Maj Gen (Dr) Ashok Kumar (Retd) : Moderator
Good day, everyone. Welcome to this webinar on a technology-related subject. Technology has become a buzzword, whether discussing the Ukraine war, the tensions between the United States and China regarding Taiwan, the Indo-Pacific, or any other significant matter. We need to consider the impact of technology on our activities. Does it make our jobs simpler, or is it more complex than it appears? What are the payoffs and options it presents to us, especially in the context of the land forces and sister services like the Air Force and Navy?
In the MRO Forum, we are particularly concerned with technology. Our first webinar on November 9, 2022, covered 3D printing, conducted by Group Captain Ashok Singh from the Air Force. Today, we return to a technology-related subject, exploring various nuances and covering both land and air forces.
To set the tone for today’s webinar, we invite Lt Gen (Dr). NB Singh, a well-known name in the strategy and thinking community and former DGEME, to give the keynote address. This address will guide our further deliberations.
Keynote Address by Lt Gen (Dr) NB Singh (Retd)
Thank you, Ashok. It’s a great privilege to deliver this opening talk on the important subject of MRO and its transformation using contemporary technologies.
Before discussing where we can insert or use technology, I want to address a core issue: the inadequate attention to the needs of MRO personnel in militaries under the Commonwealth. Unlike modern armies like the U.S. armed forces or European militaries, we face persistent problems.
To my mind, there are three key issues our military maintainers haven’t researched adequately:
1. Operational Significance of MRO: We haven’t effectively communicated the importance of MRO to the warfighter. Since they play a significant role in funding decisions, and with finite budgets needing to cover modernization and logistic requirements, cuts often fall on MRO. We lack metrics to measure equipment capability and system effectiveness, leading warfighters to underestimate the impact of MRO on operational outcomes.
2. Life Cycle Systems Management: Our acquisition process still focuses on the lowest bid without considering life cycle costs. For example, overhauling a T72 tank costs much more today than its original purchase price, yet it’s returned in the same configuration without technological upgrades. This neglect of technology insertion in weapon platforms extends to their maintenance.
3. Impact of Age, Usage, and Deployment: We haven’t studied how age, usage, and deployment affect weapon system capability. There is extensive literature on failure rates in digital and analog systems, but we’ve ignored these insights. As a result, our MRO infrastructure is outdated, using machine tools from the 40s and 50s.
We need to focus on the following areas for technology insertion:
– Assembly Line and Infrastructure
– Plant and Machinery
– Documentation
– Testing and Evaluation Infrastructure
– Skills and Competencies
– Spare Parts Management
Each area offers opportunities for modernization and cost-effectiveness, particularly in reducing manpower costs, which are significantly higher in the public sector.
The ultimate goal of introducing technology into the MRO domain is to provide commanders with tools to assess weapon system effectiveness or force effectiveness before operations. If commanders can make informed decisions about deploying units based on these assessments, the importance of modernizing MRO will be evident.
I am confident that our esteemed speakers will elaborate on these points and discuss specific technologies and methods for modernizing MRO. Thank you.]
Maj Gen (Dr) Ashok Kumar (Retd)
Thank you, sir. Good evening, gentlemen. In case you heard the speaker carefully, you would have noticed that he touched on very important issues. One key point was the need for commanders to understand the operational importance of equipment. Without this understanding, subsequent steps may fall short. He also emphasized that instead of focusing solely on L1 procurement (lowest bid), we should consider life cycle costs, which would ensure that equipment receives the necessary support at each stage. Additionally, he highlighted the challenges of maintaining system effectiveness and the significant impact of budgets on this process.
Now, I invite General Kapil Aggarwal, former DGEME, who has extensive experience with land forces equipment. He is a scholar and a warrior who will share his insights on how technology can provide solutions in the MRO (Maintenance, Repair, and Overhaul) domain and what challenges we might face. Over to you, General Aggarwal.
Address by Lt Gen Kapil Aggarwal (Retd):
Thank you, General Ashok, and good evening viewers. General NB Singh has beautifully set the stage for today’s topic on reimagining MRO for defense by leveraging technology. I will try to take this topic further.
Over the last two decades, militaries worldwide have undergone a revolution in military affairs (RMA) due to rapid technological advances, which have changed doctrines and tactics of warfighting. This transformation has accelerated with lessons learned from the Russia-Ukraine conflict. Technology has also revolutionized logistics, but the military MRO, at least in India, has not seen such advancements. The only change has been repeated rounds of manpower optimization to improve the teeth-to-tail ratio. Despite committee recommendations, significant transformations in MRO are yet to happen.
The current MRO setup faces challenges due to inadequate modernization and limited automation. These issues need urgent attention, especially given the constraints on defense budgets and manpower.
Key Triggers for Change:
1. Defense Budget: Although the defense budget has been increasing in absolute terms, as a percentage of GDP, it has been declining over the past two decades, now down to 1.4% excluding pensions. This means fewer financial resources are available for operational maintenance, impacting MRO budgets significantly.
2. Agnipath Scheme: The Agnipath scheme, with an annual intake of 92,000 recruits, will gradually reduce the overall strength of the forces. This implies that the manpower involved in MRO will also decrease. The existing MRO setup cannot function effectively with drastically reduced manpower, necessitating a complete rethink.
Proposed New MRO System:
The existing system is characterized by its manpower intensity, outdated infrastructure, and inadequate overall capability. The new system should be lean, mean, and tailored to the needs of the defense forces of 2050. Key points for the new system include:
1. Separate Tri-Services MRO Network: Automation is crucial. A secure, pan-India, tri-services MRO network for warlike equipment should be established, segmented into separate service and equipment verticals.
2. Warlike Equipment-Centric System: Equipment readiness should be the mantra. Each piece of equipment should have a designated operator responsible for updating its status. A central analytics module can monitor readiness and preempt problems.
3. Greenfield Private Sector Projects: Private industry should be encouraged to establish new projects to augment D-level repair capabilities, reducing the backlog and improving national capacity.
4. Manufacture/Indigenization of Spares: More needs to be done to support private industry in producing components and assemblies, reducing dependence on imports.
5. Modernization of MRO Infrastructure: Modernization should focus on outcome-based improvements, not necessarily the latest technology, to ensure cost-effectiveness.
6. Inventory Support by Logisticians: The logistics system should be reconfigured to a push model, ensuring timely delivery of critical items directly to the field.
7. Establishment of MRO Hubs: Specialized MRO hubs for major equipment should be established by foreign OEMs, DPSUs, or private industry in collaboration with foreign partners.
Way Forward:
To implement this new system, a committee of MRO subject matter experts should define its broad contours and develop an implementation roadmap. Simultaneously, a committee of logisticians should design a new warehousing and inventory supply chain system. This approach will lead to a lean and efficient MRO organization by 2050.
Conclusion:
The only prognosis for defense MRO is to reimagine, redefine, and re-engineer the system to ensure the readiness and reliability of equipment while managing limited resources effectively.
Thank you.
Maj Gen (Dr) Ashok Kumar (Retd)
Thank you, General Agrawal. Gentlemen, you just heard an excellent exposition on the MRO (Maintenance, Repair, and Overhaul) matter. If you really see and deliberate on the content covered by the General Officer, you will notice a few key points:
1. Acknowledgment of Technology Gaps:
– The General highlighted that the MRO field has not kept pace with technological advancements as seen in other segments. While other areas have evolved with technology, MRO has somehow not imbibed it to the same extent.
2. Need for Rapid Advancement:
– He emphasized that we cannot afford to move in an arithmetical progression; instead, we need to move in a geometrical progression. This means we must adopt multiple measures simultaneously and advance rapidly.
3. Innovative Use of Existing Resources:
– One of the best parts of his talk was his approach to working within current constraints rather than insisting on increased budgets or ideal conditions. He proposed actionable solutions and a roadmap that can leverage technology for significant improvements within the existing framework.
While we may agree or disagree on certain points, as is common with fresh ideas, I believe he has charted an actionable roadmap in the MRO domain where technology can be effectively used for broader benefits. Thank you very much.
Now, we move on to the Air Force issues. While MRO and equipment maintenance are crucial for all three services, it is particularly sensitive for the Air Force. The precision required for handling Air Force equipment, especially airborne equipment, demands a much higher standard of MRO and technological excellence.
We are privileged today to have Air Vice Marshal Rajiv Gandotra, who has served at the apex level in Air Force Headquarters and has looked after the maintenance of the entire Western Air Command. A very thorough professional in matters of maintenance across all facets of the Air Force, we are honored to hear his insights on related issues.
Thoughts on Technological Support by Air Vice Marshal Rajiv Gandotra (Retd):
Thank you very much, sir. I will now cover the issues from the Air Force perspective. As you rightly said, flight safety is paramount, and this focus is instilled in us from day one in the Air Force.
1. Maintenance and Operational Integration:
– From a maintenance point of view, our importance is on par with operations because we are conducting operational maintenance. This integration makes us part of the operational team at the O-Level (Operational Level).
2. Monitoring Equipment Life:
– Every airborne equipment, from nuts and bolts to LRUs (Line Replaceable Units), has a defined life monitored continuously. These lifespans are determined by OEMs (Original Equipment Manufacturers) and are meticulously recorded in logbooks. Once equipment reaches its designated hours (e.g., 100 hours), it must be withdrawn from service for maintenance. This strict adherence ensures the safety and reliability of our operations.
3. Technology Integration:
– The maintenance process has largely remained the same for the past 40 to 50 years, categorized into O-Level, I-Level (Intermediate Level), and Depot Level maintenance. However, with available technology, we can revolutionize this process.
4. Blockchain Management:
– One concept I find promising is blockchain management. This involves networking various blocks (design, development, production, operations, and maintenance) to create a transparent and efficient system. Similar to how bank transactions are recorded and visible across ledgers, blockchain can ensure that every flight hour of equipment is tracked and managed across all stages.
5. Use of Drones:
– Drones can be a game-changer for aircraft inspection and maintenance. By deploying drones, we can perform comprehensive inspections efficiently. However, regulatory clearances and proper training for operators are essential to avoid any damage during these inspections.
6. Robotics and Automation:
– Robots can handle heavy equipment and repetitive tasks, reducing manpower and enhancing efficiency. The use of robots in maintenance operations is another area worth exploring.
7. Virtual and Augmented Reality:
– VR (Virtual Reality) and AR (Augmented Reality) can significantly improve training, especially for emergency procedures and engine maintenance. Companies like Rolls-Royce are already using these technologies for engine maintenance training, offering a valuable tool for our personnel.
8. Smart Hangers:
– The concept of smart hangers equipped with IoT (Internet of Things) can automate many maintenance processes, reducing manpower needs. This is crucial given future constraints on manpower availability.
9. Future Prospects:
– Looking ahead, automation and technological integration in maintenance processes are imperative. We need to draft a clear roadmap for short-term, medium-term, and long-term adoption of these technologies to enhance our operational readiness and efficiency.
In conclusion, the sky’s the limit for what we can achieve with the right technological integration. We need to plan and implement these advancements strategically to meet our immediate and future needs. Thank you very much.
Maj Gen (Dr) Ashok Kumar (Retd)
Thank you very much, Air Vice Marshal Rajiv Gandotra. Gentlemen, you just heard how flight safety and related issues are paramount in the Air Force. It was fascinating to hear about the potential of technologies like blockchain, IoT, and smart hangers in addressing current challenges, especially considering the HR constraints faced by the Air Force.
Now, we will move to the concluding part of our webinar. However, I am tempted to seek a few concluding remarks from our patron, General NB Singh, before I request General Matharu to give the closing remarks.
Concluding Comments by Lt Gen (Dr) NB Singh (Retd):
Yes, I think the punch lines I gave in the initial portion of my talk still stand. A lot of good ideas have been shared today, highlighting the enormous potential for injecting technology into the MRO domain.
I’d like to emphasize that it is the responsibility of us maintainers to first clear the cobwebs within ourselves and develop clarity. Rajiv pointed out that in the Air Force and Navy, the primary focus is on safety because without the platform, you cannot execute your missions. The same is true for land systems.
Imagine you execute a classical breakout and aim to move 70-90 kilometers across a desert, only to find that sixty percent of your force is stuck, some on this side of the IB and some on the other. What force ratio will you have at the projection area? There will be none, and you could end up badly mauled, similar to the situation faced by Russian tanks around Kyiv.
Earlier, we only talked about these issues, and nobody listened. Once these issues are explained clearly, we can understand that all of this requires resources. As Kapil mentioned, resources—whether financial or personnel—will remain a challenge for the next 25-40 years. Given this, we need to think out of the box and find ways to convince those controlling the purse strings to allocate a part of that budget to us.
Thank you.
Maj Gen (Dr) Ashok Kumar (Retd)
Thank you very much, sir. Now, I invite General Matharu, who has served as the DGIS and Commandant MCME. He is well-known among us and is the driving force behind the MRO Forum and various activities undertaken by this platform. Sir, I request you to give the closing remarks for today’s session.
Lt Gen JS Matharu (Retd): Concluding Remarks
Thank you very much, and a special thanks to all our esteemed speakers, whom I hold in very high regard. As stated in our forum’s byline, we need to focus on optimal solutions and out-of-the-box thinking, as the challenges we face are real. Despite the problems, we find that certain solutions are emerging, and there is a convergence of ideas.
I firmly believe that wars are won by the correct and effective utilization of our technical edge. We cannot afford to relax; we must overcome any policy issues that hinder the implementation of technology. For example, we have significant technical resources and immense capacity to build spares within our country. If we establish good data standards, simple steps can lead to substantial results. For instance, if every HR program has the same fields and national standards are used for spares, we create a matrix of different software systems that can communicate with each other effectively.
In our civilian fleets, we already have advanced health management systems. These systems allow us to monitor the state of vehicles remotely. Implementing such steps in the military can significantly improve our operations.
Regarding data visibility, we need to leverage our high bandwidth capabilities in the hinterland. However, in forward areas, we often face bandwidth limitations. Nonetheless, the vehicle systems do most of the work internally, outputting only a few numbers that can be easily transmitted over any radio. The major processing can occur where these numbers are received.
We have already seen successful examples of this approach. Brigadier YVR Vijay delivered an excellent talk on how he turned around the Suzlon MRO system, demonstrating how even with limited technology, significant improvements can be made.
Technology offers solutions to many of our problems, but we need to address policy barriers that prevent us from leveraging our strengths. Our forum members, with their expertise and insights, can help identify and overcome these barriers. I am confident that with the collective efforts of our community, we will make progress.
Thank you, everyone, for your contributions. I now hand over to the moderator Maj Gen (Dr) Ashok Kumar (Retd) for the final remarks.
Maj Gen (Dr) Ashok Kumar (Retd): Moderator
Thank you, General Matharu, for your insightful closing remarks. Today, we have had an enriching webinar on a very important subject. Many ideas and solutions have been discussed. We have realized that while technology offers numerous options, it also presents challenges that require changes in the ecosystem, policy formulations, and cybersecurity measures.
It is crucial for the apex leadership of the defense forces to understand the importance of equipment in warfare, as demonstrated in the Russia-Ukraine conflict. If we fail to convince our leaders of this importance now, we may lose many opportunities in the future.
With this, we conclude today’s session. We will return with another subject in due course. Besides webinars, our forum engages in dialogues, monologues, and snippets, and we plan to expand our activities for the greater good of the nation and the defense forces.
Thank you very much for your participation.
