/Dell
with the proper distribution of parts to each site.

The spare parts will include:

Item Quantity

-   2200 Mah Batteries 120

-   Cradles w/AC Adapter 110

-   Charger Adapters 60

-   SD Cards (512 MB -- imaged and labelled) 60

-   Stylus 50 packs

-   Auto Adapters 60

-   Modems 60

-   GPS Receivers 60

-   RJ 11 Modem cords 60

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-   Ship the spare parts kits to the Census sites based on the
    distribution provided by the BOC. The vendor is responsible for the
    safe delivery of the equipment, inside delivery and removal of all
    shipping pallets and trash where necessary and all costs incurred.

Phase IV. Receive, Verify functionality and clean up approximately 510
devices and assorted quantities of spare parts used during the Address
Canvass Census Operation***:* September 1, 2005 -- October 30, 2005**

-   Following the Address Canvass operation, the LCOs will ship used
    equipment back to WWT to be received, functionally tested and
    cleaned-up for use in later operations.

> The following quantity of kits and spare parts should be returned to
> WWT:
>
> Item Quantity
>
> PDA Kits 510
>
> 2200 Mah Batteries 120
>
> Cradles w/AC Adapter w/ charger adapter 110
>
> Charger Adapters 60
>
> SD Cards (512 MB -- imaged and labelled) 60
>
> Stylus 50 packs
>
> Auto Adapters 60
>
> Modems 60
>
> GPS Receivers 60
>
> RJ 11 Modem cords 60
>
> With the kits broken out, the quantities would be:
>
> Item Quantity
>
> PDAs 510
>
> PDA Case 510
>
> 2200 Mah Batteries 1140
>
> Cradles 620
>
> AC Adapters 620
>
> Charger Adapters 680
>
> SD Cards 570
>
> Stylus 2190
>
> Auto Adapters 570
>
> Modems 570
>
> GPS Receivers 570
>
> RJ 11 Modem cords 570

-   The WWT must receive the equipment.

    -   The BOC will provide final counts of the number of kits and
        parts that WWT will receive from each Census Site.

    -   WWT must break down the kits and provide counts of each
        component received by Census site. Weekly reports will be
        required during this task until the equipment has been accounted
        for.

-   WWT must functionally test the equipment to ensure that it is in
    working order.

    -   Assumptions are that PDAs are all under warranty.

    -   The units have the image on them.

    -   The SD cards have the image on them.

Conduct functional test on each of the following:

-   PDA

    -   **Every** PDA must be excercised for 2 hours. BOC will provide a
        Read/Write Looping Program that should be used to exercise the
        unit. The unit should be in the cradle during this test (not
        running off battery power).

        -   If any unit fails during this test it must be replaced.

        -   The cradle should be tested during this test. If any cradle
            fails during this test it must be replaced.

        -   The AC Adapter/Power Cord should be tested during this test.
            If any AC Adapters/Power cords fail during this test, they
            must be replaced.

-   Additional Cradles and AC Adapters should be tested to make sure
    that the PDA charges when attached to the unit and cradle is plugged
    in.

-   Batteries:

    -   All batteries should be fully charged and drained 4 hours to
        make sure they hold the charge.

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-   SD Cards

    -   Verify that each card can be read and that it shows that it has
        512MB of total space (no corruption).

    -   If any cards fail, they should be set aside for the BOC and
        arrangements made with to receive replacement cards (should have
        a lifetime warranty).

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    -   Auto Adapter

        -   Plug into 12V power and to device. Make sure device charges.

    -   56Kbps Modem

        -   Connect each modem to a device and a phone line and make a
            connection. If the modem fails, run the test again with
            another device. If it it fails again, set the modem aside as
            a nonworking part.

    -   CF GPS -

        -   Connect each GPS receiver to a device. Power on the device,
            launch ArcPad, verify that the GPS receiver picks up
            coordinates (more information will be provided on this).

        -   Any device that does not pick up coordinates must be set
            aside as a nonworking part.

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-   Provide counts of working and non-working parts to BOC by October
    15, 2005 so replacement parts can be ordered in time for the
    Non-Response Follow-Up Operation.

-   Clean any functional devices so that the product can be comfortably
    used again.

Phase V. Test, Integrate, Kit and Ship up to **1427** PDA Kits to the
LCOs for the Non-Response Follow-Up Operation: **December 15, 2005 --
February, 7, 2006**

> **BOC would like designated technical staff at WWT to work with during
> this development process.**
>
> **BOC expects to review process plans for this phase to ensure that
> all requirements are addressed.**

**Assumptions entering this phase:**

The kit packing previously designed and approved will be used.

> The imaging process previously developed
>
> The GPS firmware has been updated to the BOC requirement
>
> The BIOS Rev on the units has been updated to the BOC requirement
>
> All of the equipment has been functionally tested and is working
> (including any replacement equipment received)
>
> The following items are available for integration and kitting:

Axim X50 520 MHZ Unit with Cradle/AC Adapter/Standard

Battery/Standard Case: 1427

2200 MAH Extended Batteries: 3016

Pocket Map CF GPS Receiver: 1589

Socket 56KBPS CF Modem: 1589

Axim 12-Volt Auto Adapter: 1589

Ultra Scan 512 MB Secure Digital Cards 1589

3 Pack Styluses 1589

Axim X50 Cradle with AC Adapter 212

Axim AC Adapter/Power Cord 162

Axim Charger Adapters 200

# Tasks:

-   Verify that the previously designed imaging process will work with
    the NRFU images (BOC will have new applications on the image(s)).

-   Receive test images from the BOC to test the imaging/replication
    process prior to production.

-   Receive a final image from the BOC for each of the Denver and Dallas
    sites.

-   Complete a test of the production imaging, integration, QA and QC
    process with the BOC (BOC will need to sign off on the image before
    production begins).

-   Charge 2845 batteries (2 per kit) to OEM recommended levels to
    sustain charge the longest while in shipping and storage.

-   Replicate BOC provided software image onto 1589 SD cards and label
    each card by region.

-   QA each SD card after imaging to ensure that the card was good and
    that the image was complete.

-   Replicate software image onto the device (via the SD card that will
    be used with that device). The units for each region must be kept
    separate at this point.

-   QA each of the devices to ensure they replicated properly (QA plan
    to be developed later)

-   Label each kit box with the OEM service tag number, Census Barcode
    number, and Region.

-   Place a BOC produced kit picture and repacking instructions in each
    kit box.

-   Attach a colored "Warning Label" (provided by BOC) to each Cradle
    USB Cord.

-   Pack and QA the kits to ensure all parts are included (assumes kit
    boxes for 510 units are ready and available).

-   Provide space for BOC to conduct a QC of the vendors work (prior to
    shipping).

Ship BOC provided quantities of kits to the Census sites. The kits
should be palletized and shrink-wrapped. The vendor is responsible for
the safe delivery of the equipment, inside delivery and removel of all
shipping pallets and trash, and all costs incurred.

**Phase VI.** Kit and Ship Spare Parts for Non-Response Follow-up

> Operations to the LCOs for the Non-Response Follow-Up Operation:
>
> **January 15, 2006 -- February 7, 2006**

The BOC has a requirement to have spare parts securely packed in
oversized boxes and shipped to the Census locations in quantities
specified by the BOC. The spare parts would have been functionally
tested during Phase 1. Extra imaged/labelled Secure Digital cards will
be included in these sets of spare parts. The BOC will provide WWT/Dell
with the proper distribution of parts to each site.

The spare parts will include:

Item Quantity

-   2200 MAH Batteries 162

-   Cradles w/AC Adapter 212

-   Charger Adapters 200

-   SD Cards (512 MB -- imaged and labelled) 162

-   Stylus 162 packs

-   Auto Adapters 162

-   Modems 162

-   GPS Receivers 162

-   RJ 11 Modem cords 162

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-   Ship the spare parts kits to the Census sites based on the
    distribution provided by the BOC. The vendor is responsible for the
    safe delivery of the equipment and all costs incurred.