IOTV: Interceptor’s Incremental Improvement

IOTV: key features
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The USA’s Interceptor OTV (Outer Tactical Vest) Body Armor, and its SAPI/ESAPI ceramic plate inserts, offer a significant improvement over its 1990s predecessors in terms of both weight and protection. After episodic issues with production ramp-up and quality control, this gear is widely fielded with the US Army and several allied militaries (the US Marines replaced it with the MTV). In May 2007, controversy regarding the armor’s effectiveness boiled over in the wake of a TV news feature. The US Army responded with rare public claims about a competing product, even as several high-profile legislators advocated independent civilian tests to ensure that US soldiers were really getting the best system.

Meanwhile, improvements were being made to the OTV system in response to feedback from the field. Hence the Improved OTV, whose Generation II model is now in production.

The IOTV: Improvements

older Interceptor OTV
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What’s clear is that the US Army procurement system is moving ahead on system improvements to a broad range of items. We’ll leave the question of which system is best to independent testing, and there are legitimate arguments about whether the improvements have been timely enough. What is inarguable is that the US military is moving faster than it used to – and also faster than most other militaries around the world.

The IOTV began with a body armor industry day in the spring of 2006, which subsequently attracted revised designs from vendors. The US Army’s PEO Soldier announced the new vest in April 2007, and issued the first order in June 2007.

The new vest is more than 3 pounds lighter than its predecessor, but provides an equal level of protection over an increased area by eliminating overlap and changing design features like the vest’s cut in the arm pit area, adding an integrated throat protector instead of an attachable version, and adding integrated side plate carriers. That, plus an overhead instead of a front-opening design, decrease the vest’s profile overall, but extend its coverage by 52 square inches.

Other IOTV features include:

• Quick Release: A single-stage quick release added to the front of the vest that removes the vest in 2 pieces. This is very useful to medics, who can also use an opening on the left shoulder if maintaining protection is important. It’s even more useful to soldiers trapped in overturned or submerged vehicles, which has been a consistent issue in Iraq.

• Comfort: An internal waistband moves more of the weight from the shoulders to the waist, mesh lining adds comfort, and channels/storage for those ubiquitous cables are surely appreciated.and long variants are surely a relief to the beanpole body types.

• Additions: PALS webbing for attachments is added on the front, back and sides, and more MOLLE attachments for pouches etc. are possible in front now that the opening isn’t placed there.

IOTV Generation II

In September 2009, DoD releases began referring to “IOTV Generation II.” This was actually a series of incremental revisions, led by Lt. Col. Rickey of PEO Soldier, with assistance from Point Blank. The changes were added to production vests over time, and finally attracted the official designation of “Generation II” after enough changes were made.

If you held the Generation I & II vests side by side, it might be hard to tell the difference. For operators in the field, however, even a set of subtle changes can have far-reaching effects. For example, one change set involved expanding vertical adjustment of the side plate carriers, and allowing horizontal changes. This allows IOTV to properly fit a wider variety of soldier sizes, including women. The other major Generation II change involves 2 D-Ring attachments on the front. that makes it easier to add gear, including a load-bearing system (Tactical Assault Panel) that goes beyond MOLLE velcro’s holding capacity.

As befits a product in more or less continuous development by the Army and Point Blank, minor changes of various sorts have also accumulated due to feedback from the field. The IOTV Gen II design converted back to Cordura for mesh, because the previous material was so “aggressive” that it was damaging the uniform underneath. One can imagine what that meant to the soldier’s body underneath the uniform. Another change involved streamlining the quick release cable handle to reduce pinch-points or friction, so it can weigh less and work better.

Going forward, the design itself is treated as a “DoD community” design. Point Blank, and other manufacturers, can expect to continue working with the Department of Defense community to make changes to IOTV.

Woman-friendly Generation III

Less shoulders, more chest

In 2011/12, Natick Soldier Research, Development and Engineering Center (RDEC) and Program Executive Office Soldier worked on further improving IOTV to better fit female soldiers. The smallest (x-small) IOTV II design was still found too large and long for many females, nor was it fitting female body shapes well. That’s not exactly a surprise to anyone who has designed or worn scuba buoyancy compensator vests.

The IOTV III design introduces more sizes. It has 10 measurement sizes, with narrow shoulders and more chest space. Smaller plates are inserted inside the vest from new locations. The emergency release has also been reworked. Fielding started in the 2nd half of 2012, to see how it fit out of the dressing room.

Contracts & Key Events

IOTV: Components
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Unless otherwise specified, the U.S. Army Research, Development, and Engineering Command (ARDEC) at Aberdeen Proving Ground, MD issues any contracts related to the IOTV. Orders for plate inserts to the IOTV are handled in a separate DID article, as they are common to other vest designs as well.

Feb 26/14: BAE Systems. BAE Systems Aerospace & Defense Group in Phoenix, AZ receives a maximum $80 million firm-fixed-price, indefinite-delivery/ indefinite-quantity contract modification, exercising option year 2 for IOTVs and individual repair kits. The FY 2015 award should wrap up this contract.

Work will be performed in Arizona and Pennsylvania until Feb 27/15, on behalf of the US Army and USAF. The Defense Logistics Agency Troop Support in Philadelphia, PA manages this contract (SPM1C1-12-D-1027, PO 0102)

Feb 25/14: PBE. Protective Products Enterprises Inc. in Sunrise, FL receives a maximum $76.7 million firm-fixed-price, indefinite-delivery/ indefinite-quantity contract modification, exercising option year 2 for IOTVs and individual repair kits. The FY 2015 award should wrap up this contract.

Work will be performed in Arizona and Pennsylvania until Feb 27/15, on behalf of the US Army and USAF. The Defense Logistics Agency Troop Support in Philadelphia, PA manages this contract (SPM1C1-12-D-1026, PO 0102).

Oct 20/13: BAE Systems. BAE announces that DLA has issued more orders, worth about $60 million for IOTVs and repair kits, to be delivered by December 2014. They have received more than $140 million from this contract so far.

Feb 27/13: BAE Systems. DLA issues a maximum $78.3 million modification, exercising their firm-fixed-price contract’s 1st option year. Work will be performed in Pennsylvania and Arizona, with a Feb. 27/14 performance completion date.

That makes it very similar to PBE’s award 2 days earlier. Indeed, the amount is different, but the specific purchase order number is the same. (SPM1C1-12-D-1027, PO 0009).

Feb 25/13: PBE. Point Blank subsidiary Protective Products Enterprises Inc. (PPE) in Sunrise, FL receives a $79.5 million contract modification, exercising the 1st option year for IOTVs to equip the US Army and Air Force, using FY 2013 and 2014 working capital funds.

Work will be performed in Florida until Feb 27/14. The Defense Logistics Agency Troop Support group in Philadelphia, PA manages the contract (SPM1C1-12-D-1026, PO 0009). Recall the May 3/12 merger of PPE with Point Blank, under Sun Capital Partners.

Dec 10/12: BAE. BAE Systems announces a $35 million order from the U.S. Defense Logistics Agency (DLA) for IOTVs, as part of the March 1/12 contract. BAE has received a total of $83 million under the contract so far.

IOTVs are produced at the company’s Jessup, PA facility, and this order is scheduled to be complete by October 2013. Since 2007, BAE Systems has produced more than 800,000 OTV and IOTV body armor vests for U.S. troops serving in Iraq, Afghanistan and around the world.

May 3/12: PBE + PPE. Point Blank Enterprises, Inc. has finalized its merger with USMC MTV vest manufacturer Protective Products Enterprises, LLC. Both companies are owned by affiliates of Sun Capital Partners, a leading private investment firm specializing in leveraged buyouts.

April 26/12: PBE. Point Blank Enterprises, Inc. announces a firm-fixed price contract from the Defense Logistics Agency to provide IOTV and OTV components to support U.S. Army and USAF personnel. This contract has a maximum value of $119.9 million and the Company expects the first year’s value to be about $50 million, with 3 more 1-year option awards thereafter.

March 1/12: BAE. BAE Specialty Defense Systems in Jessup, PA wins a maximum $108.5 million firm-fixed-price contract for IOTVs, OTVs, and individual repair kits, for the US Army, Air Force, and Marine Corps. Subsequent releases place the contract’s maximum value at $267 million, over a 4-year period.

There were 5 responses to the Web solicitation, FY 2012/2013 Defense Working Capital Funds will pay for the buy, and the base contract runs to Feb 28/13. US Defense Logistics Agency Troop Support in Philadelphia, PA manages the contract (SPM1C1-12-D-1027).

May 20/11: PPE. USMC MTV vest manufacturer Protective Products Enterprises in Sunrise, FL wins a $26.9 million firm-fixed-price, indefinite-delivery/ indefinite-quantity contract for 48,000 IOTVs in the Army’s Operation Enduring Freedom (Afghan theater’s ACU MultiCam) camouflage pattern.

Work will be performed in Sunrise, FL, with an estimated completion date of Feb. 1/12.The U.S. Army Contracting Command at Aberdeen Proving Ground, MD solicited bids, with 5 bids received (W91CRB-10-D-0010).

May 20/11: KDH. KDH Defense Systems in Eden, NC won a $34.3 million firm-fixed-price, indefinite-delivery/ indefinite-quantity contract for 60,343 IOTVs in the Army’s ACUPAT universal camouflage pattern.

Work will be performed in Eden, NC, with an estimated completion date of Jan 30/ 12. The U.S. Army Contracting Command at Aberdeen Proving Ground, MD solicited bids, with 5 bids received (W91CRB-09-D-0049).

Dec 26/10: BAE Systems announces a $35 million contract from the U.S. Army for 60,000 IOTVs. Production of the vests will take place at BAE Systems’ facility in Jefferson City, Tennessee, with deliveries scheduled through July 2011.

Feb 26/10: KDH Defense Systems, Inc. in Johnstown, PA received an $87 million firm-fixed-fee contract for 150,000 IOTVs. This is one of an ongoing set of potential awards. Work will be performed in Eden, NC, with an estimated completion date of August 2010.

Bids were solicited on the World Wide Web, with 8 bids received by the U.S. Army Research Development & Engineering Command, Contracting Center in Aberdeen Proving Ground, MD (W91CRB-09-D-0049).

Jan 19/10: The US Army is looking at new materials that it can incorporate into protective systems like IOTV, but the solicitation is information-only and makes no commitments. FedBizOpps #W91CRB10RBALFIBER:

“The United States Army Program Manager Solider Protective & Individual Equipment (PM-SPIE) is requesting information regarding the manufacture of ballistic fiber for soft body armor. Information requested includes vendor capabilities and limitations with regard to the production of high performance ballistic fibers, to include material capabilities, ballistic performance data package (ballistic testing shall be conducted at independent NIJ certified ballistic laboratory), place of manufacture, source of materials, proven production capacity and surge rate, as well as all known interoperability issues with all equipment currently used by US Army. Additionally, information regarding vendors products currently in production is also requested. Ballistic package (fabrics, non-woven, and other forms of materials using ballistic fibers) must meet Improved Outer Tactical Vest (IOTV) ballistic performance requirements at areal density less than 0.85 pound per square foot. This sources sought is for information and planning purposes only…”

Dec 29/09: PBE. Point Blank Body Armor, Inc. in Pompano Beach, FL receives a $26.5 million firm-fixed-price contract for 44,501 more IOTVs. Work is to be performed in Pompano Beach, FL, with an estimated completion date of April 30/10. Bids were solicited on the World Wide Web, with 3 bids received (W91CRB-09-C-0124).

Sept 9/09: PBE. Point Blank Solutions, Inc. in Pompano Beach, FL announces a $38.5 million contract to produce the New, Generation II IOTV. Under the terms of the contract (W91CRB-09-C-0124), the Company will begin production in October 2009 and expects to complete the order by January 2010. The firm’s release adds that this contract award is not part of the IOTV Main Buy, which is W91CRB-07-0079.

Aug 14/09: KDH. Small business qualifier KDH Defense Systems, Inc. announces that, after over a year of fierce competition and a rigorous selection process, it has been awarded a 5-year, Indefinite Delivery/ Indefinite Quantity contract from the U.S. Army REDCOM Acquisition Centerc, to supply the U.S. Army with IOTVs (W91CRB-09-D0049).

The contract includes the production and delivery of up to 736,000 total IOTVs and 253,000 Deltoid and Axillary Protection Systems (“DAPS”). Individual orders will be placed as required. Notice of this award came just days after KDH had begun first article production for a firm-fixed-price contract to supply the Defense Logistics Agency with 65,000 IOTVs. President and CEO Dave Herbener:

“It was a bit unexpected, but we have been planning and positioning ourselves for some time… We have been patiently watching market trends, gaining relevant experience with smaller scale contracts, and improving the efficiency in our process… We have concentrated efforts to lower the cost and improve the performance of our soft ballistic packages in order to provide quality systems, on time, and at a fair and reasonable price.”

In June 2009, KDH says it was awarded a sub-contract by the Industries of the Blind, Inc. in support of the U.S. Army’s Universal NAPE Pad procurement. NAPE pads fit on the backs of soldiers’ helmets.

Feb 5/09: BAE. BAE Systems Security & Survivability Systems announces that it will be manufacturing 75,000 IOTV vests under a $43.7 million contract.

The contract will restore 100 jobs at the Grainger County, TN plant, and BAE Systems officials anticipate returning to full production at the Jefferson and Grainger county, TN facilities by the end of March 2009. Production is expected to be complete by the end of 2009’s third quarter, with a peak monthly production rate of 25,000 vests per month.

Aug 18/08: Interceptor vest production continues. Point Blank Solutions, Inc. announces a $22.2 million contract from the Defense Supply Center, Philadelphia for 45,000 of the old model Outer Tactical Vests. Pursuant to the terms of the contract, the Company expects to complete production by January 2009, at the latest.

July 3/08: PBE. Point Point Blank Body Armor, Inc. in Pomapano Beach, FL wins an $86.2 million contract to produce 150,000 IOTVs at a rate of 25,000 per month for 6 months. Production will begin immediately, and will be complete by Dec 31/08. Two bids were solicited on March 18/08, and 2 bids were received by the U.S. Army Research, Development and Engineering Command (ARDEC) at Aberdeen Proving Ground, MD (W91CRB-07-C-0085).

The order is actually the product of an important procurement delay. In mid- 2007, the US Army awarded 2 contracts for its initial fielding requirement of 230,000 IOTVs. The other 736,000 were slated for a follow-on full and open competitive solicitation, bringing the total to the desired 966,000 IOTVs. That solicitation was released in November 2007, but the RFP was delayed at the request of potential bidders. Hence the need for a bridge buy, to keep production going and units supplied while the larger RFP is delayed.

At present, IOTV armor can be made by Point Blank or by Specialty Defense Systems. While the Army found that both companies had the manufacturing capabilities to meet the Bridge Buy IOTV production and performance requirements, the “best value” nature of the contract means that there is only one winner for the bridge buy. See also Point Blank release.

Nov 20/07: Industrial. BAE Systems formally opens a 33,000 square-foot facility in Grainger County, eastern Tennessee, to manufacture IOTV vests. The company has more than 1,000 employees located at the Jefferson City and Kingsport, Tennessee facilities. To date, IOTV shipments exceed 70,000 vests, with approximately 400 vests to be produced at the Grainger facility per day.

The facility creates 185 new jobs, and during 2008, a $700,000 grant secured by the Douglas Cherokee Economic Development Authority will expand the Grainger facility from 33,000 to 53,000 square feet. The new facility also qualifies the Grainger community for a $1.5 million grant from the U.S. Department of Commerce and Economic Development Administration, in order to support the development of a new local wastewater treatment facility. BAE release.

June 14/07: BAE. BAE Systems receives a $112 million contract for IOTVs. The June 8/07 contract is awarded at the same time as its competitors Specialty Defense Systems and Point Blank – but the contract is not announced on the Pentagon’s DefenseLINK per regulations, and related announcements note only 2 bids received. Source.

June 14/07: SDS. Specialty Defense Systems in Dunmore, PA received an $112 million firm-fixed-price contract for improved outer tactical vests. Work will be performed in Dunmore, PA and is expected to be complete by March 31/08. There were 2 bids solicited on May 21, 2007, and 2 bids were received (W91CRB-07-C-0084).

Specialty Defense would later become part of BAE.

June 14/07: PBE. Point Blank Body Armor Inc. in Pompano Beach, FL received a $52.7 million firm-fixed-price contract for improved outer tactical vests. Work will be performed in Pompano Beach, FL and is expected to be complete by March 31/08. There were 2 bids solicited on May 21, 2007, and 2 bids were received (W91CRB-07-C-0085).

Additional Readings

• US Army (Sept 18/12) – Deploying Soldiers test new female body armor prototype.

• US Army RDECOM (May 11/11) – Improved Fit and Performance of the IOTV for Female Soldiers [PDF]

• Police One (Sept 13/12) – Why understanding the type of protection your body armor provides is critical for survival

• US GAO (Oct 16/09) – Warfighter Support: Independent Expert Assessment of Army Body Armor Test Results and Procedures Needed Before Fielding

• US Army (Jan 25/08) – Soldiers Try out Improved Body Armor. U.S. Army Europe’s 2nd Brigade Combat Team, 1st Armored Division is training with the IOTV, in preparation for a Spring 2008 deployment to Iraq.

• US GAO (April 26/07, #GAO-07-662R) – Defense Logistics: Army and Marine Corps’ Individual Body Armor System Issues