September 21, 2023 | International, Aerospace
Australia Commits to Additional MQ-4C Triton
The contract award will bring the total fleet size in Australia to four aircraft
May 14, 2020 | International, Aerospace
Some F-35 suppliers are having trouble delivering parts on schedule, and Turkey’s departure could make that worse
By: Valerie Insinna
WASHINGTON — Lockheed Martin's F-35 Joint Strike Fighter is on the verge of full-rate production, with a decision slated for early 2021. But a congressional watchdog group is concerned that as the company ramps up F-35 production, its suppliers are falling behind.
And those supply chain problems could get even worse as Turkish defense manufacturers are pushed out of the program, the Government Accountability Office said in a May 12 report.
According to the GAO, the number of F-35 parts delivered late skyrocketed from less than 2,000 in August 2017 to upward of 10,000 in July 2019.
The number of parts shortages per month also climbed from 875 in July 2018 to more than 8,000 in July 2019. More than 60 percent of that sum was concentrated among 20 suppliers, it said.
“To mitigate late deliveries and parts shortages — and deliver more aircraft on time — the airframe contractor has utilized methods such as reconfiguring the assembly line and moving planned work between different stations along the assembly line,” the GAO said.
“According to the program office, such steps can cause production to be less efficient, which, in turn, can increase the number of labor hours necessary to build each aircraft,” which then drives up cost, the GAO added.
Those problems could be compounded by Turkey's expulsion from the F-35 program, which was announced last year after the country moved forward with buying the Russian S-400 air defense system. Although Turkey financially contributed to the development of the F-35 as a partner in the program, the U.S. Defense Department has maintained that Turkey cannot buy or operate the F-35 until it gives up the S-400.
The Pentagon has also taken action to begin stripping Turkish industry from the aircraft's supply chain, a process that involves finding new companies to make 1,005 parts, some of which are sole-sourced by Turkish companies.
Ellen Lord, the Pentagon's undersecretary for acquisition and sustainment, had hoped to stop contracting with Turkish suppliers by March 2020, but in January she said that some contracts would extend through the year, according to Defense One.
While the Defense Department has found new suppliers to manufacture the parts currently made in Turkey, it is uncertain whether the price of those components will be more expensive. Furthermore, as of December 2019, the new production rates for 15 components were lagging behind that of the legacy Turkish producers.
“According to program officials, some of these new parts suppliers will not be producing at the rate required until next year, as roughly 10 percent are new to the F-35 program,” the GAO said.
“Airframe contractor representatives stated it would take over a year to stand up these new suppliers, with lead times dependent on several factors, such as part complexity, quantity, and the supplier's production maturity. In addition, these new suppliers are required to go through qualification and testing to ensure the design integrity for their parts.”
The F-35 Joint Program Office disagreed with the GAO's recommendation to provide certain information to Congress ahead of the full-rate production decision, including an evaluation of production risks and a readiness assessment of the suppliers that are replacing Turkish companies.
In its statement, the JPO said it is already providing an acceptable number of updates on the program's readiness for full-rate production.
Hard times for the F-35's engine supplier
Not all F-35 production trends reported by the GAO were bad for the aircraft. Since 2016, Lockheed has made progress in delivering a greater proportion of F-35s on schedule, with 117 of 134 F-35s delivered on time in 2019.
However, one of the biggest subsystems of the F-35 — the F135 engine produced by Pratt & Whitney — drifted in the opposite direction, with a whopping 91 percent of engines delivered behind schedule.
At one point in 2019, Pratt & Whitney stopped deliveries of the F135 for an unspecified period due to test failures, which also contributed to the reduction of on-time deliveries.
According to the Defense Contracts Management Agency, “there have been 18 engine test failures in 2019, which is eight more than in 2018, each requiring disassembly and rework,” the GAO wrote. “To address this issue, the engine contractor has developed new tooling for the assembly line and has established a team to identify characteristics leading to the test failures. Plans are also in place for additional training for employees.”
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December 24, 2023 | International, Security
US unveils international force to defend Red Sea. Here’s what we know.
Several nations have announced their contributions to Operation Prosperity Guardian, a new multinational security initiative in the Middle East.
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July 23, 2020 | International, Aerospace
Trilateral Tempest Expands Industrial Base
Tony Osborne Ninety percent of Britain's front-line combat aircraft are crewed, but British Defense Secretary Ben Wallace says he expects a “major reversal” of these proportions by 2040. Wallace's speech at the opening of a virtual Farnborough Airshow on July 20—a message reminiscent of the late Duncan Sandys' 1957 defense white paper that declared the manned fighter redundant and guided and ballistic missiles to be the future of Britain's defense—may hint at a radically altered Royal Air Force (RAF) with heavy fielding of swarming UAVs and other additive capabilities such as “loyal wingmen” dominating fleets. But Wallace's comments also touched on the trajectory for the UK-led Tempest Future Combat Air System (FCAS), which is targeted to begin to replace the UK's fleet of Eurofighter Typhoons from 2035. Air Chief Marshal Mike Wigston, chief of the Air Staff, said at the RAF's annual air power conference on July 15 that he intended any FCAS to be optionally manned. Sandys' defense plan sent reverberations through the UK aerospace industry, but the vision for the Tempest calls for a similar fundamental revolution. Saab spending £50 million on UK FCAS hub Technologies are being matured to support year-end business case submission BAE Systems says its factory of the future will subsume the need for heavy, fixed and long-lead tooling—halving production time compared with previous programs. And industry is looking to new players for cybersecurity technology from the banking world and materials technology from the automotive sector, companies from outside the typical defense industrial base. Two years since the announcement of Team Tempest—the industry consortium of BAE Systems, Leonardo, MBDA, Rolls-Royce and the British government's Combat Air Strategy that coalesced at the 2018 Farnborough Airshow—the group is growing for the first time, with the inclusion of Bombardier UK, Collins Aerospace, GE UK, GKN, Martin-Baker, Qinetiq and Thales UK. The additions to the team come in the form of a first wave of industrial agreements, with BAE hinting that more industrial partners will follow. Of the new partners, Collins announced it had been contracted by BAE to provide advanced actuation capabilities. Sweden's Saab announced also on July 20 that it is investing £50 million ($58 million) into the creation of an FCAS center in the UK. The facility will serve as a hub for the company's participation in the FCAS and represent Stockholm's first tentative steps into the venture. Saab does not name the Tempest specifically, with CEO Micael Johansson hinting that Sweden's involvement is focused more on the technology rather than the future platform. “Saab's FCAS strategy ensures that the technology is in place to support a long-term future air capability and also to support continuous upgrades of Gripen E for decades to come,” Johansson said. While the international partnership model for the Tempest has yet to be finalized, British officials have suggested that the partnerships could be agile and scalable. In other words, allowing nations to “partner in a way that suits them,” Richard Berthon, the UK Defense Ministry's Combat Air acquisition program director, previously told Aviation Week (AW&ST July 13-26, p. 52). Johannsson said nations looking to refresh their fleets with the current generation of fighters, like the Gripen or Typhoon, should not be concerned about the push to deliver the Tempest during the 2030s. “A strong joint partnership around a future combat air system will also guarantee Gripen and Eurofighter access to new technologies,” Johannsson said. Existing customers, he said, should see the FCAS as a “seal of approval as we safeguard continuous fighter development.” Until now, the work between the national partners had been on a bilateral basis. The aim was “to define our common objectives,” BAE Systems CEO Charles Woodburn says. But this work has now extended into trilateral studies that include “assessing how we can start to realize the huge potential for collaboration across our three nations,” Woodburn says. Although the talks are now trilateral in nature, the UK says it is still keen to see more international partners “join our flightpath to discovery,” Wallace adds. Industry is already beginning to think trilaterally, with GKN Aerospace in Sweden confirming it will work with Rolls-Royce in the UK and Avio Aero in Italy on feasibility studies for a future fighter jet engine. GKN states it was contracted in the first quarter of 2020 by Sweden's defense materiel agency, FMV, to conduct a study in collaboration with Rolls-Royce. Few details have emerged on the 60 technology demonstration programs currently being developed and matured by Team Tempest in support of the UK Future Combat Air System Technology Initiative (FCAS TI). Michael Christie, BAE's head of Future Combat Air Systems, says work on maturing the technologies ready to support the business case submission to the British government at the end of this year has seen the partners “at least achieve or exceed” the maturity targets set, doing so “at great pace” and providing “fundamental evidence to the business case.” “Every one of these [60] projects will deliver a UK, European or world first,” says Cecil Buchanan, the RAF Rapid Capability Office's chief scientist. https://aviationweek.com/ad-week/trilateral-tempest-expands-industrial-base