26 avril 2019 | International, Aérospatial

Government watchdog finds more problems with F-35’s spare parts pipeline

By:

WASHINGTON — Only about half of the F-35s worldwide were ready to flyduring an eight-month period in 2018, with the wait for spare parts keeping jets on the ground nearly 30 percent of the time, according to a new report by the Government Accountability Office.

Over the past several years, the Defense Department has sought to improve mission capable rates by making improvements to the way it and F-35 contractor Lockheed Martin order, stockpile and repair spare parts. However, GAO's findings imply that the situation may have gotten worse.

The GAO's report, released April 25, investigated how spare parts shortages impacted F-35 availability and mission capable rates in 2018, with most data gathered between a May and November sustainment contract period.

“In 2017, we reported that DOD was experiencing sustainment challenges that were reducing warfighter readiness, including delays of 6 years in standing up repair capabilities for F-35 parts at its depots and significant spare parts shortages that were preventing the F-35 fleet from flying about 20 percent of the time,” GAO said in the report.

“According to prime contractor data, from May through November 2018, F-35 aircraft across the fleet were unable to fly 29.7 percent of the time due to spare parts shortages,” it said. “Specifically, the F-35 supply chain does not have enough spare parts available to keep aircraft flying enough of the time necessary to meet warfighter requirements.”

That lack of improvement may make it more difficult for the U.S. Air Force, Navy and Marine Corps to hit an 80 percent mission capable rate by the end of fiscal year 2019, as mandated by then-Defense Secretary Jim Mattis last fall.

The military services stopped providing mission capable rates for aircraft last year, citing operational sensitivities. However, the data put forth by the GAO indicates that progress stagnated in the lead up to Mattis' order.

From May to November 2018, mission capable rates — which measure how many planes possessed by a squadron can perform at least one of its missions — hovered around 50 percent for all versions of the F-35.

But when GAO assessed how many planes were fully mission capable — meaning that they were ready to fulfill all of their mission sets — all variants were far from meeting the 60 percent target. Only 2 percent of F-35C carrier takeoff and landing versions hit the fully mission capable mark, with the F-35Bs slightly better at 16 percent and the F-35A at 34 percent.

The GAO is skeptical that the services will be able to hit the 80 percent mission capable rate goal this year, and it is even more critical of the Defense Department's plans to fund spares in future years.

The department intends to buy “only enough parts to enable about 80 percent of its aircraft to be mission-capable based on the availability of parts.” However, that planning construct will likely only yield a 70 percent mission capable rate at best, the GAO said, because it only accounts for the aircraft on the flight line and not jets that are in the depot for longer term maintenance.

No silver bullet for parts shortage issues

Like all complicated problems, there is no single solution for the F-35 spare parts shortage, which is driven by a number of factors.

GAO indicated that the Defense Department still has “a limited capacity” to repair broken parts, creating a backlog of 4,300 parts still needing to be addressed. Between September and November, it took more than six months to fix parts that should have been repaired in a window of two to three months.

The F-35's much-maligned Autonomic Logistics Information System (ALIS) was designed to be able to track parts and automate the process of generating and expediting work orders, however, GAO notes that the system still requires manual workarounds from users in order to accomplish tasks.

Supply and maintenance personnel cited challenges such as “missing or corrupted electronic spare parts data,” limited automation and problems caused by ALIS's subsystems not communicating with each other properly, it said.

As the F-35 is still a relatively new platform, it has taken time for the program to assess which parts have been failing more often than previously estimated — but that is an area where the Defense Department is making progress, the GAO stated.

“DOD has identified specific parts shortages that are causing the greatest aircraft capability degradation, and it is developing short-term and long-term mitigation strategies to increase the quantity and reliability of these parts,” the report said.

One such component is a coating used on the F-35's canopy to help it maintain its stealth characteristics, which has been found to peel off at an unexpected rate, creating a heightened demand for canopies.

“To address these challenges, the program is looking for additional manufacturing sources for the canopy and is considering design changes,” the GAO stated.

But — somewhat paradoxically — the F-35 has been flying for a long enough time that there is significant parts differences between the first jets that rolled off the production line to the most recently manufactured planes. The GAO found “at least 39 different part combinations across the fleet” on top of variations in software.

“According to the program office, DOD spent more than $15 billion to purchase F-35 aircraft from the earliest lots of production, specifically lots 2 through 5 ... but it faces challenges in providing enough spare parts for these aircraft,” the report stated.

One problem — the cannibalization of F-35 aircraft for parts — is partially user-inflicted.

“From May through November 2018, F-35 squadrons cannibalized (that is, took) parts from other aircraft at rates that were more than six times greater than the services' objective,” the GAO stated. “These high rates of cannibalization mask even greater parts shortages, because personnel at F-35 squadrons are pulling parts off of other aircraft that are already unable to fly instead of waiting for new parts to be delivered through the supply chain.”

During an interview this February, Lt. Col. Toby Walker, deputy commander of the 33rd Maintenance Group, told Defense News that F-35 maintainers at Eglin Air Force Base, Fla., had stopped pulling parts off a cannibalized F-35 and had seen some improvements to mission capable rates as a result.

“We're not continually moving parts from one aircraft to another. We're relying on the program to provide our parts,” he said. “It was a very strategic plan to do that to increase aircraft availability by not sitting an aircraft down.”

In a statement, Lockheed Martin said that it had taken key steps to improve parts availability, such as transitioning some suppliers to performance based logistics contracts that incentivize companies to meet certain targets, as well as “master repair agreements” that will allow other suppliers to make longer term investments in their production capability.

“These actions are beginning to deliver results and we're forecasting additional improvement. Newer production aircraft are averaging greater than 60 percent mission capable rates, with some operational squadrons consistently at 70 percent,” the company said.

“From a cost perspective, Lockheed Martin has reduced its portion of cost per aircraft per year by 15 percent since 2015. Our goal is to further reduce costs to $25,000 cost per flight hour by 2025, which is comparable to legacy aircraft while providing a generational leap in capability.”

https://www.defensenews.com/air/2019/04/25/government-watchdog-finds-more-problems-with-f-35s-spare-parts-pipeline

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  • Head of Saudi Arabia’s defense industry umbrella org talks Vision 2030

    28 août 2018 | International, Aérospatial, Naval, Terrestre, C4ISR

    Head of Saudi Arabia’s defense industry umbrella org talks Vision 2030

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That was the key decision to go ahead, and they decided to build a nucleus which is covering any kind of [military] activities, starting from space, ground or naval activities under one big umbrella company to set up a kind of sustainable business instead of having different companies of smaller size. Are they operating relatively independently, or is it really one management structure? SAMI itself is acting as a kind of active holding company. We will operate through four business divisions. Each of the business divisions will be composed of a set of business units. A business unit is a joint venture with a foreign partner, but it would also integrate the existing assets in the kingdom into this umbrella environment; assets which are already joint ventures today but also nationally owned assets, which will be allocated to the various business divisions. I know you have an extensive career with defense companies. You were with Rheinmetall, and you spent time at Airbus. 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In the new scheme, we change from this kind of supplier-vendor relationship to a partnership model, a partnership model to the extent that we expect the foreign partner — under the terms of their exclusivity access to Saudi Arabia — to bring all their technologies, all the skills and knowledge into the kingdom. That typically is established through a joint venture so we can build up local competence not only by getting licenses for production, but in the engineering and R&D field to be able to develop the next generation of weapons systems, within the joint venture, within the kingdom. And you established a joint venture with Boeing. Can use that as an example? Saudi Arabia has a very long-lasting, strategic relationship with Boeing. It started many years ago, and we already have an established joint venture in the kingdom, where we conduct substantial aircraft MRO activities. 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And yes, companies have to be trained, in that they have to change the mindsets and mentality in order to do this kind of normal type of commercial sales activity and to become a commercial partner on an industrial level rather than on a political or governmental level. They'll need to convince the Pentagon to allow them, too, because there's a lot of cases where the Pentagon tends to put in restrictions and wants to be in control of that relationship. You are absolutely right. This is a burden on the U.S. companies, and I wish them all the best in order to overcome the hurdle [so we] will be equally treated as many other companies who are not restricted by their governments. Some western European countries, for example, are offering much more support in that respect. Offering more opportunities for the companies to transfer their ideas, their technologies into the kingdom. Saudi Arabia had a bit of a shakeup in terms of its own military leadership. 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And in line with that, some people have to be replaced, to be in full support with this new vision and to be completely in line with our targets, and I can tell you we have relationships with all the national stakeholders, and we consider ourselves with them as partners. They are no longer a client, we are no longer vendor to them; we are partners. You mentioned R&D. What areas do you see the greatest potential in terms of investment for development and product development? We will put our focus on software technologies, electronics, microwave, space-based technologies, robotics, laser weapons systems on the midterm and long term, but in in the short term we have to give the short-term needs, which are conventional in nature. So, in the beginning, as all the other companies are doing, are on the classical systems. How do you meld what Saudi Arabia as a nation needs for its own military with the potential for global export? Upmost importance and top priority is the security of the country. That means, yes, our top priority is to serve the needs of our armed forces, and we try in parallel to satisfy also the needs of our strategic partners. In most of the cases those are quite complementary. You see a lot of efforts in the United Arab Emirates to bolster defense. Is there a collaboration between the military organizations that are stood up in a country like UAE and what you're trying to establish in Saudi Arabia? Top leadership of UAE and Saudi Arabia have recently agreed on a strong collaboration on defense, and defense industries, so we are highly encouraged to align our thoughts and to align our strategies with our counterparts in the UAE. This process is ongoing, but we've had very fruitful collaborative talks, and soon we'll hopefully be in a position to announce some great, common achievements. https://www.defensenews.com/interviews/2018/08/27/head-of-saudi-arabias-defense-industry-umbrella-org-talks-vision-2030

  • FVL: The Army’s 10-Year Plan For FARA Scout

    31 mars 2020 | International, Aérospatial

    FVL: The Army’s 10-Year Plan For FARA Scout

    The Army's urgently developing new air-launched drones, long-range missiles, and electronic architecture to go on the Future Attack Reconnaissance Aircraft that Bell and Sikorsky are vying to build. By SYDNEY J. FREEDBERG JR WASHINGTON: The Army's Future Attack Reconnaissance Aircraft program is much bigger than the two ambitious high-speed helicopters that Bell and Sikorsky will now get more than $1 billion to build. At least five other major moving pieces must come together on time to turn the final aircraft, whoever makes it, into a working weapon: a new Improved Turbine Engine built by GE; helicopter-launched mini-drones called Air Launched Effects (ALE); a new Long-Range Precision Munition (LRPM), with the Israeli Spike-NLOS as the initial version; an Integrated Missile Launcher (IML) to launch both the missile and the drones; and the underlying electronic framework of standards and interfaces to plug it all together, the Modular Open Systems Architecture (MOSA). 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Each company has already received a “digital model” of how their design must conform to the Modular Open Systems Architecture (MOSA), which will allow the government to plug-and-play MOSA-compliant components from any company, not just the manufacturer, over the life of the program, program manager Dan Bailey said: “We, the government, will control the interfaces internal to the aircraft so we can efficiently upgrade.” December: The Army will conduct a Final Design Review of both designs to confirm “that they are postured for success and risk is acceptable,” Bailey said. “After that, they will begin to build the aircraft.” 2021 Bell and Sikorsky build their prototypes. Despite their very different designs, each company must incorporate certain common Government Furnished Equipment (GFE) provide by the Army. That includes a 20mm cannon; the GE T909 Improved Turbine Engine, which will also be retrofitted to existing Apache and Black Hawk helicopters; and the Integrated Munitions Launcher (IML), which will use MOSA interface standards to connect missiles and ALE mini-drones to the aircraft – without having to modify the aircraft each time a new weapon is developed. If the Army's 2021 budget request is approved, this year the service will buy $152 million of Spike NLOS (Non-Line-Of-Sight) missiles from Israel armsmaker Rafael as an interim Long Range Precision Munition. 2022 Bell and Sikorsky begin ground testing of their prototypes. The Army fields Spike-NLOS missiles on existing aircraft across three Combat Aviation Brigades (CABs), providing both immediate combat power and hands-on experience with the technology to refine either the Spike or a competitor into the full-up LRPM. November: The Bell 360 Invictus and Sikorsky Raider-X fly for the first time. Flight testing begins. 2023 Summer: The prototype aircraft move from their builders' test sites to Redstone Arsenal to begin Army flight testing with all-government crews. The Army finalizes its formal requirements for FARA based on how the prototypes actually perform. Fall: The Army conducts a Weapons System Preliminary Design Review – that is, not of the aircraft alone, but of how all the pieces work together – and, in context of that holistic assessment, selects either Bell or Sikorsky to build the aircraft. By December 31st: The Army launches an official Program Of Record (POR) to acquire FARA. While the first few aircraft will cost more, the service's long-term goal is to spend no more than $30 million per FARA, the same price as the current AH-64 Apache gunship. 2024-2025 The Air-Launched Effects (ALE) mini-drones begin to enter service on existing Army aircraft. As with the Spike missile, this early deployment provides both immediate military benefit and the necessary experience to refine the technology for FARA. 2028-2030 The first FARA aircraft enter operational service. The Army hasn't specified how many it ultimately plans to build or for what price. But the Army's Program Executive Officer (PEO) for Aviation, Patrick Mason, told reporters today that “I have no reason to disagree with” widely circulated independent estimates of 300-400 aircraft for $15-20 billion. “We've got a series of gates” over the years, Mason said. “This is a constant assessment as we go through, and this is really the beauty and benefit of the prototyping design of this program: We will get to see both vendors as they go to their final designs and they build their prototype air vehicle, as we simultaneously carry forward [with] the other elements that are part of the FVL ecosystem.” “We're going to see very, very clear indication of the technology maturity, the readiness, and the ability of the prototype aircraft to meet the requirements,” he said. Novel Contracts, Novel Technology, Tight Schedule It's worth delving into some detail on what happened yesterday, when the Army announced that Bell and Sikorsky would get the chance to build competing prototypes of FARA – the Bell 360 Invictus and the Sikorsky Raider-X – while designs from AVX, Boeing, and Karem were rejected. Each of the five companies had received up to $15 million for design work, while Bell and Sikorsky will each get up to $735 million more to build and test their prototypes. The exact figures are competition-sensitive, and each vendor has invested much of its own money in any case. The contracts call for one-third private funding and two-thirds government funding over the design and prototyping phases combined, but the companies have almost certainly outspent the government so far. Technically, FARA program manager Dan Bailey told reporters, “we actually aren't awarding anything at this time.” Instead, last April, all five contenders got Other Transaction Authority Prototyping (OTAP) contracts for both the design and prototyping phases, but with clauses allowing the Army to cut any vendor at any time. It's that option they've just exercised. Rather than making an award, Bailey said, “yesterday, we notified two that we would continue to fund them into Phase 2 and we notified three that we would stop funding them.” (Emphasis ours). This novel approach, among other benefits, is nigh-impossible for losing bidders to appeal against, Rugen said: “There really is no ability to protest per se with the GAO [Government Accountability Office]. There is legal recourse potentially through the courts but, again, our legal team has advised us the risk is low.” That's helpful because – as the JEDI cloud computing contract proves – legal battles can delay Defense Department programs for months. The Army has a tight timeline for FARA, which it sees as essential to fill the gap in its aerial reconnaissance capability left by the retirement of the aging and much-upgraded Bell OH-58 Kiowa. While the competing designs are very different, Army simulations so far show that either would meet the military needs “Both are advanced rotorcraft configurations,” Brig. Gen. Rugen said. “Both did very well with speed, range, endurance at range, in our European scenario.... The power [for] takeoff with payload out of ground effect was also, again, leap-ahead.” The Bell 360 Invictus is basically a conventional helicopter with small wings for added lift, using fly-by-wire and rotor technology developed for the civilian Bell 525. The Sikorsky Raider-X is a compound helicopter with coaxial rotors and a pusher propeller for added thrust, derived from Sikorsky's S-97 Raider – which is a real, flight-testing aircraft – and ultimately the award-winning X2. “The X2 technology continues to impress,” Rugen said. While Bell's design may not have struck some observers as revolutionary, he said, “the efficiency” with which Bell's engineers stripped out every possible bit of drag – allowing much higher speeds – “was truly innovative. “We've got two great competitors ... on a program that we must deliver for the Army,” Rugen said. https://breakingdefense.com/2020/03/fvl-the-armys-10-year-plan-for-fara-scout

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