Back to news

February 4, 2021 | International, Aerospace, Naval, Land, C4ISR, Security

As mission-capable rates languish, Pentagon should embrace digital engineering

Ben Kassel and Bruce Kaplan

While many Pentagon initiatives face a change of course under new Defense Secretary Lloyd Austin, its digital engineering strategy deserves a push forward.

The strategy, issued in 2018 by then-Under Secretary of Defense for Research and Engineering Michael Griffin, aimed to help military services harness modern sustainment methods like additive manufacturing, digital twin and augmented reality. For the Department of Defense, enterprisewide implementation of these techniques would lower costs, increase weapon systems' mission-capable rates and afford flexibility in fleet modernization.

But digital engineering requires digital, 3D data — and the DoD doesn't have enough.

Modern sustainment practices hinge on the availability of what's known as the model-based definition, 3D models and digitized descriptive information for a system or component. Using computer-aided design programs, engineers can manipulate the data to enable practices like condition-based maintenance, eliminating weapon systems' unnecessary downtime. Digital data can facilitate seamless transit from original equipment manufacturers, or OEM, to procurers and sustainers in the field and at maintenance depots worldwide.

However, the technical data for most weapons systems remains elusive to the services and their program management offices, or PMO, or the datasets are available only in 2D documentation, such as blueprints.

Meanwhile, readiness suffers. Of 46 weapons systems reviewed by the Government Accountability Office, only three achieved annual mission-capable targets at least five times between 2011 and 2019. More than half (24) failed to meet their goal even once, according to GAO's November 2020 report.

The KC-13OJ Super Hercules air refueler and the MV-22B Osprey tiltrotor were among the programs to miss their target all nine years. GAO cited inaccessible technical data as a contributing factor for both programs. Of the Super Hercules, the report says: “The Navy and Marine Corps were unable to obtain the technical data of the aircraft ... the lack of the technical data compromises [their] ability to analyze and resolve sustainment issues.” Similar concerns were raised about the P-8A Poseidon anti-submarine aircraft, saying “technical data needed for maintenance has not been readily available to the Navy.” Dozens of systems, including the F-35 fighter jet, face similar obstacles.

Notably, the GAO report referred not to 3D, model-based data but rather legacy incarnations: blueprints and documents that may have been converted “digitally” into PDFs. This is a far cry from the machine-readable formats required to use digital engineering technologies across the enterprise.

The GAO cited the production of 170 “structural repair manuals” as a means of narrowing the Osprey's technical data gaps. The labor-intensive replication of physical documents — the PMO projected five years to deliver all of them — is a piecemeal solution, at best. Troublingly, modern sustainment methods seem beyond the reasonable expectation of not just PMOs but even forward-looking organizations like the GAO.

To foster its DoD-wide implementation, the digital engineering strategy needs reinforcement, which could take the following forms:

  • Champion the availability of model-based technical data in policy. Modern sustainment requires a shift from decadesold practices. Paper data that supports secondhand manuals and haphazard 2D-to-3D conversion should no longer be the norm. Services cannot lead this transition on their own, however. Federal guidance on the acquisition, creation, use and management of authentic, model-based technical data would jump-start the movement toward digital sustainment.
  • Educate PMOs to acquire technical data rights strategically. Policy must be partnered by the right mindset. One reason PMOs don't have technical data is that sometimes they never asked for it. An afterthought at the time of procurement, technical data is often overlooked until maintenance is needed. Then it's too late — or too expensive — to acquire the needed rights. Leadership can encourage PMOs to identify potential sustainment solutions — and the technical data rights needed to execute them — at the time of acquisition.
  • Assert the government's rights to model-based technical data. A sea change in sustainment depends on building unprecedented trust between OEMs and PMOs. OEMs understandably need to protect intellectual property, but their grip on model-based technical data must loosen for digital sustainment to flourish at scale. This can be accomplished without OEMs surrendering their competitive advantage. In many cases, OEMs need not transfer custody of the data itself for sustainment activities. Limited-rights agreements and trusted third-party arrangements can be tailored to enable data availability only when needed or to execute specific solutions. Giving OEMs confidence in these approaches will entail extensive dialogue and commitment by DoD leaders. Given the GAO's assessment, seeking a breakthrough is worth the attempt.

Operationalizing the DoD strategy requires work in other areas as well, particularly in removing intra- and inter-organizational stovepipes, and securing the data's transmission and storage. But the first step toward a model-based sustainment enterprise is ensuring the availability of modern technical data. This need will only grow more crucial.

Today's sustainment practices too closely resemble those of 30 years ago, not what they should be 30 years from now. We're already playing catch up. It's time to view sustainment with 3D glasses.

Ben Kassel is a senior consultant at LMI. He previously worked with the U.S. government on defining and exchanging technical data used for naval architecture, marine and mechanical engineering, and manufacturing. Bruce Kaplan is a fellow at LMI. He previously served as technical director of logistics for research and development at the Defense Logistics Agency.

https://www.c4isrnet.com/opinion/2021/02/03/as-mission-capable-rates-languish-pentagon-should-embrace-digital-engineering/

On the same subject

  • US Army triggers design competition for future attack reconnaissance helicopter

    October 4, 2018 | International, Aerospace

    US Army triggers design competition for future attack reconnaissance helicopter

    By: Jen Judson WASHINGTON — The U.S. Army has kicked off a major design competition for its Future Attack Reconnaissance Aircraft by releasing a request to industry on Oct. 3 to submit plans that could lead to a chance to build flyable prototypes in just a few years. The service, in June, released a draft solicitation that outlined its intention to get two different helicopter prototypes flying in 2023. The effort is part of the Army's larger move to procure a family of Future Vertical Lift, or FVL, aircraft in the early 2030s, if not sooner. The Army has been talking about procuring an FVL family of helicopters for the better part of a decade and has debated whether to prioritize the pursuit of a medium-lift helicopter to replace UH-60 Black Hawks and AH-64 Apache helicopters. Alternatively, the service was considering buying an armed reconnaissance helicopter to fill the gap left by the OH-58 Kiowa Warrior's 2014 retirement. With the advent of the Army Futures Command and its focus on six modernization priorities, of which FVL is third, progress is being made at lightning speed to make FVL a reality. The service, through an FVL Cross-Functional Team, led by Brig. Gen. Wally Rugen, has settled on going after both a long-range assault helicopter and a Future Attack Reconnaissance Aircraftsomewhat back-to-back. But the FARA procurement plans are fast-paced and lead straight to a winner through a fly-off competition, which deviates from the way the Army has gone about its future medium-lift helicopter development. While the Army collected designs, reviewed them and selected two teams to build prototypes to fly in a Joint Multi-Role technology demonstration for a medium-lift aircraft, the results will simply inform requirements for the Army to move into a program of record where the service will make a determination on how it will compete, build and procure a long-range assault variant of FVL. With the FARA competition, the Army plans to award four to six initial design contracts in June of 2019, and then nine months later — to avoid camping out in the PowerPoint stage — the service will choose up to two designs to move forward in fiscal 2021 with a fly-off planned to start in the first quarter of 2023 (November 2022 to be specific, according to the solicitation). The Army will choose a winner and move forward into a milestone appropriate to advance the procurement of the helicopter, whether that is a technology development phase or engineering and manufacturing development or even a production phase, Rugen told a small group of reporters in an Oct. 3 media roundtable. It all depends on where the technology stands following the fly-off and what phase of the acquisition process the Army will enter once it chooses a winner, Dan Bailey, the Army's JMR-TD director, said in the interview. “The Army currently lacks the ability to conduct armed reconnaissance, light attack, and security with improved stand-off and lethal and non-lethal capabilities with a platform sized to hide in radar clutter and for the urban canyons and mega cities,” the solicitation states. The helicopter would be the “ ‘knife-fighter' of future Army Aviation capabilities” in a small package with “maximized performance,” it describes. The Army doesn't want to carve out requirements in granite, according to Rugen, and intends to be flexible as technology capability unfolds in the program, but the solicitation does state it wants a 40-foot maximum rotor diameter, and the fuselage should also not exceed 40 feet in width. By staying flexible, the Army hopes to steer clear of some of the mistakes it has made in the past attempting to acquire an armed reconnaissance helicopter. The Army failed three times to procure a new aircraft — the most memorable being the cancellation of the Comanche helicopter program in 2004 after two aircraft were built and $6.9 billion was spent. Rugen said the Army also wants to make sure affordability considerations are driven into the program and the designs from the beginning are a top requirement for industry to consider. The Army also wants the designs to incorporate the Improved Turbine Engine Program, or ITEP,engine that is being competitively developed to replace the engines in Black Hawks and Apaches. The Army is close to choosing a winner from two teams designing engines to move into the engineering and manufacturing development phase of the program within the next few months. The Army plans to spend approximately $15 million per industry participant in the initial design phase. Participants would receive $8.5 million in FY19 and $6.5 million in FY20. The two participants selected to continue into the prototype phase of the program would receive about $735 million each from FY20 to FY23. Rugen and Bailey said industry interest following the release of the draft solicitation in June has been higher than anticipated and included both industry partners that were not expected and all of those that were. Bailey said that, based on industry interest and participation so far, choosing six designs would be a competitive process because there are more than six possible entrants that have expressed interest in submitting designs. Tim Malia, Sikorsky's program director for FVL light development, told Defense News in a recent interview that the Lockheed Martin-owned company planned to use its X2 technology that is used in its S-97 Raider coaxial helicopter program as the centerpiece to its design offering for the FARA competition. The company is already scaling its X2 technology used in Raider up to a medium-lift aircraft — called the SB-1 Defiant that is participating in the JMR technology demonstration and expected to fly by the end of the year. Malia said it would not be difficult to scale the helicopter from the 34-foot main rotor diameter size of the Raider to the desired 40-foot diameter rotor blades envisioned for FARA. The company has also been working on designs to outfit Raider or any aircraft it builds with X2 technology with the ITEP engine. Sikorsky announced Oct. 3 that its Raider aircraft exceeded 200 knots in a flight test at its West Palm Beach, Florida, flight test center. Bell, which has been flying its V-280 Valor til-trotor helicopter as part of the JMR-TD effort for the better part of a year, continues to hold tight its plans for a design to submit to the FARA competition. https://www.defensenews.com/land/2018/10/03/us-army-triggers-design-competition-for-future-attack-reconnaissance-helicopter

  • Space Development Agency orders 8 satellites to track hypersonic weapons

    October 6, 2020 | International, C4ISR

    Space Development Agency orders 8 satellites to track hypersonic weapons

    Nathan Strout WASHINGTON —SpaceX and and L3 Harris will contribute satellites to track hypersonic weapons to the Space Development Agency's planned mega-constellation, with the nascent agency announcing it had selected the two companies to build its first wide field of view satellites Oct. 5. Under the contracts, each company will design and develop four satellites equipped with wide field of view (WFOV) overhead persistent infrared (OPIR) sensors. Operating in low Earth orbit, the sensors will make up the inaugural tranche of the SDA's tracking layer—the Pentagon's new effort to track hypersonic weapons from space. “This SDA tracking layer is going to consist of a proliferated, heterogeneous constellation of WFOV space vehicles that provide persistent global coverage and custody capability. That's going to combine with activities in the Missile Defense Agency as they build toward their Hypersonic and Ballistic Tracking Space Sensor (HBTSS) medium field of view (MFOV) space vehicles,” Acting Deputy Undersecretary for Research and Engineering Mark Lewis told C4ISRNET. According to the announcement, SpaceX will receive $149 million while L3 Harris will receive $193 million. According to SDA Director Derek Tournear, the awards were the result of a full and open competition, with the selection based purely on technical merit. SpaceX has made waves with its Starlink constellation—a series of satellites built to provide commercial broadband from low Earth orbit—and the Department of Defense has tested using Starlink to connect various weapon systems. However, the company does not have a history building OPIR sensors. According to Tournear, the company will work with partners to develop the sensor, which it will then place on a bus it is providing. SpaceX already has a production line in place to build a bus based on its Starlink technologies, added Tournear. “SpaceX had a very credible story along that line—a very compelling proposal. It was outstanding,” he said. “They are one of the ones that have been at the forefront of this commercialization and commodification route.” L3 Harris will develop an OPIR solution based on decades of experience with small satellites, small telescopes and OPIR technologies. “They had an extremely capable solution. They have a lot of experience flying affordable, rapid, small satellite buses for the department,” noted Tournear. “They had the plant and the line in place in order to produce these to hit our schedule.” Tracking hypersonic weapons The contracts are the latest development as the SDA fleshes out its National Defense Space Architecture (NDSA), a new constellation to be comprised of hundreds of satellites primarily operating in low Earth orbit. These satellites are expected to make up tranche 0 of the SDA's tracking layer, which will provide global coverage for tracking hypersonic threats. The glue that holds the NDSA together will be the transport layer, a space-based mesh network made up of satellites connected by optical intersatellite links. Like most planned SDA satellites, WFOV satellites will plug directly into that network. “The idea is it connects to the National Defense Space Architecture—the NDSA transport layer—via optical intersatellite links,” said Lewis. “And that will enable low latency dissemination for missile warning indications. It will provide track directly to the joint war fighters.” SDA issued two contracts in August for its first 20 transport layer satellites. York Space Systems was awarded $94 million to build its 10 satellites, while Lockheed Martin was awarded $188 million. That transport layer capability is essential to the tracking layer's mission. Because they are so much closer to the Earth's surface than the U.S. Space Force's missile tracking satellites in geosynchronous orbit, the WFOV sensors will naturally have a much more limited field of vision. In order to track globe traversing hypersonic missiles, the WFOV satellites will have to work together. Once the first satellite picks up a threat, it will begin tracking it until it disappears over the horizon. During that time, it is expected to transmit its tracking data to other WFOV satellites over the transport layer. So as the first satellite loses sight of the threat over the horizon, the next WFOV is ready to pick it up, and so on and so forth. From there, the WFOV satellites will pass the tracking data — either directly or via the transport layer — on to the medium field of view satellites being developed by the Missile Defense Agency as their HBTSS. “SDA is developing the low cost proliferated WFOV space vehicles that provide the missile warning and the tracking information for national defense authorities, as well as tracking and cueing data for missile defense elements,” explained Lewis. “Meanwhile, the Missile Defense Agency is developing the high resolution HBTSS MFOV space vehicles — those can receive cues from other sources including the WFOV system—and they'll provide low latency fire control quality tracking data.” “The MFOV HBTSS satellites will then be able to hone in and actually be able to calculate the fire control solution for that missile, send those data to the transport satellites with a laser comms system ... and then the transport system will disseminate that to the weapons platform as well as back to [the continental United States, where MDA can broadcast that information],” added Tournear. MDA issued $20 million contracts to Northrop Grumman, Leidos, Harris Corporation and Raytheon to develop HBTSS prototypes in Oct. 2019. Tournear noted that proposals for HBTSS “are being written as we speak.” Together, HBTSS and the SDA's tracking layer are meant to provide the data needed to take out hypersonic threats—which Congress is increasingly concerned by. “It's part of an integrated DoD OPIR strategy. So the wide field of view sensors and the medium field of view sensors are really integral to this whole NDSA system and legacy strategic missile warning capability,” said Lewis, praising MDA and SDA for working together to build a heterogeneous solution. Spiral development Of course, this initial tranche won't provide global coverage up front. As part of its spiral development approach, SDA plans to continuously add satellites to its mega-constellation in two-year tranches, with each tranche including more advanced technology. The tracking layer is not expected to reach global coverage until 2026, said Tournear. But as the constellation is built out, the more limited initial capabilities will be used to help integrate the space-based assets with war fighters. “We call tranche 0 our war fighter immersion tranche,” said Tournear. “What that means is, its goal is to provide the data in a format that the war fighters are used to seeing on tactical timelines that they can be expected to see once we actually become operational. The whole purpose of tranche 0 is to allow the war fighters to start to train and develop tactics, techniques and procedures so that they can create operational plans for a battle where they would actually incorporate these data.” With tranche 1 in 2024, the tracking and transport layers will essentially reach initial operating capability, said Tournear. That will include persistent regional coverage. According to Tournear, the tranche 0 satellites are set to launch in September 2022. Tournear told C4ISRNET his agency is planning to issue a separate solicitation for launch services later this week. That solicitation will cover all of the tranche 0 satellites, including the 20 transport layer satellites the agency ordered in August, the eight WFOV satellites and the HBTSS satellites https://www.c4isrnet.com/battlefield-tech/space/2020/10/05/space-development-agency-orders-8-hypersonic-weapon-tracking-satellites/

  • US Navy making Aegis updates, training changes based on Houthi attacks

    March 21, 2024 | International, Naval

    US Navy making Aegis updates, training changes based on Houthi attacks

    The U.S. Navy and Lockheed Martin have developed and fielded software updates for destroyers shooting down Houthi missiles and drones in the Red Sea.

All news