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STATEMENT OF
MG JOSEPH L. BERGANTZ
PROGRAM EXECUTIVE OFFICER
AVIATION

AND

DR. THOMAS KILLION
DIRECTOR FOR TECHNOLOGY IN THE OFFICE OF THE ASSISTANT SECRETARY OF THE ARMY
ACQUISITION, LOGISTICS AND TECHNOLOGY

BEFORE THE
TACTICAL AIR AND LAND FORCES SUBCOMMITTEE
UNITED STATES HOUSE OF REPRESENTATIVES
ON THE
ARMY ROTORCRAFT PROGRAMS AND
FUTURE TECHNOLOGY INITIATIVES

MARCH 12, 2003 

 

Mr. Chairman and distinguished members of the Committee, thank you for this opportunity to report to you today on the Posture of Army Aviation Rotorcraft programs. 

With me today are Dr. Thomas Killion, Director for Technology in the Office of the Assistant Secretary of the Army (Acquisition, Logistics and Technology), and Colonel John Bendyk, Chief, Aviation Division in the Office of the Deputy Chief of Staff, G-8.

Army aviation is a key combat enabler capable of shaping the battlefield, developing situational awareness, providing long range fires, shielding the maneuver force, close support, and extending the tactical and operational reach of commanders for the Interim and Objective Forces as well as Home Land Defense.  Aviation is critical to the Army's stability and support requirements.  Aviation brings these and other capabilities to the battlefield:  RAH-66 (Comanche),  AH-64 (Apache), UH-60 (Black Hawk), CH-47 (Chinook), OH-58D (Kiowa Warrior), and the Tactical Unmanned Aerial Vehicles.  Aviation includes extensive recapitalization of the Apache, Black Hawk, and Chinook programs,  Joint/combined force digitization and connectivity, and upgraded Aircraft Survivability Equipment (ASE).  Our program also includes Hellfire missile modernization and development of a lighter weight version plus an Advanced Precision Kill Weapon System to augment Hellfire, and development of the technologies for and the ability to team with Unmanned Aerial Vehicle interoperability with next generation/future system development.

The acquisition process must begin with a solid statement of requirements.  The key body associated with determining those requirements is the Joint Requirements Oversight Council (JROC).  The JROC is an advisory council to the Chairman of the Joint Chiefs of Staff (CJCS).  In this capacity, the JROC reviews all warfighting deficiencies that may necessitate major defense acquisition programs and validates that such deficiencies cannot be satisfied by non-materiel means, e.g., changes in doctrine, tactics, training, or organization.  Additionally, the JROC assists the CJCS in identifying and assessing the priority of joint military requirements, among existing and future major acquisition programs, to meet the National Military Strategy (NMS).  The JROC ensures that the assignment of such priorities conforms to and reflects resource levels as projected by the Secretary of Defense through the Defense Planning Guidance.  At the CJCS's direction, the JROC also evaluates alternatives to satisfying warfighting requirements by comparing the cost, schedule, and performance criteria of selected programs and identified alternatives. 

To accomplish these tasks, the JROC oversees a Joint Capabilities Integration and Determination System (formerly Requirements Generation System) which standardizes the analysis required for mission-need determination, validation, and approval prior to start of the acquisition process.   The JROC ensures that emerging performance objectives and thresholds adequately address the warfighting mission need and that the delivered capability and timing of that delivery are linked to the NMS.  

JROC actions on aviation programs in the last 5 years include:  on October 3, 2002, Comanche JROC Operational Requirements Document (ORD) approval supporting a Restructured Program Milestone II; on March 5, 2001, UH-60M model Black Hawk JROC ORD approval supporting Milestone B decision; on March 27, 2000, Comanche JROC ORD approval for supporting Milestone II decision; and on April 13, 1998, Chinook JROC Key Performance Parameters approval.

The Comanche, a multi-role helicopter for the Objective Force, will be capable of executing a range of missions in support of close combat, vertical maneuver, and mobile strike operations.  Recently, on October 7, 2002, the Defense Acquisition Board approved a restructured Comanche program.   The acquisition strategy includes Engineering and Manufacturing Development through Block III, a Low Rate Initial Production (LRIP) of 73 aircraft, and a procurement quantity of 650 with a maximum production rate of 60 helicopters per year.  We look forward to a LRIP decision in Fiscal Year (FY) 2007, with deliveries beginning in late FY 2008.

The Comanche's basic unit is a 12-ship organization that will team with Unmanned Aerial Vehicles to enable the commander to see first, understand first, and act decisively by employing joint and coalition munitions for precision effects.  Comanche is capable of employing the current and future family of rockets and missiles, but its ability to collect and share data through a "common operational picture" sets it apart from current helicopters.  Comanche will have the data links, on-board computer processors, sensor payloads, and weapons suite essential to prosecuting the joint warfight.  Comanche's stealth, agility, and joint interoperability make it equally capable from peacekeeping and small-scale contingencies to major engagements. 

The Apache is a heavy attack helicopter, interoperable with the Objective Force.  Organized into battalions or squadrons of from 18 to 21 aircraft, attack helicopters have the mission to find and destroy enemy forces, day or night, in less than optimal weather, in support of the Joint Force Commander.  Apache's primary weapon system is the Hellfire missile, with a range of 8 kilometers (5 miles). The Apache is fully interoperable with joint tactical level communications architectures, and is capable of operating with any Joint Force.  The current Apache program is funded through FY 2006, completing 501 Longbow production aircraft.  The 284 Block I (Lot 1 - 5 of Multi-Year (MY) I & lot 6 of MY II) aircraft just completing production provides our current force with a significant advancement in technology over the legacy Apaches (AH-64A model).  The Block II (Lot 7 to 10 of MY II), currently in production through FY 2006, will deliver 217 units capable of supporting Interim Forces with digital connectivity and full digital situational awareness using the Tactical Internet.  Apache usage rates averaged 175 flight hours per aircraft in FY 2002.  The average Class A accident rate (Class A is defined as involving costs of $1 million or more and/or destruction of an Army aircraft) was 6.99 per 100,000 flight hours in FY 2002.  Since 1985, a total of 45 Apaches have been lost to accidents.

The Black Hawk, also interoperable with the Objective Force, is the Army's utility helicopter.  The Black Hawk is used in multiple roles in support of the Joint Force Commander.  Its primary mission, air assault, transports infantry soldiers and light artillery directly into battle positions.  In its general support role, the Black Hawk is used to move personnel and cargo across all echelons of the battlefield, from the front lines to the rear areas.  Approximately 24 percent of the Army's Black Hawk fleet performs the Aeromedical Evacuation mission.  The Black Hawk will also serve as the host aircraft for the new Army Airborne Command and Control System.  In Special Operations, the MH-60 model  platform is used as both an assault and armed defensive aircraft.  The Black Hawk is interoperable with Joint Forces and variations are in use in the Navy and Air Force.  The Black Hawk aircraft is currently in its 26th year of production with Sikorsky Aircraft Corporation.   The current UH-60L model FY 2002 to FY 2006 multi-year contract was based on a firm commitment by the Army to buy 80 aircraft and by the Navy to buy 82 aircraft over the next 5 years (roughly 32 aircraft per year).  UH-60M model new production quantities for the years FY 2008 to FY 2011 average 5 new production aircraft per year (supplemented with an average of 60 remanufactured aircraft per those years).  The primary source of UH-60M models to the Objective Force is the remanufacturing line.  Low  production and remanufacturing rates may lead to stagnation of business, design, and manufacturing capabilities.  The Black Hawk new production line is scheduled to end in FY 2011.  The UH-60L and UH-60M models have a maximum gross weight of 22,000 pounds.  The Black Hawk can carry an internal load of 11 combat equipped soldiers.  The UH-60L model carries an external load of 5,200 pounds consisting of carrying vehicles, ammunition, and supplies.  The UH-60M model carries 5,300 pounds.  Black Hawk  averaged 174 flying hours per aircraft in FY 2002 for both the Active and Reserve Components.   Class A accident rates for FY 2002 were 1.63 per 100,000 flying hours.  Since 1988, a total of 73 Black Hawks have been lost to accidents.

The Chinook is a twin engine, tandem rotor, cargo helicopter with three external cargo hooks rated for a maximum hook load of 26,000 pounds.  It is the Army's only helicopter capable of moving external payloads of more than 9,000 pounds.  The Chinook also has an internal capacity of 33 troops. The Chinook is a theater and corps asset with two companies of 14 each at theater and four companies of 14 each per corps.  A total of 173 of the Army's 429 CH-47s were originally manufactured prior to 1966 as -A, -B, or -C models.  Those same aircraft will begin remanufacturing into CH-47F/MH-47G models, with the first entering the production line this year.  The CH-47F model, with its upgraded cockpit, will be interoperable with joint tactical level communications architectures and capable of operating with any Joint Force. 

The MH-47 model is the Army's Special Operations variant of the Chinook.  The MH-47 model is modified with an aerial refueling probe, larger internal fuel system, an advanced glass cockpit, and multi-mode radar.  Current technology will allow the CH-47F model to be a viable part of the Objective Force modernization effort and will allow interoperability with the Future Combat Systems (FCS).  The CH-47F model remanufacturing line is currently operational and block upgrade strategies will allow the CH-47F model to stay interoperable for the immediate future.  The Cargo Helicopter Project Office is developing growth strategies to allow the Chinook to partially meet these emerging requirements.  A new aircraft will be required to meet the full requirement to provide a vertical maneuver capability to the FCS equipped Objective Force.  Current studies show that the AMT equipped aviation force will still need a Chinook-like capability well into the future.  The AMT concept is currently not funded.  Critical technologies to allow the Chinook to grow include:  integrated high-performance turbine engine technology, unmanned vehicle technology, advanced high-speed rotorcraft research, alternative fuels, advanced rotors and drive systems, lightweight structures, signature management, active and passive protection systems, electronic counter-measures, artificial intelligence, decision aids, improved modeling and simulation, and mission planning and rehearsal capabilities.  Usage Rates averaged 139 flying hours per aircraft for FY 2002.   Class A accident rates for FY 2002 were 6.78 per 100,000 hours.  There have been a total of 19 CH-47D/MH-47D/E A/C model losses since 1985.  Both the Class A accident rate and the total aircraft losses include recent combat activity.

The Kiowa Warrior is a light attack and reconnaissance helicopter.  The aircraft is organized into attack battalions in Light Infantry and Airborne Division and Cavalry Squadrons in all divisions.  The Kiowa Warrior attack battalion helicopters have the mission to find and destroy enemy forces, day or night, in support of the Joint Force Commander.  The Cavalry Squadrons provide aerial reconnaissance throughout the Joint Force Commander's area of operations. The Kiowa Warrior can carry the Hellfire laser guided missile, 2.75" rockets, and the .50 caliber machine gun.  The Kiowa Warrior continues to conduct armed reconnaissance/security, target acquisition/designation, command and control, light attack, and air combat (defensive) missions in support of combat and contingency operations.  Out of production, the normal peacetime OPTEMPO for the Kiowa Warrior is 240 hours per aircraft per year.  The accident rate in FY 2002 was 5.46 Class A mishaps per 100,000 flight hours.  To date, a total of 36 have been lost to accidents.  Kiowa Warriors will begin moving out of the force in 2009 as Comanches replace them.

The TH-67 (Creek) is the Army's initial entry training helicopter for Flight School XXI.  The current requirement is 185 aircraft.  The TH-67 comes in three variants: TH-67 VFR variant, TH-67 IFR variant, and the TH-67A+.  All initial entry rotary wing pilots will train in these aircraft through the instrument phase of training prior to training in their advanced aircraft (Apache, Black Hawk, Chinook, or Kiowa Warrior).

The Army's Unmanned Aerial Vehicles (UAV) are an emerging capability with the potential for immense operational impacts.  The Army's use and development of Unmanned Aerial Vehicle Systems (UAVS) centers on the abilities of soldiers and commanders to use these systems in flexible and adaptive tactical operations from the platoon through corps echelons. 

September 2002 saw a Department of Defense (DoD) milestone when the Tactical Unmanned Aerial Vehicle (TUAV) (Shadow) system was approved by the Army Acquisition Executive and the Army Systems Acquisition Review Council for full rate production.  The Shadow is a brigade-level asset that provides the brigade commander with the ability to shape and fight the battle.  Shadow systems are currently fielded at Fort Huachuca, Arizona; Fort Hood, Texas; and, Fort Lewis, Washington.  Shadow fielding is planned through 2009.  The Army's Hunter UAV is our most extensively used system with over 24,000 flight hours and 7,000 separate flights.  The Hunter is deployed to corps units requiring long range and long endurance.  Currently, Hunter UAV companies are assigned to Fort Hood, Texas; Fort Polk, Louisiana; and, in Summer 2003, will be fielded to US Army Europe (USAREUR).  The Hunter program will extend through 2009.

The Army has initiated two new UAV programs - the Extended Range and Multi-Purpose (ER/MP) UAV program and the interim Small UAV program.  The ER/MP is designated to be employed at the division or corps-level with fixed wing, long-range capability for Reconnaissance, Surveillance and Target Acquisition, communications relay, and weaponization.   The ER/MP First Unit Equipped could be as early as FY 2006.  The interim Small UAV is designated to be employed at the squad and platoon-level for the dismounted soldier.  The Army has notified Congress of a FY 2003 new start program for the interim Small UAVs. 

The Army is scheduled to field the first FCS equipped battalion in FY 2008 for the Unit of Action (UA), brigade sized organization.  FCS contains four classes of UAVs from the platoon through brigade-level.  The UAVs in FCS are fundamental to the success of the FCS program and the UA concept. 

Please allow me to address some of the critical issues affecting us in Army aviation today.

First is obsolescence.  As a consequence of moving away from the use of military specifications and standards to a greater reliance on commercial items, the rapid and constant change in commercial technology has accelerated obsolescence problems in aviation systems when viewed from the life cycle of a major weapon system.  Development efforts must anticipate and include provisions for planned technology upgrades, therein requiring a continual infusion of research and development funding into fielded systems.  Production planning must include some degree of life buys and obsolete component replacements.  We are currently receiving Congressional support to reprogram $5 million from research and development funds to procurement funds for the one time buyout of  Pentium processors for the Comanche program.  Operation and Support planning must include investments for planned replacement/upgrade to restore or improve reliability lost through obsolescence.

Another issue involves Contractor Rate increases.  Rates have been impacted by the merger of corporations as reflected by changes in company processes such as accounting practices, changes to standard operating procedures, and the application of new management policies.  In addition, corporate organizational changes and economic impacts, business base impacts as older programs draw to a close, or as mergers include potential reductions in overall facility requirements have resulted in less capital expenditures in contractor facility upgrades to offset the rising costs of operations. The application of additional corporate overhead costs primarily derived from issues in the commercial product lines being shared across defense products are impacting rate structures.  The result is that our aviation programs are being faced with rising costs unrelated to performance.

Another issue involves contractor competition.  Business for primes has been dwindling as we bought fewer new airframes over the past five years and instead focused on the modifications.  Modifying existing airframes usually involves a sole source negotiation with the original equipment manufacturer.  Our options are limited because we cannot afford to miss out on important advancements or risk losing industrial suppliers critical to sustainment of our fielded systems.  The result is that aviation programs are being faced with increased costs and limited competition.

Also, we are seeing other effects in the aviation industrial base as a result of mergers and acquisitions.  DoD faces the potential loss of major subcontractors that, through multiple acquisitions, have moved into the commercial market with the defense customer no longer their primary source of business.  LHTECH, the Comanche engine manufacturer, is a good example.  Two years ago when the commercial market for the T-800 engine did not materialize as planned, corporate discussions were held to determine whether it was profitable for LHTECH to continue with the engine program if defense was going to be the primary customer.  Only through several high level Department of Army leadership assurances that there would be continued support for the program and the corporation's specific commitment to Comanche, was the threat abated. We remain concerned about potential losses in our major subcontractor community and the resultant effects on increasingly complex aviation systems.

Another concern arises from the effects of reduced production rates on the ability of our manufacturers to maintain a fully staffed and trained work force.  At lower volumes of production/remanufacturing, the manufacturer cannot effectively maintain a large work force.  This usually results in many older workers retiring as production staff decreases.  With this, we lose their skills and the available work force is challenged in its ability to meet priority surge production.  This situation, combined with the lack of investment in tooling or production line improvements  requiring the contractor to accommodate a surge requirement with a diminished base of production will be extremely difficult, if not impossible.

Currently, reduced readiness rates are primarily due to unavailability of spares and repair parts.  Funding constraints in the recent past have caused a depletion of critical spares (i.e., dynamic components).  This trend has resulted in our contracting for spares at rates much less than our requirements.  Consequently, many commercial vendors are much less motivated to stay in the defense spare parts business.  These lower quantities drive increased unit cost and have a longer-term effect of reducing the competitive base.

Army's Transformation to the Objective Force.  This Transformation presents an opportunity for aviation acquisition programs to align themselves with the maturation of FCS through smaller, focused block upgrades.  This approach will ensure our major aviation systems (both manned and unmanned) remain technologically and operationally relevant well into the future and is consistent with other major DoD acquisition programs.  Similarly, the Army's Unit Set Fielding approach for UA and Units of Employment (UE) provide aviation Program/Project/Product Managers and Weapon System Managers with the ability to reorganize existing aviation units into Objective Force squadrons and battalions that enjoy consistencies and commonalities in Command, Control, Communications, Computers, Intelligence, Surveillance and Reconnaissance (C4ISR) architecture, sensor packages, and ground support equipment.  In doing so, UA or UE gain synergies from digital connectivity and interdependence of this system of systems environment.  A key part of this interoperability relies on continued development of the Joint Tactical Radio System (JTRS).  In that regard, we plan on equipping Army aviation systems that will remain in the Objective Force with JTRS ahead of the FCS.  Combined with enhancements of the Improved Data Modem, Army aviation platforms will attain an unprecedented degree of interoperability with Army and joint air and ground systems.

Key force structure decisions that have not yet been made (for UE and Reserve Component) will influence both procurement objectives for new systems (Comanche and Objective Force compliant models of the Longbow, Black Hawk, and Chinook) and recapitalization efforts of our current fleet of aircraft.  Focused recapitalization initiatives currently in place must continue in order to maintain safe operations and acceptable levels of reliability.  Other modernization efforts that are designed to improve the overall quality of our aviation fleets - apart from those required in the Objective Force - compete with other Army requirements and priorities.  Posturing aviation acquisition programs to support Army Transformation to the Objective Force - with parts of this not completely defined and while sustaining our current capabilities (and maintaining our current combat overmatch) - represents a considerable challenge.  Current events in Iraq and Korea place a greater financial burden on all the Services and will undoubtedly impact future acquisitions.  While these events are unfolding, we are developing a strategy that is affordable and prudent.

The Army aviation Science and Technology (S&T) program produces new knowledge to fuel revolutionary aviation development, expands scientific knowledge in the area of manned and unmanned helicopters, and matures and demonstrates manned and unmanned helicopter technologies in support of the Objective Force and Joint Vision 2020.  Based on the Army Transformation, this effort has been focused to investigate and mature technologies applicable to unmanned systems and to support selected opportunities for manned systems.  The Vertical Takeoff and Landing (VTOL) UAV potentially brings unprecedented agility, maneuverability, and lethality to the Objective Force, while increasing survivability.  The transformational nature of the UAV has energized the aviation field in industry and academia to seek application of truly innovative technologies.  The benefit to DoD and the Army will be revolutionary warfighting capabilities, as well as enhancements to the current force.

The Army has a unique responsibility within DoD as the Service lead for rotorcraft S&T investment.  Under DoD Project Reliance, the Army has the responsibility to address the rotorcraft S&T requirements of all services and the Special Operations Command in those areas that are not service or command unique.

The aviation S&T program investment is in the three areas of basic research, applied research, and advanced technology development.  In the area of basic research, the Army invests in world-class expertise in academia, industry, and other government agencies, as well as in state-of-the-art equipment.  A highlight of basic research is the investment in the Rotorcraft Centers of Excellence at Pennsylvania State University, the Georgia Institute of Technology, and the University of Maryland.  Basic research is conducted by the Aviation and Missile Research, Development and Engineering Command's (AMRDEC) Aeroflightdynamics Directorate located at the Ames Research Center, Moffett Field, California, and by the Army Research Laboratory (ARL) Vehicle Technology Directorate at the Glenn Research Center, Cleveland, Ohio, and the Langley Research Center, Langley Air Force Base, Virginia.

The Army aviation applied research program provides the enabling technology and baseline for aviation development.  The research includes enabling technologies for manned and unmanned rotorcraft in propulsion, rotors, drive train, and structures.  A highlight of the program is the expansion of knowledge in air system autonomy and manned-unmanned teaming.  The applied research program also invests in the National Rotorcraft Technology Center, a partnership of government, industry, and academia to develop air vehicle designs and other rotorcraft technologies.  The program is executed at the Ames Research Center, the Langley Research Center, and the ARL Vehicle Technology Directorate at the Glenn Research Center. 

A key element of the aviation applied research program is the longstanding partnership between the Army and the National Aeronautics and Space Administration (NASA).  This partnership, first established in 1965, has resulted in an exemplary, highly integrated national technology program that is fully coordinated with industry and devoid of duplication of facilities and programs.  The Army and DoD have leveraged NASA intellectual capital in rotorcraft and world-class facilities; all of the United States fielded military rotorcraft, and derivations that have established our commercial base, can be traced back to this Army/NASA partnership.  The DoD/Army rotorcraft and VTOL UAV technology development strategies depend on the continuing partnership with robust, closely related NASA technology programs.

The aviation advanced technology development program is focused on UAVs, with an emphasis on demonstrations to provide the warfighter with the menu of technology for development and integration into the force.  The demonstration programs will mature technology into realistic and robust prototypes.  Technologies that enable autonomous flight, higher aerodynamic airframe loads, and increased maneuverability with UAVs will be demonstrated.  The program also invests in propulsion, drive train, and structure technologies that enable UAV application and have technology transfer opportunities to manned airframes.

The highlights of the advanced technology development program are the major demonstrations for manned-unmanned teaming, and the Army-Defense Advanced Research Projects Agency (DARPA) partnering on UAV platforms for lethality, surveillance, and communications relay.  The Airborne Manned-Unmanned System Technology and the Hunter-Standoff Killer Team Advanced Concept Technology Demonstration constitute the major efforts to demonstrate manned-unmanned teaming.  The Army is pursuing increased lethality for the Objective Force through the Unmanned Combat Armed Rotorcraft (UCAR) program, an armed VTOL UAV, designed to team with manned or unmanned systems.  Increased surveillance capability is being pursued through the A-160 Hummingbird program, a medium altitude, long endurance VTOL sensor and communications platform, and the Organic Air Vehicle (OAV), a ducted fan VTOL UAV that can be carried by the soldier and/or launched from a vehicle.  The UCAR, A-160 and OAV are joint Army-DARPA projects.  The advanced technology development  program is managed by the AMRDEC Aviation Applied Technology Directorate at Fort Eustis, Virginia. 

The investment by the Army in aviation S&T is guided by the requirements of the Objective Force, and investment in advanced technology development is growing in the coming years to meet the challenges of those requirements.  The Army is confident that the aviation S&T investment represents a prudent program that meets DoD and Army Transformation goals.

In summary, Army aviation is well positioned to respond to today's challenges on and off the battlefield, and is ready to assume its key role in the Army's Objective Force.