Tag Archive for: ASC

The national shipbuilding plan: a first look

Image courtesy of the Department of Defence.

At last we have the Turnbull government’s naval shipbuilding plan. It claims to be the first such plan, yet the Howard government released one in 2003 and we had a de facto one from the Gillard government in 2013. So much for corporate memory.

But while it’s not unprecedented, it’s a useful document. It draws together recent announcements into a credible narrative, and provides some useful additional information about infrastructure, workforce and schedules. Yet it leaves some questions unanswered and raises others.

At the heart of the plan is a four-part strategy, focusing on infrastructure, workforce, industry and national coordination. Of course, it’s not that concise, and no positive adjective was left behind. In the veil of management-garble used throughout the report, ‘workforce’ becomes ‘a highly capable, productive and skilled naval shipbuilding and sustainment workforce’.

On infrastructure, some of the recent machinations surrounding ASC and infrastructure are finally explained. The government has decided to retain ownership of the shipyard infrastructure at Osborne in South Australia and Henderson in Western Australia that was formerly owned by ASC. One of the component parts of last year’s ASC split, now named Australian Naval Infrastructure Pty Ltd, will take ownership of those properties. And the Commonwealth will also buy out the infrastructure built at Osborne by the SA government.

We think those are smart moves, especially for the SA yards. If the shipyards and associated infrastructure had been sold off to the builder of the future frigates, it would’ve created an effective monopoly that would have been hard to break in the future. We warned about such a possibility in an earlier analysis. The UK government made that mistake, and BAE now has it in an invidious position. With the local infrastructure still in Australian government hands, the build contract for future classes can be subject of a competitive process, providing at least a modicum of competition. The Williamstown dockyard in Melbourne only rates a mention as an historical note—it looks set to play no role in future naval construction or sustainment. And there’s no mention of the Forgacs yard in NSW at all. Consistent with the theme of consolidation, there’s no mention of subcontracting ship module builds in the plan—vertically integrated monopolies seem to be the order of the day for construction.

There’s a lot in the plan about the workforce required to realise the vision. The bottom line is that the government isn’t prepared to leave the development of the workforce to the market players who will design and build the ships and submarines. The government is going to intervene by providing the educational equivalent of shipyard infrastructure, in the form of a new Naval Shipbuilding College based in Adelaide. Skilled workers will become government furnished equipment.

The plan is at pains to stress that it’s not all about the two yards in SA and WA. There’s ‘something for everyone’ or, as the plan terms it, ‘a national approach to the Naval Shipbuilding Plan’. And there’s no hyperbole spared:

‘This national endeavour is the most significant nation building project Australia has ever undertaken. Larger and more complex than the Snowy Mountains Hydro-Electric Scheme and the National Broadband Network…’

We might wish that the author of those words had spoken to the IT industry about the NBN (or to a reputable economist about either) but there’s no denying that the enterprise being built will cross state and territory boundaries, and will involve educational institutions and businesses across the country. To help grease the wheels, Defence will be establishing a national consultative body.

Much of the document is about the management framework, and a lot of the discussion is general. But there are also some numbers and indicative timetables in several graphics showing the timing and sequencing of planned projects. As useful as they are, they raise several questions.

The first is the confusing and inconsistent use of the terms ‘continuous’ and ‘rolling’ production to describe the submarine program. We know for certain that the frigates and minor vessels will be built in continuous production runs, with the build of a new class of vessel commencing as the previous one concludes. Until now, most observers have assumed that the White Paper use of the term ‘rolling production’ signified that there would be substantial breaks in the submarine program. But in various places the Plan refers to submarine production as being either continuous or rolling. To make matters worse, a diagram in the Plan (Figure 1.2) shows submarine work continuing long after the 12th boat is due to be delivered. Why not just say what’s planned? (And it’s not like the first time that this confusion has surfaced—Defence took pains to explain the difference to us when we assumed they were synonyms.)

As expected, the Plan maintains a 2018 start for the Offshore Patrol Combatants and a 2020 start for the Future Frigates—though the term ‘cutting steel’ has been dropped. More importantly, the in-service date of the first Future Frigate is given as 2027-30. That’s one- to four-years later than the RAND shipbuilding report (upon which the government’s plan is based), which assumed a 2020 start date. It looks as though the rumored late start to the frigate program has been quietly slipped into the plan.

Elsewhere the plan exhibits a disappointing lack of attention to detail. For example, it has the ninth Future Frigate arriving in 2038 and a two-year drum-beat of production. While they are described as ‘indicative’ dates, on face value they defy arithmetic. Similarly, by counting 1,700 submarine supply chain jobs as direct jobs, it appears to overstate the number of direct jobs produced. And the estimate of total costs uses a ratio of 30% acquisition to 70% sustainment costs—whereas the conventional 70/30 split is based on acquisition versus all other ownership costs, including not just sustainment, but also personnel and training costs (which are appreciable). Once again, the quality of advice on industry going to the government is questionable.

Finally, on arguably the most critical issue of all—how to drive productivity in the resulting monopoly shipyards—the Plan says that ‘robust and complementary performance frameworks must be developed and reported against regularly through the National Security Committee of Cabinet’. That’s good, but then it goes on to say that the reporting will be ‘informed by advice from the independent Naval Shipbuilding Advisory Board’. Sorry, a part-time board, half of whom live in the United States, is not going to cut it. Here’s what a proper solution would look like.

Interpreting the ASC split

Yesterday the Australian government (with the PM and three cabinet ministers in attendance) announced that it’s going to split ASC into three separate but still government-owned companies, to ‘support the key capabilities of shipbuilding, submarine sustainment and infrastructure’. It was heartening to see some movement on the issue. It’s vitally important that government gives serious thought to the industrial arrangements for projects that will cost the taxpayer tens of billions of dollars—something we noted last year.

At yesterday’s announcement, the government was at pains to note that it ‘does not have a plan to privatise these three new companies’. So what’s been gained and lost by the split? On the positive side, the newly created businesses will be able to focus single-mindedly on their respective specialisations. And the separation will provide greater public transparency into the business performance of the three components (though the government won’t necessarily see that as a benefit).

On the negative side, we’ll see corporate overheads (including board positions) multiplied by three. At the same time, interactions between the three newly created companies will generate additional transaction costs. Where once an internal company memo would suffice, a legal contract will become necessary; and where sharing of human resources between business units was once possible, now there’ll be competition for talent.

No doubt the consultants advising the government provided a compelling case for why the swings outweighed the roundabouts. But irrespective of what the government’s plans are today, the split manifestly creates the option of selling some of the businesses down the track, while keeping the shipyard infrastructure in government hands. There’ll be some negotiation required with the South Australian government, which has stumped up $300 million of its own money for infrastructure down at Osborne, but the federal government seems determined. The Finance Minister was

… very clear. This is a strategic asset of national significance and it is explicitly the Government’s intention to maintain the infrastructure business and infrastructure assets in Commonwealth ownership.

By owning the infrastructure, the government can then sell the other businesses, leasing out the facilities to users as required. That’s smart, inasmuch as it allows the government to retain the option of competition for future projects, rather than granting monopoly control of core naval maintenance and construction assets to a single commercial entity in perpetuity. That’s why the Commonwealth retained ownership of the facilities at Garden Island in Sydney.

It’s interesting that yesterday’s announcement made no mention of submarine building. That’s probably because there’s no submarine construction at the moment, and likely won’t be for some years, given that the contract with DCNS for the commencement of the design phase for the future submarine was signed only two weeks ago. By retaining ownership of the infrastructure in Adelaide, the government now has the option of simply letting some space to DCNS for the construction phase, rather than once more going into the submarine building business itself. And it can also opt to move the now separate submarine sustainment business to Western Australia (where ASC already has a maintenance facility) if space at Osborne is at a premium.

The ways ahead for the Future Frigate and Offshore Patrol Vessel (OPV) programs are less clear, though competitive evaluation processes are underway for each. It’s not simply a matter of choosing designs; that’s the easy part. The real challenge will be to put together an industrial and commercial package that delivers value-for-money to the taxpayer (also true for the submarines).

The government has promised a continuous major warship production program for South Australia and a continuous minor warship program for Western Australia. It remains to be seen how the government will achieve efficiency from the two long-term monopoly shipyards it plans to create. Given the substantial political power we’ve seen exercised by the South Australian shipbuilding lobby over the past 20 months, the government will begin negotiations on the back foot.

To further complicate matters, the OPV production program is planned to commence in Adelaide (to provide a gap-filler between the AWD and Frigate programs) before shifting to Western Australia to retain skills in the South Australian yards. Unless a single firm wins both contracts, it’s unclear how the split OPV program will be managed. And it again raises the question of ownership. Workforce continuity would most easily be achieved by either awarding the gap-fill OPV and Future Frigate contracts to the newly created ASC shipbuilding spin-off, or selling the newly created shipbuilding spin-off to whichever firm wins the Frigate contract.

Whether the government keeps the new businesses it created or sells one or more is irrelevant from a financial perspective. The government’s the only likely customer for the activities in the South Australian shipyards. So, either way, the net result is a flow of money from the government to the private sector. Think of it this way: any firm that buys a naval shipbuilding business from the government is really just lending the government money temporality.

The crux is really how well the entire enterprise is managed. And, in the long term, private sector ownership is likely to result in better management. Yesterday’s announcement at least showed that the government is thinking about it and creating options for moving ahead. If nothing else, that puts us ahead of where we’ve been for much of the past decade.

Defence White Paper FAQs: the enduring relevance of submarines (part 1)

USS Missouri - Radar Control Panel

As a member of the Defence Minister’s White Paper panel, I’ve had many discussions about issues that paper will wrestle with (and a few that it certainly won’t, but that’s a post for another time). With the obvious disclaimer that I’m not about to divulge any white paper content, I thought it was worth addressing some of the questions that have come up repeatedly.

Naturally, questions about the future submarine are near the top of the list. Many topics are predictable enough. Where will they be built? How many do we need?

I’m surprised at how often I’ve been asked whether we’re wasting our money because submarines are about to become passé. That question is based on one of two premises: that the oceans are about to become ‘transparent’ due to new detection technologies, or that submarines will be replaced by unmanned underwater vehicles (UUVs).

Both propositions have a reasonable pedigree, and neither can be dismissed out of hand. And both technologies will have a significant impact on the future conduct of submarine operations. But when examined closely, they actually point towards an increased relevance for submarines.

Let’s start with the detection issue. The attribute that most contributes to the effectiveness of submarines is their stealth. An adversary faces significant uncertainty even with just the possibility of a submarine being present. A great deal of effort has to be put into anti-submarine warfare to have even a reasonable chance of nullifying their effect. Having a capable submarine somewhere in a theatre of maritime operations complicates planning everywhere—or at least within a large circle of possible locations that grows steadily with time.

The ability to quickly and reliably find submarines would certainly change their cost benefit calculus, and the notion of making the ocean ‘transparent’ isn’t a new one. The Cold War USN put a great deal of effort into being able to track Soviet nuclear missile-carrying boats, building an array of networked underwater sensors under the Long Range Acoustic Propagation Project. Their effort met with considerable success and the USN often had a pretty good hold on Soviet submarine movements.

But there are two important caveats. First, those were earlier generation nuclear submarines which were noisier than their current counterparts. Second, even when Soviet submarines were detected, precise localisation wasn’t always possible. The arrays were heavily supplemented by other techniques, not least of which was the ‘tailing’ of Soviet boats by American submarines. (See the ‘ripping yarn’ bestseller Blind Man’s Bluff for a popular account). In fact, when the arrays picked up the sounds of the destruction of its own USS Scorpion, the USN still took four months to locate the wreckage. The simple fact is that reliable localisation of sound sources in large ocean basins is a formidably difficult task that gets progressively harder as the difference between the source and background noise gets smaller—as is the case with modern submarines.

Of course, detection technologies and the ability to analyse collected data have also improved. I wrote about the effect of Moore’s Law on submarine detectability here, and it’s true that future submarines will face challenges in remaining hidden. They’ll also have to worry about techniques other than acoustics, such as wake detection, thermal signatures or even the light given off by sea creatures disturbed by their passage. Given enough data and enough signal processing power, even very subtle signs could be giveaways—potentially even from orbit.

Nonetheless, the real world is a noisy and untidy place. Covering very wide areas with sufficiently sensitive sensors with high bandwidth to link them together and having the ability to respond quickly and effectively to a detection—especially given a likely high ‘false positive’ rate—will be beyond even the best resourced forces. Much more likely is that high performance ASW capabilities will be concentrated on key focal areas, such as around task groups, near naval bases, and chokepoints such as critical sea lanes through straits and narrows. The old model of submarines getting ‘up close and personal’ in their adversary’s strongholds probably doesn’t have much future.

But in terms of avoiding detection, being under the water will always be preferable to being on top of it. And if the submarine can carry out its mission from a reasonable distance, there’ll still be ocean enough to hide in. To remain viable, future submarines will have to be even more stealthy. They will need be able to stand off and deploy medium to long range sensors and weapons—in a sense perhaps becoming ‘underwater motherships’ for sensor and weapon packages. In fact, as life gets harder on the surface, that ability will become more relevant, not less.

And that’s a neat segue to UUVs. In the next post I’ll discuss their strengths and weaknesses and explain how the complementary package of manned submarine and unmanned subsystems could come together to help defeat improved sensors.

Ships ahoy!

ASC, Tony Abboty and Kevin Andrews

The government’s announcement of an ‘$89 billion shipbuilding program’ today is bold on two fronts. First, in the implicit assumption that much of the price premiums paid on past and current projects and the poor performance—by any reasonable measure—of the Air Warfare Destroyer program are mostly artefacts of the recent ‘boom and bust’ cycle of naval shipbuilding. Second, by committing to a continuous build of surface combatants, the government has placed a large bet on the continuing relevance of surface vessels in an age of precision targeting.

While neither of those propositions is demonstrably wrong, both are at least questionable. Let’s start with the surface combatant question. Both the Rudd and Abbott governments have exhibited a broad support for aligning Australia’s military capabilities with the US, especially at sea. The 2009 Defence White Paper talked up the future frigate program and an expanded submarine fleet as vital responses to the changing power balance in the Asia–Pacific—a thinly disguised response to increased Chinese naval power.

Of course, the 2009 White Paper was never delivered on, but the current government shows every sign of following the same path to a larger and more capable navy, albeit with more surface combatants and (perhaps) fewer submarines. But if support of the US is one of the aims, we should think carefully about the best way to contribute to alliance sea power and take note of the USN’s own strategic directions.

The USN has made a significant effort in recent years to maintain its numbers of submarines in build, even at a time of significant budget pressures. It even considered cutting its number of nuclear aircraft carriers before it was overruled by Congress. At the same time, the highest priorities for the service are continued acquisition of Virginia class submarines, a replacement for the nuclear missile Ohio class boats and ‘maintaining undersea dominance‘. That’s not surprising. Modern naval warfare has to take into account precision targeting, enabled in part by space based surveillance systems that allow ‘over the horizon’ shots. As well, a diverse combination of stand-off cruise and ballistic missile systems will make life on the surface much harder.

As far as the industry side of shipbuilding goes, we’ve written a lot on the topic over the years, most recently a few weeks ago, and—to be blunt—we’re far from convinced of the soundness of a continuous build program. But beyond that overarching point, it’s difficult to say much more given the paucity of detail in today’s announcements.

What we do know is that the Future Frigate project (SEA 5000) will be brought forward by two years to allow a continuous-build program to commence in 2020. In addition, the Offshore Patrol Vessel project (SEA 1180) will also be brought forward by two years to allow a continuous build program to commence in 2018. A Competitive Evaluation Processes (i.e. ‘beauty contests‘) will be held for each program. By bringing the programs forward and commencing continuous-build programs, it’s anticipated that efficiencies will be achieved along the lines outlined in the recent RAND shipbuilding report (a critical analysis of the report can be found here).

Frustratingly, we weren’t told how many vessels of each class will be built, nor the frequency with which they will be built. As a result, we don’t know how a continuous-build program will be achieved in either instance. Will the fleet expand to accommodate a continuous-build scheme, or will the life-of-type be cut to allow more frequent replacement? Either way, there’ll be substantial additional costs; which might explain why the notion of twelve future submarines seems to have morphed into acceptance of a fleet of only eight.

The government also announced today, a ‘strategic review’ of ASC’s shipbuilding capacity, the results of which will be ‘considered in conjunction with future decisions on submarines and surface shipbuilding programme’. That means that the government is yet to come to grips with the long list of things that will have to be done in setting up a continuous-build program. Key questions include:

  • What will happen to ASC? Will it be sold or retained in government hands as a Government Business Enterprise (GBE) or, perhaps, reestablished as a Government Owned Corporately Operated (GOCO)?
  • If ASC is sold, will it be sold intact or broken up into its submarine and shipbuilding component?
  • How will the resulting shipbuilding monopolies be managed? What will stop the private sector monopolies from delivering public sector productivity while booking private sector profits?

The government also announced its next steps for the troubled AWD program. With a turn of phrase befitting Sir Humphrey Appleby, we were told that ‘an additional $1.2 billion will be invested in the programme budget’. Unless the government gets the details right in its ambitious $89 billion plan for naval shipbuilding, we might find ourselves making similar ‘investments’ in the years ahead.

The case for building submarines in Australia

Williamstown Naval Dockyard

If there’s one thing we’ve learned in the last 25 years, it’s that government can’t successfully run naval dockyards in Australia. This is why the National Commission of Audit recommended the immediate privatisation of ASC.

There are three other important lessons that we must heed if we are to create an efficient, enduring naval construction industry in Australia. The first is the requirement for a single highly competent prime contractor responsible for the delivery of the whole vessel, including systems integration.

Second, we must ensure that the chosen platform is subject to tight capability and configuration control and the use of the most advanced existing systems and equipment. Avoid R and D type solutions at all costs, and go with proven performers.

Finally, we should have confidence that we can successfully build complex warships here, adding to our high technology base and giving us the intellectual property and local capability to maintain, modify, and update naval vessels over a 30-year operating life.

Local construction gives us a much larger degree of independence than a build in an overseas dockyard. This is particularly important for a country at the end of a long maritime supply chain. The savage reality of this lesson was learnt early in WW2 when we struggled to defend ourselves.

The best recent example is the Anzac Warship Project, where 10 ships were delivered on time and on budget with full operational capability. They were designed by Blohm and Voss (now ThyssenKrupp Marine Systems TKMS) to suit Australian and New Zealand requirements, and built and integrated by a single prime contractor—Transfield Defence Systems—at the privatised Williamstown Naval Dockyard. With a new, vastly more productive workforce, ten Anzac frigates were built under fixed price contracts.

The combat system for the Anzac frigates was supplied by Sweden and developed in Adelaide. The cost penalty over a full ship build in Germany was negligible and more than offset by the long-term local industry support network. Local content in the project amounted to 80%.

These hard-learned lessons should be applied to the acquisition of our next generation submarines. The RAN has unique requirements: quiet, conventionally powered vessels able to operate in littoral waters and undertake extended, long-range patrols far from Australia. An ‘off-the-shelf’ solution to replace the Collins class isn’t an option.

We should build on the lessons learned from the Collins-class submarines which, despite the well-known problems with systems integration and overseas suppliers, were successfully built in Adelaide. Both the Anzac frigate project and the Collins submarines’ construction reached international benchmarks of productivity and quality as well as helping sustain more than a thousand SMEs across Australia.

We also need to learn from the difficulties and cost overruns experienced by the Air Warfare Destroyer (AWD) project. It isn’t fair to use the AWDs as the key criterion to make decisions about the capability of local defence industry to undertake future naval construction in Australia. The AWD alliance structure was flawed from the start, with the ship’s designer left out of the alliance, and without a single experienced naval shipbuilder in charge.

The construction of the Anzac frigates and the Collins class submarines followed a series of well-established procedures in Defence procurement, starting with a careful identification of the RAN’s top-level requirements for each platform. After the selection of a short-list of experienced offshore designers, funded project definition studies led to the submission of fixed price tenders for a local build which maximised the involvement of Australian industry. The Abbott government should follow this well-proven, risk-reduction path.

Our successful naval shipbuilding experience in Australia in the 1990’s showed that we could build surface warships and submarines simultaneously. The Abbott government should have confidence that, with the right defence procurement procedures and contractual arrangements in place, and with construction in privately-operated dockyards, the future submarines and the future frigates can be built successfully in Australia.

Our next generation submarines should be built in Adelaide in a privatised dockyard with a single prime contractor using a proven, suitable design from a proven designer. This isn’t for xenophobic reasons. It’s for sound strategic and economic reasons.