Platform Modernization

Platform Modernization
A Cost-Effective Strategy for Evolving Mission Requirements

by
Lee Wilbur
wilbur_lee@bah.com
Robert Smith
smith_robert@bah.com

A Cost-Effective Strategy for Evolving Mission Requirements

The traditional way to modernize a platform for military, being solely reliant on OEMs. Platform modernization
defense, and civilian agencies is to replace the old one follows a four-step engineering process to: 1) understand
with a new and improved version. Under the current fiscal what to change and why, 2) develop a design, 3) prototype
environment, approval of new platforms is so rare that the design, and 4) provide a Technical Data Package to
agencies must often make do with existing platforms and the government for specifying the acquisition. With this
coax continued service from these assets—way beyond their information, an agency can steer engineering requirements,
original intended lifespans. control the acquisition process, and avoid monopoly
deals. The agency can do this by executing modernization
Achieving economies across a platform lifecycle is a
internally with organic resources, or by leveraging market
worthy objective, but it continues to be an elusive goal
competition for better results at a lower cost.
for planners. For example, maintenance of obsolete
platform capabilities or technologies often proves to be too
expensive or infeasible to implement because components
How Reliance on Legacy Platforms
may be out of production. As a result, agencies must modify Poses Challenges for Maintenance and
and maintain the capabilities of existing platforms in order New Capabilities
to meet evolving mission requirements. These agencies The specter of perpetual large national budget
typically go back to the original equipment manufacturers deficits has throttled approval for new platforms
(OEMs) to perform upgrades and modernization because across military, intelligence, and civilian agencies. For
the government does not own the technical data rights example, within the Department of Defense, only the
for its own platforms. Historically, acquiring from a single US Army has a new platform under development. In
source supplier is a near certain path to higher costs due this fiscal climate, agencies are expected to manage
to the glaring lack of competitive incentives. budgets, often with declining growth rates or direct
cuts to appropriations. Given that critical services
Platform modernization is a new strategy that is designed must continue, agencies are now resorting to the
to help US federal agencies meet the operational fallback strategy of maintaining legacy platforms
challenges of today’s fiscal environment. It allows and incrementally modifying them to meet their
them to extend the service life of existing platforms missions. As a result, many mature platforms will
while adding new capabilities for an array of evolving continue in service for years to come. The figure below
mission requirements. The essence of this strategy is provides examples of vital military platforms serving
to independently furnish agencies with the necessary overextended periods of time.
technical information for modernizing platforms without

Platform Year Put In Service Projected Retirement ~ In Service Years
M1 Abrams 1980 2050 70
M113 1960 2017 57
HUMVEE 1984 2040 56
B-52 1955 2040 85
C-130 1957 2025 68
F-16 1974 2025 51

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There are significant challenges to keeping legacy Technical Data Package, which effectively decouples
platforms like these running 20 to 50 years past the historical process of always having to work
their original intended lifespans. Despite high hopes with designated OEMs to modernize their particular
that the fallback strategy will aid budgeting, platform platforms. With platform modernization, agencies
lifecycle costs are even harder to control in the new will independently discover the best way to update
environment. The culprit is high maintenance costs a particular platform with an engineering partner like
due to obsolescence of equipment requiring service on Booz Allen Hamilton.
outdated sub-systems and parts that are no longer
By steering engineering requirements and owning the
in production.
Technical Data Package that governs manufacturing, an
As for meeting evolving mission requirements, the agency can control the acquisition process, minimize
absence of new replacement platforms requires risk, and avoid monopoly deals.
agencies to modify the capabilities of existing
platforms. Typically, agencies have OEMs perform Methodology for Platform Modernization
upgrades and modernization because the government The methodology for platform modernization entails
does not own the technical data rights for its four phases, which are applied according to an
platforms. Not having these data rights makes it agency’s requirements for a program or project.
significantly riskier for government agencies to
modify or redesign aspects of the modernization 1. Deciding What to Change
package that—using aviation as an example—will Modernization must work with an existing platform’s
affect airworthiness or impact critical components characteristics such as size, weight, and power
for flight safety. Agencies that acquire upgrades and requirements. To optimize modernization and avoid
modernization from a single source supplier usually unintended consequences, the agency must first
pay more, given the lack of competitive bidding for decide what to change and why. This is largely
platform changes. A single source also limits the range accomplished through the conduct of trade studies
of technology that may be considered for integration. and analyses to determine the most beneficial trade-
offs available. Desired capabilities might include
To provide the government with more flexibility and
incremental improvements such as faster airspeed,
control and minimize risk in meeting these challenges,
communicating at higher data rates, providing more
agencies are turning to use of a new strategy called
detailed sensor data, or shooting a weapon with more
platform modernization.
accuracy. Other capabilities might be entirely new,
such as providing line-of-sight communications,
Platform Modernization Helps Agencies
engaging satellite links, or adding armament to
Meet New Operational Challenges unarmed platforms.
Platform modernization is a proactive strategy that
allows agencies to cost-effectively extend existing As changes like these are made over extended lifecycle
platforms with new capabilities for evolving mission timeframes, it’s important for agencies to consider
requirements. The essence of this strategy is to top-level system performance when deciding what
independently furnish agencies with the necessary to change. The new functionality must not adversely
technical information for modernizing platforms without impact existing functionality. Improving the architecture
being solely reliant on OEMs. to decrease integration burdens will result in smoother
modernization efforts—both for meeting the immediate
Platform modernization follows a four-step systemic
objective and for subsequent changes in the future.
engineering process culminating in the delivery of a

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Case Study: US Air Force
Problem The US Air Force needed to modernize its missile launch range systems and enable data-driven decisions for
range infrastructure.

Solution Booz Allen Hamilton established a technical baseline for the Launch Test Range System’s aging infrastructure of sensors
and command capabilities. We engineered an integrated architecture with requirements for 11 subsystem specifications.
For the ER Telemetry Subsystem Roadmap, we performed dozens of trade studies weighing requirements against current
capabilities and risks to assess future architectural options.

Result Booz Allen developed project-level architecture, requirements, and CONOPS for multiple projects and acquisition efforts
including separate US$100 million and US$150 million network modernization projects, and a US$40 million Command
Destruct project. We are helping the Air Force achieve a more cost-effective, disciplined battle rhythm for program
management of its launch ranges.

Strategic Impact of a Trade Study—US Army Aviation
Trade studies for platform modernization can profoundly fleet age is over 30 years, not the 21 years used by the Army
affect the government’s strategy and investment policy. For and Department of Defense for planning and budgeting. This
example, Booz Allen conducted a trade study for the US Army accelerated airframe and fleet aging impacts milestone decision
on factors affecting the age of its rotary wing fleet. A decade points in the aviation investment strategy. The calculation
of warfare in severe wind, sand, water, altitude, and hostile for total ownership cost of a platform must consider “aging”
combat environments had dramatically increased maintenance, factors for efficient lifecycle and fleet management. Longer
structural, and modification work on all rotary aircraft. The goal term, the age of the fleet is a greater risk than an aircraft
was to learn if increased operational tempo (OPTEMPO) had shortfall. Cumulative effects of increased usage and airframe
prematurely aged the fleet and, if so, by how much time. fatigue have a direct impact on when the Army must invest in
recapitalization and/or procurement of new aircraft to maintain
Methodology and Analysis for the Trade Study. The trade study
aviation capability.
addressed activity and structural analysis for Utility (UH-60),
Attack (AH-64), Cargo (CH-47), and Scout (OH-58) rotary wing Strategic Impact on the Army
fleets. Fleet data covered years 2002-10, during which rotary
• Avoided about US$1 billion in proposed cuts to its
aircraft had flown more than 6.7 million hours. The methodology
aviation budget
included a process of: a) secondary and primary data collection,
b) definition of key independent and dependent variables, c) • Will apply this “aging” methodology to all commodities and
analysis and modeling, and d) interpretation of results. Trade- calculate the impacts of war on all Army equipment
offs accounted for structural wear on maintenance engineer
calls and cumulative OPTEMPO impacts on airframe service life. • Will apply this methodology to the Army fixed-wing fleet
The key result was to directly compare three measures of age: • Advanced key acquisition milestones and decision points
actual age, activity fatigue age, and structural fatigue age. by 3 to 5 years for next-generation rotary aircraft, and
Trade Study Findings. Results revealed that higher OPTEMPOs increased Science and Technology funding for Army aviation
and structural damage had aged the rotary-wing fleet by • Initiated better data collection for ongoing aging analysis
an average of 9 additional years. While airframe model
upgrades officially reset the clock to “zero-time” for calculating • Advanced understanding and use of total ownership cost for
maintenance, they retain an irreversible, cumulative aging budgeting
of the original structural airframe. As a result, the average

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Exhibit 1 | Determining the Real Age of the Rotary Fleet

Source: Army Aviation Service Life Analysis Phase II developed by Booz Allen Hamilton

2. Developing a Design 3D laser scanning provides millions of data points
Making an adaptable, cost-efficient blueprint to for generating technical drawings, which increases
modernize a platform may require additional trade accuracy and decreases the time required to develop
studies. For example, will the modernized platform usable computer-aided design data for replacement
re-specify old parts that might be obsolete or no longer parts. In addition to physical measurement, reverse
manufactured, or can it use existing commercial off- engineering may entail evaluation of other aspects
the-shelf sub-systems? Understanding these trade-offs including mechanical, electrical, software, and
often entails reverse engineering, a process used interfaces. This phase may also employ physics-based
by Booz Allen to generate the technical data used engineering analysis that uses science to validate the
for designing new sub-systems and systems, and potential for platform designs.
integrating those with the platform.
Reverse engineering provides several benefits
To accomplish reverse engineering, Booz Allen for platform modernization. First, it eliminates a
conducts precise measurement and analysis of requirement to redesign entire systems to replace
the existing relevant system components. Use of a a single “obsolete” component. The agency gets
portable coordinate measurement system that employs continuous use of original systems without an increase

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in complexity or future cost. The only requirement
Case Study: US Army is a small expenditure of labor for measurement
and electronic data development. Second, reverse
Problem The US Army needed to add protective
engineering allows an agency to quickly integrate new
armor to Heavy Tactical Vehicles to mitigate
hardware onto existing systems with a high degree of
against new threats, while also allowing for
safe and expedient ingress and egress by accuracy, without having to obtain detailed technical
the driver and co-driver. data from OEMs. Third, reverse engineering also
supports analysis and development of existing systems
Solution The Booz Allen Engineering Services team
used reverse engineering to integrate an (see Case Study: US Army), and exploitation and
expedient armor package onto the M915A3 analysis of threat systems. Finally, the most significant
Line Haul Tractor. The integration kit allows benefit is that the government can obtain complete
the armor package to swing out of the rights to detailed technical data without the additional
way of cab doors. Analysis was performed costs associated with purchasing Technical Data
to ensure that the additional weight
Packages and related documentation from OEMs.
was evenly distributed and the vehicle
performance would not be impacted. Having the technical data is a fundamental requirement
The hinged armor boxes were manually
for platform modernization, and reverse engineering
operated using pneumatic linear actuators
may be the only way to obtain these data. For
with an electronic control system.
example, an agency may have possessed the data in
Result Supply chain drivers can now safely the past but lost it. For older platforms, it’s possible
enter and leave the modernized tractor
that an OEM is no longer in business, which is another
cab with automated deployment and
retraction of protective armor. This roadblock for obtaining technical specifications.
solution used commercial off-the-shelf Reverse engineering is a vital capability for putting an
(COTS) components and was successfully agency in control of modernization efforts.
completed without having to rely on the
OEM for technical data, which allowed for a
large cost savings.

Practical Uses of Reverse Engineering
Reverse engineering can provide many practical uses for Analysis Modeling. A product improvement program may
acceleration of platform modernization, including: require modeling existing hardware as a baseline for analysis.
An example is creating 3D solid models of an armor system in
Mechanical Data Generation. When data is unavailable for
order to conduct survivability/vulnerability analyses, and then
mechanical components, reverse engineering produces the data
modify the baseline design to correct observed deficiencies.
electronically for 3D solid models, 2D drawings, and electronic
technical documentation. This is valuable when OEMs may Technical Data Generation. An agency may need to remove
no longer exist for manufacturing replacement parts for software copy protection or circumvent single sources of supply.
antiquated components. Reverse engineering enables development of technical data
packages based on existing prototype equipment. The reverse
Integration Modeling. Reverse engineering can model existing
engineered package allows the agency to own and use technical
hardware for integration of new components. A common
data for obtaining cost-effective suppliers of equipment.
example is measurement of physical dimensions for developing
component attachment interfaces or pathways for cable routing. Exploit Foreign Material. Reverse engineering is used to exploit
analysis of a captured enemy vehicle or weapon system.

5

3. Prototyping a Design
Developing a prototype is mandatory for platform Case Study: US Defense Intelligence Agency
modernization. The prototype provides a model that
Problem The US Defense Intelligence Agency needed
allows an agency to test and prove that the new
a highly sensitive, special purpose radio
design works before proceeding with production. The
frequency (RF) measurement and signal
prototype is used for matching form and fit, and to intelligence (MASINT) sensor system.
gauge achievement of desired new functionality for the
Solution Booz Allen designed, developed, integrated,
modernized platform. It can apply to many deliverables
and operationally tested a prototype
such as a physical part or hardware system, an system that reduces space, weight, and
electrical design, or a software application. A prototype power, nearly by a factor of 10, and enables
may focus on form or design, aim to provide a user automatic, near real-time processing. The
experience, or demonstrate working functionality custom RF front-end was designed and built
ranging from partial- to full-featured. The ultimate goal for detecting very low power, low phase-
noise signals over wide RF bandwidths.
of a prototype is to derive working specifications for
The full system was constructed in
fulfilling platform modernization. our laboratory facilities. It extensively
uses COTS components in a modular
For example, a project conducted by Booz Allen for
architecture. Custom software supports
the Defense Intelligence Agency produced a working
real-world operations.
prototype of a radio frequency (RF) measurement
and signal intelligence (MASINT) system (see Case Result All project activities were within time and
budget. Lab testing was completed within
Study: US Defense Intelligency Agency). In addition to
4 months, integration onto the aircraft
inventing the new RF sensor, we created a modular within 5 months, and demonstration of a
COTS-focused architecture to simplify assembly and fully mission-capable system in theater-like
prevent a single component failure from impacting environments within 7 months of the start
other components. Prototype testing entailed multiple of contract.
phases that allowed our system engineers to fine
tune custom hardware and software for effective
performance at relevant operational altitudes in a
from the printer. A soluble support structure material
theater-like environment. The prototype allowed the
makes post-processing parts much easier. Software
client to know exactly what the solution would provide
enables advanced editing of the final build envelope
after manufacturing and fielding.
and full control of support structure generation for
For physical prototypes, Booz Allen often uses a manufacturing the physical part.
process employing additive manufacturing with
4. Providing the Agency with a Technical
a 3D printer, which provides the ability to build
Data Package
models quickly to validate concepts. High resolution
With results from the first three steps of platform
printing (also called fused deposition modeling)
modernization, we are able to create a Technical
enables variable layer thicknesses as thin as .007”
Data Package (TDP) for the agency. The TDP is the
for highly detailed models. Parts are made of rigid
foundational documentation to support acquisition
acrylonitrile butadiene styrene (ABS) plastic, which
of the modernized platform. It contains the technical
in many cases allows pieces to be usable directly
data for engineering and production lifecycle such as

6

performance requirements; engineering drawings for modernization approach using independent process
form, fit, and function; specifications for parts and for acquiring the necessary technical information
processes; quality assurance; and packaging. to modernize a platform without an overreliance on
OEMs. Using an independent partner like Booz Allen
Booz Allen follows standard data item description
to conduct the essential trade studies and analysis,
guidelines for a TDP that were established by the
develop a design, prototype the design, and provide
Defense Federal Acquisition Regulation Supplement
a Technical Data Package will provide government
and Procedures, Guidance, and Information.1
agencies more flexibility in the acquisition of needed
The information in a TDP is critical for exercising platform improvements, thereby saving significant time
control of the platform modernization acquisition and money while preparing our nation’s vital equipment
lifecycle. Data in the TDP allow the agency to to meet the demands of an uncertain world.
determine whether it should perform modernization
internally with organic assets, acquire the modernized
platform directly from an OEM, or conduct a
competitive procurement. Note that the government
always retains unlimited ownership rights for all
technical data related to form, fit, and function
and may use that data for purposes of competitive
procurement.2

However, for most current platforms, federal agencies
do not own the TDP, which is retained by the OEM.
In nearly all cases, the agency must pay the OEM
to obtain the technical data. This leads to a circular
process that limits flexibility by the agency and
concentrates risk in one provider. With platform
modernization engineered by Booz Allen, the end
product is a TDP that provides the agency with the
technical data it needs to cost-effectively drive the
acquisition process and minimize risk.

Capturing the Benefits of
Extending the service life and capabilities of existing
platforms is the de facto strategy for fulfilling mission
requirements in today’s budget-conscious environment.
In that the traditional execution of this strategy
required close reliance on OEMs, the ability of an
agency to achieve the necessary flexibility, efficiency,
and fiscal economy is a matter of record. Alternatively,
an agency can elect to implement a platform

1 efense Procurement and Acquisition Policy; see www.acq.osd.mil/dpap/dars/dfarspgi/
D
current/index.html
2 ee DFARS 252.227-7013 at www.acq.osd.mil/dpap/dars/dfars/pdf/
S
r20120906/252227.pdf
7

About the Authors
Lee Wilbur is a Booz Allen Hamilton Senior Vice Robert Smith is a Booz Allen Hamilton Senior Vice
President where he brings more than 25 years of President who specializes in the delivery of acquisition
executive management, program management, and sustainment support services to US government
and systems engineering experience with missile clients. He currently leads the firm’s support to the
defense, space, aircraft, and ground combat systems. Army Materiel Command (AMC), Aviation and Missile
His background includes extensive experience in Command (AMCOM), Program Executive Office
complex system development and supporting system for Aviation, and Aviation and Missile Research,
engineering technologies. Development, and Engineering Center (AMRDEC)
organizations, all based in Huntsville, Alabama.

Contact Information:

Lee Wilbur Robert Smith
Senior Vice President Senior Vice President
wilbur_lee@bah.com smith_robert@bah.com

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About Booz Allen
Booz Allen Hamilton has been at the forefront of resources, and deliver enduring results. By combining
strategy and technology consulting for nearly a a consultant’s problem-solving orientation with deep
century. Today, Booz Allen is a leading provider of technical knowledge and strong execution, Booz Allen
management and technology consulting services helps clients achieve success in their most critical
to the US government in defense, intelligence, and missions—as evidenced by the firm’s many client
civil markets, and to major corporations, institutions, relationships that span decades. Booz Allen helps
and not-for-profit organizations. In the commercial shape thinking and prepare for future developments
sector, the firm focuses on leveraging its existing in areas of national importance, including
expertise for clients in the financial services, cybersecurity, homeland security, healthcare,
healthcare, and energy markets, and to international and information technology.
clients in the Middle East. Booz Allen offers clients
Booz Allen is headquartered in McLean, Virginia,
deep functional knowledge spanning strategy and
employs approximately 25,000 people, and had
organization, engineering and operations, technology,
revenue of $5.86 billion for the 12 months ended
and analytics—which it combines with specialized
March 31, 2012. Fortune has named Booz Allen one
expertise in clients’ mission and domain areas to
of its “100 Best Companies to Work For” for eight
help solve their toughest problems.
consecutive years. Working Mother has ranked the
The firm’s management consulting heritage is firm among its “100 Best Companies for Working
the basis for its unique collaborative culture and Mothers” annually since 1999. More information is
operating model, enabling Booz Allen to anticipate available at www.boozallen.com. (NYSE: BAH)
needs and opportunities, rapidly deploy talent and

To learn more about the firm and to download digital versions of this article and other Booz Allen Hamilton
publications, visit www.boozallen.com.

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