Breathing new life into older equipment: How to extend the service life of military assets
In this white paper, Evan Butler-Jones reviews the intricacies involved in extending an asset’s lifecycle and how organisations can keep life extension projects on schedule, within budget and meet strict safety requirements.
The trend of lifecycle extension in military organisations
There is an increasing trend in military organisations to extend the lifecycle of aircraft and other equipment. Examples include the U.S. Navy extending the lifecycle of the F-16, B1-B and B-52 for decades. The primary driver is the high cost of new equipment; with procurement focus often on next-generation assets like the F-35, budgets for other equipment are limited, necessitating cost-effective ways to stretch service from existing assets.
Changing political climates and complex decision-making processes involving networks of stakeholders also lead to delays in procurement, resulting in the need to buy time and maintain military capability by increasing the lifecycle of in-service equipment.
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Overcoming challenges with modern software tools
Extending an asset's lifecycle presents significant maintenance and support challenges. Modern capabilities in instrumentation, simulation, and computer monitoring provide the tools needed to track, analyse, and manage the extra complexity of airframe modifications and fatigue life. Supporting software is now much more sophisticated than the legacy platforms operating on these aircraft and should be retroactively introduced during life extension programmes.
Key solutions include:
Advanced Data Analytics: Improving safety and efficiency through better data collection and planning tools.
3D Printing: Implementing programs like Quality Metal Additive Manufacturing (Quality MADE) for on-demand production of metal parts.
Augmented Reality: Using Microsoft HoloLens headsets to support real-time knowledge transfer from experienced technicians to newer recruits.
Benefits of an integrated approach
Building control and visibility into the supply chain allows decision-makers to understand 'choke points' and know the lead time on parts. An integrated approach across the supply chain ensures that the part being fitted is safe and that maintainers have access to reliability history to inform unscheduled maintenance demands.
Industrial AI moves from pilot to scale
While 28% of manufacturers have fully scaled AI, many are still struggling with barriers like data quality governance, cybersecurity and data privacy concerns, or integration challenges with legacy systems. Focusing on removing these key blockers is crucial to fully realizing the value of AI in optimizing operations and driving predictive, real-time decision-making.
Operational ROI
By standardising documentation and digitising maintenance work orders, organisations can track part status and task completion with high precision. This allows commanders to predict to the hour when an aircraft will be available, leading to double-digit percentage reductions in aircraft time in the hangar and improved force readiness.
Conclusion: Securing the future of key assets
Fleet life extension is a key consideration for military procurement and asset management. While it is a complex process with many potential roadblocks, these can be navigated with the right approach. Organisations that act quickly to take control of these projects with robust organisational processes and modern software support will reap the rewards of increased efficiency, safety, and force readiness.
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