Location: 141 acres of the 300-acre Bannister Federal Complex.

Date Established: 1949.

Present Mission:

Primary - Produce and procure nonnuclear electric, electronic, electromechanical, mechanical, plastic, and nonfissionable metal components for the Department of Energy (DOE) weapons program in support of the stockpile management restructuring initiative.

Secondary - Support environmental restoration and waste management mission objectives, and establish technology partnerships in the pursuit of industrial partnership initiatives.

Employees: 3,704 (as of October 1996), including 315 associates at AlliedSignal Federal Manufacturing & Technologies, New Mexico (ASFM&T/NM).

Annual Budget: $382 million target budget for fiscal year 1997.

Cognizant Secretarial Officer (CSO): Assistant Secretary for Defense Programs (DP) is the lead CSO. The principal DP office is the Office of Nuclear Weapons Management (DP-22); the Assistant Secretary for Environmental Management (EM) also has programmatic responsibility--the principal EM office is the Office of Southwestern Area Programs (EM-45).

Responsible Operations/Area Office: Albuquerque Operations Office (AL)/Kansas City Area Office (KCAO)

Integrating Contractor: AlliedSignal Federal Manufacturing &

Technologies/Kansas City (ASFM&T/KC)

Subcontractors: Commercial and Mechanical Construction: Rand & Son Construction

Engineering: Black & Veatch; Burns & McDonnell; Clark, Richardson & Biskup (CRB); George Butler Associates (GBA)

Industrial Wastewater Pretreatment Facility (IWPF): Professional Services Group (PSG)

Environmental Analysis: Pace Analytical Services

Fissile Material: Plutonium-beryllium sources containing 1.2 grams of plutonium-239 as a sealed source in analytical equipment.

Major Site Activities: Site management operations at the KCP consist mainly of hazardous waste storage in preparation for off site treatment or disposal.

The KCP environmental restoration program is addressing solid waste management units (SWMUs) and total toxic organics (TTOs).

The stockpile management restructuring initiative involves downsizing and consolidation of the KCP over a four year period.

Construction activities include: (1) replace Microminiature Electronic Facility, (2) replace Emergency Notification System, (3) replace Temperature and Humidity Condition Systems, (4) upgrade Materials Engineering Laboratory, (5) consolidate non-nuclear processes, (6) upgrade life safety, and (7) upgrade to meet seismic standards.

The Kansas City Plant (KCP) is situated on approximately 141 acres of the 300-acre Bannister Federal complex located within the city limits, 12 miles south of downtown Kansas City, Missouri. The plant shares the site with nine other Federal agencies: Federal Aviation Administration, Defense Finance and Accounting Service, U.S. Marine Corps, General Services Administration (GSA), Internal Revenue Service, National Oceanic and Atmospheric Administration, and the National Logistics Support Center.

The Plant was established in 1942 to build aircraft engines for the U.S. Navy. After World War II, the site was used for storage and in 1949 was selected to manufacture non-nuclear components for nuclear weapons. In the early 1960s, the General Services Administration began warehouse operations in the western portion of the site.

The KCP is a major operational facility engaged in the production of non-nuclear weapons components for the Department of Energy (DOE) nuclear weapons program. The principal mission of AlliedSignal Federal Manufacturing and Technologies/Kansas City (ASFM&T/KC), the integrating contractor, is to serve DOE by producing and procuring non-nuclear electric, electronic, electromechanical, mechanical, plastic, and non-fissionable metal components for the DOE nuclear weapons program. No operations directly involving radioactive materials or explosives normally associated with nuclear weapons are assigned to the KCP.

Currently, the non-nuclear production work maintains the existing stockpile in support of the draft Stockpile Stewardship and Management Restructuring Initiative. Due to the change in the DOE mission, a study was conducted in 1994, titled the Stockpile Stewardship and Management Programmatic Environmental Impact Statement, to review either relocation of production operations from the KCP to various DOE laboratories or significant downsizing of production operations to match future projected workload and to reduce cost. On February 29, 1996, the Secretary of Energy announced the preferred option: continue the KCP mission in support of the stockpile management restructuring initiative, which includes downsizing production operations at KCP to match future workloads and to reduce cost.

DOE's non-nuclear weapons manufacturing processes at the KCP will be consolidated. Thirteen weapon technologies are being relocated from DOE's Mound, Pinellas, and Rocky Flats Plants to the KCP. The stockpile management restructuring initiative will downsize and consolidate the KCP and reduce the plant from 3.2 million square feet to approximately 1.8 million square feet for defense program activities. It is planned for the Technology Transfer Center and the Manufacturing Support Building facilities to be totally emptied of defense program activities. All operations and support functions required for the non-nuclear fabrication mission are planned to be accomplished within the reduced floor space of the Main Manufacturing Building. The downsized KCP facility is planned to consist of the following major factories and product-oriented departments: Electronic Factory, Mechanical Factory, Engineer Materials Factory, Joint Test Assembly and Special Electronic Assembly Department, Reservoir Fabrication and Assembly Department, and Transportation Safeguards Department. Facility modification to establish the downsized and consolidated KCP con-figuration will take approximately four years.

The Albuquerque Operations Office (AL) is responsible for programs related to nuclear weapons production, stockpile maintenance and surveillance, and field non-nuclear testing. AL provides policy and guidance to the KCP site. At this time, the Area Manager of the Kansas City Area Office (KCAO) has line management responsibility for activities related to manufacturing non-nuclear components for the DOE nuclear weapons program and for contractor oversight at KCAO. The KCAO consists of three offices: the Office of Resource Management and Security, the Office of Technical Management, and the Office of Stockpile Support.

The KCP site is operated by ASFM&T/KC under a cost plus award fee contract (DE-AC04-76-DP00613) with DOE. The Manager, KCAO, is the Administrative Contracting Officer for the contract. The contract was renewed on April 1, 1995, and expires five years from that date. As of October 1996, ASFM&T/KC has 3,704 associates, which includes 315 associates at ASFM&T/New Mexico facilities.

Waste management operations at the KCP consist mainly of hazardous waste storage in preparation for offsite treatment or disposal. Small quantities of low-level radioactive waste are also generated. Some waste is considered classified for national security reasons, due to the nature of the generating process and/or constituents. All classified hazardous wastes were shipped offsite to Eagle-Picher for sanitization and reclamation. Sanitization on site is planned for non-hazardous classified waste. The KCP performs no onsite waste disposal. Treatment operations are limited to industrial waste water pretreatment and selective recycling. The disposal of solid and liquid sanitary waste (plant trash, construction debris, and plant sewage) is funded through general plant operating funds.

The stockpile management restructuring initiative is a four-year downsizing and consolidation of the KCP from 3.2 million square feet to 1.8 million square feet, and personnel reduction from 3,382 to approximately 2,400 employees. Programmatic activities will be affected by the effort to downsize many of the facilities within the Main Manufacturing Building due to reduced schedules, privatization, and im-proved efficiency of operations. This project involves the consolidation of equipment and process operations in areas of the Main Manufacturing Building, Technology Transfer Center (TTC), and Manufacturing Support Building (MSB).

KEY FACILITIES

Main Manufacturing Building and Primary Support/Production Buildings

The site is dominated by the Main Manufacturing Building, a low-hazard facility constructed in 1942 that houses the key manufacturing operations of the KCP. In addition, the following buildings support the Main Manufacturing Building: (1) Polymer Building, (2) High Power Laboratory, (3) Mold Heating and Cooling Building, (4) Plating Building and Spray Mask Facility, (5) Technology Transfer Center, (6) Special Processes Building, and (7) Manufacturing Support Building. The Main Manufacturing Building provides approximately 2.6 million square feet of contiguous space. This space is shared between the DOE and the GSA. The DOE has control of, or permit to, approximately 2.07 million square feet of space within this building. In addition to the Main Manufacturing Building, the site has approximately 1.18 million square feet of space within additional buildings.