Title: Shipbuilding and the Industrial Base: Ready for a Potential Maritime Competition
1Shipbuilding and the Industrial BaseReady for a
Potential Maritime Competition?
- Robert O. Work
- Center for Strategic and Budgetary Assessments
- April 5, 2006
2When I Reread This Brief, I Had a Sudden,
Unsettling Vision
Adm Crenshaw
Adm Hamilton
Admiral Mullen
Me
Adm Nathman
3Therefore, Id Like to Make This Disclaimer
- The views expressed in this brief are Ms.
Allison Stillers and Mike Toners. - I agreed to present their views in return for a
tour of the Exposition and a ball point pen. - All subsequent questions should be directed to
them.
4In 1815, After Britain Defeated Revolutionary
France, It Found Itself in Command of the High
Seas
- Key question how best to sustain maritime
supremacy with no clear naval challenger in
sight? - Had a large fleet of ships designed for the last
war (first, second, and third rates) which were
very manpower intensive - Confronted a serious transnational threat (human
slavery and piracy) - Needed to hedge against the rise of a naval peer
competitor - Resurgent France?
- Rising Russia, possibly an ally of France?
- Rising democratic America? (potential maritime
rival with enormous latent economic potential) - Faced with relatively tight budgets
- The Admiraltys answer
- First, fight the war youre in
- Declare war on human slave trading and piracy and
fight the war with an expanded fleet of small,
cheap combatants (frigates, sloops, brigs) - Adopt a competitive strategy of the second move
(hold what you've got exploit the Royal Navys
huge lead) - Rely on the (commercial) industrial base as
competitive hedge - Prepared to make bold moves to quickly advance
the lead when necessary (1860 and 1906) - Key supporting goal reduce manpower costs
- Lay up the big warships
5In 1989, as the Berlin Wall Came Down, the U.S.
Found Itself in Command of the High Seas
- Key question how best to sustain maritime
supremacy with no clear naval challenger in
sight? - Had a large fleet of ships designed for the last
war (108 guided missile ships and general
purpose destroyers) that were manpower intensive - Confronted with myriad global responsibilities,
but no clear naval threat - Needed to hedge against the rise of a naval peer
competitor - Resurgent Russia?
- Rising China?
- Rising Indiaa potential democratic maritime
partner or rival? - Faced with relatively tight budgets
- The Navys initial answer
- Given uncertainty, hold force structure line by
emphasizing presence over warfighting - Adopt a holding strategy emphasizing carriers
large multi-mission combatants - Exploit blue water dominance and platforms by
emphasizing littoral strike operations (aviation
and guided missile strikes) - Cut submarine force and protection of shipping
combatants - Cut amphibious lift requirement
- Get rid of small combatants, transfer riverine
capabilities to the Marines, transfer PCs to USCG - Key supporting goal reduce manpower and OM
costs - Cut the overall size of the force, civilianize
the CLF, cut the MLF, move to an all-gas
turbine combatant fleet
6These Initial Answers Were Reflected in the 1997
QDR
- The 1997 300-ship navy was roundly criticized
by Navy leadership spurred the development of
many alternatives - Adm Murphys 460-ship fleet
- 360-ship risk reduction fleet
- 375-ship Global ConOps Navy
- JCS SSN Study
Note numbers in red did/do not count in the
official TSBF
7By 2005, the U.S. Still Commanded the High Seas,
But it Was Confronted by Two Maritime Challenges
- Key question how best to sustain maritime
supremacy? - Continued to build toward a large fleet of ships
designed for the last war (84 AEGIS/VLS
combatants94 percent of 600-ship Navy
requirement) that were manpower intensive - Was tasked with fighting a global war against a
transnational threat (radical extremism and
piracy) - Increasingly concerned over the rise of a
potential naval peer competitor - Rising Chinaa potential maritime rival with
enormous latent economic potential - Faced with relatively tight budgets
- The Navys answer
- Fight the war youre in really shift to the
littorals (reluctantly?) - 1,000-ship Navy, NECC, reconstitute riverine,
retrieve PCs, new small combatant (LCS),
increased support for Naval Special Forces - Adopt a competitive strategy of the first move
(expand the lead) - Prepare immediately for war against a naval near
peer - Build more capable and more expensive warships,
with an emphasis - on surface combatants
- Key supporting strategy reduce manpower costs
- Reduce crew size through automation
8The Navys Competitive Strategy is Reflected in
the 2006 QDRs 313-Ship Navy
- A 300-ship navy hailed as a great advance
- Actually, the plan has six fewer warships than
the 1997 QDR!
Note numbers in red did/do not count in the
official TSBF
9Where Has/Does Industrial Base Planning Fit Into
U.S. Naval Competitive Strategy?
- Essentially, it appears to be an afterthought (or
at least a very low priority) - First reflected in the decisions concerning the
submarine design, build, and supplier industrial
base in the 1990s - During the 1990s, did not authorize new submarine
production for six years - Will have two yards that will build half a
submarine a year for ten years - No new submarine design ongoing with attendant
problems (personnel, supplier base declining,
cost of parts increasing) - By 2005, it was increasingly clear that the Navy
began to think of the industrial base as just a
commercial vendor rather than a valued partner in
pursuing its competitive strategy - The decision to close a shipyard...is up to
industry. We dont define the industrial base.
Its up to the market to arrive at these
conclusionsits a commercial world, and they
make commercial decisions. - Secretary of the Navy Gordon England
- January 2005
- During the last year of Admirals Clarks tenure,
it seemed that the Navy laid most of blame on the
Navys shipbuilding woes on industry - Especially with regard to the escalating costs of
ships - However, most objective reports link the high
cost of ships to Navy design requirements,
changes to the shipbuilding plan, and ship change
orders
10Is The Apparent Lack of Concern Over the U.S.
Shipbuilding Base Wise Policy?
- Assigning blame on the industry and allowing
commercial decisions to drive the character of an
industrial base which will have a major that
impact on U.S. naval competitive strategy do not
appear to be wise choices, especially if we are
indeed on the leading edge of a disruptive
maritime competition with China - Unlike Britain in 1815, we cannot rely on the
commercial shipbuilding industry to maintain our
naval prowess - Moreover, China is the first potential naval
competitor weve faced since 1890 with an
industrial capacity as large as (or potentially
larger than) our own - By 2004, China had the fourth largest merchant
fleet in the world by deadweight tonnage (U.S.
was sixth) - Like the Soviet model, some of these ships could
be dual use - China is building the worlds largest single
shipyard - Navy exhortations to the shipbuilding industry to
change its Cold War focus seems to be a proxy
argument directed at Congress - Two key questions
- Will current shipbuilding plans sustain the US
competitive advantage in designing and building
naval warships and battle networks over time? - If not, what should we do about it?
11The Answers to The First Question Begins to Form
by Comparing the 1997 and 2006 Plans and Their
Respective Costs
- According to the DoN, the 2007 30-year
shipbuilding plan will cost an average of 15.4
billion a year in constant FY 07 dollars
(including nuclear refueling costs) - Considerably higher than the average 11 billion
annual shipbuilding budgets seen since the end of
the Cold War
Note numbers in red did/do not count in the
official TSBF
12To Execute the New 30-Year Shipbuilding Plan,
Five Things Must OccurSimultaneously
- The Navys plan prudently assumes a flat
Departmental topline (no real growth). To
increase the average shipbuilding procurement
budget to an average 15.4 billion a year, the
plan makes the following five assumptions - RD must go down and stay down
- Is this logical if we are on the verge of a
concerted maritime challenge? - No real growth in OM
- 500 million in back maintenance on the FY 07
Unfunded Deficiency List - Rising price of oil
- No real growth in personnel
- Navy has a good plan, but its outcome is largely
out of the Navys hands - 250 million in unfunded fact of life
increases in FY 07 Unfunded Deficiency List - Savings may be diverted to Army and Marines)
- Must hit stretch goal ship cost targets on
every ship programLCS, SSN-774 and 774I, CVN-21,
DD(X), CG(X), HSS, JHSV, DDG(X), SSBN(X)with no
cost growth - Will fence shipbuilding and take up any
procurement delta in aviation procurement
accounts - Two versions of JSF, MV-22 BAMS, ACS, E/A-18G,
CH-53K, etc., etc.
13These Assumptions Have No Historical Precedent
- For example
- RD and procurement generally follow similar
trend lines would be most unusual for RD to go
down while procurement goes up - OM costs generally have not been contained
- Personnel costs have risen substantially since
1973, and particularly since 1999 - Statistically speaking, assuming there is a 90
percent probability each assumption is true, the
likelihood they will all come true is 60 percent - .9 x .9 x .9 x .9 x .9 approximately 60
percent - If the probability that each assumption falls to
87 percent, the likelihood that the five
assumptions all hold true falls below 50-50 - Recipe for instability?
14Setting Aside the Assumptions, Given the Similar
Numbers Between the 1997 and 2006 Plans, What
Accounts for the Dramatic Planned Cost Increases?
- The majority of the cost increase, at least
between now and the 2020s, can be explained by
noting the differences in the composition of
ships in the surface combatant/mine warfare
category, and their increased costs
Note numbers in red did/do not count in the
official TSBF
15A First-Order Reaction the New Plan Will Put
Enormous Pressure on the Two Remaining Large
Surface Combatant Yards Already Under
Considerable Strain
- Went from a plan that called for 116 large
combatants to one that built 88 (all 55 LCSs are
to be built in Tier II yards) - 116 surface combatants / 35 year ESL an implied
sustained shipbuilding rate of 3.31 ships per
year (10 ships every three years) - 88 surface combatants / 35 year ESL an implied
sustained shipbuilding rate of 2.51 ships per
year (10 ships every four years) - But high cost of the ship design (DD(X)) means
will build only 13 ships between FY 07 and 15, at
a rate of 1.44 ships per year (10 ships every
seven years) - After that, the sustained shipbuilding rate
settles at 2 ships per year (ten ships every five
years) - Similar calculations can be made for the
submarine fleet - 48 SSNs / 33 year ESL an implied sustained
shipbuilding rate of 1.45 subs per year - This explains Navys clear desire to go to one
combatant yard, and the logic behind calls to
move to one submarine yard - Makes sense in terms of efficiency what about in
terms of competitive strategy? - In any event, seems clear Congress wants two
yards for both warships and subs
16But the Impact of the New Surface Combatant Plan
Will Ripple Far Beyond the Two Surface Combatant
Yards
- In 1997, the plan was to
- Build the last of the DDG-51s in 2004
- Authorize the first DD-21 in 2004
- Build 3 DD-21s per year between FY 06 and 15,
then one (the 32nd ship) in FY16 target cost for
the fifth ship of the class was for 1.06 billion
in FY 07 dollars (objective) - Modernize the CG-47s and extend their expected
service lives (ESLs) to 40 years first would
retire in 2023 - Build first CG-21 in 2016 skip a year and then
build at a rate of 2-3 per year. For this
exercise, I assume first ship cost of
approximately 3.0 billion in FY 07 dollars - In other words, after building 57 DDG-51s, the
1997 QDR plan was to spend 37 billion between
FY04 and FY 16 on surface combatants thereafter
continue a high sustained ship rate to replace
the Ticos and Burkes as they reached the end of
their ESLs - Average of 2.84 billion per year
- Approximate aggregate crew size for 32 DD-21s and
one CG-21 (assuming a crew size of 145 per ship)
would be approximately 4,785 officers and Sailors
17Compare These Figures With Those Found in the New
30-Year Shipbuilding Plan
- In contrast, the new plan (using Navy planning
figures) - Built two more DDGs in FY 04 and three in FY 05
average cost of approximately 1.4 billion
apiece - Builds 55 LCS between FY 05 and FY 2016 average
cost for the sea frames is estimated to be 296
million in FY 07 dollars average cost for two
modules per hull is estimated to be 140 million,
for a total of 436 million per ship - Builds seven DD(X)s between FY 07 and FY 13, at
average cost of 2.8 billion per ship - Builds six CG(X)s between FY 11 and FY 16, at
projected average costs of 2.7 billion per ship - Modernizes the CG-52 class but does not extend
its 35-year ESL - This plan costs 67 billion between FY04 and FY
16 - Average of 5.13 billion per year on surface
combatants - Requires an aggregate crew size of approximately
10,240 officers and Sailors (over 5,000 more than
the 1997 QDR plan) - When you have had average shipbuilding budgets of
11 billion since 1989, such a dramatic jump has
a disproportionate impact on the entire
shipbuilding plan - The resource planning allocation for surface
warships jumps from 26 to 47
percent of the baseline budget
18The Dramatically Higher Cost of the 2006 Surface
Combatant Fleet Shapes the Outline of the Entire
30-Year Shipbuilding Plan
- It helps to explain both the high cost of the
shipbuilding program as well as its basic
outline, which is to - Build cheap seabasing, auxiliary, and amphibious
ships up front, and then stop building themfor
periods between seven to ten years - Rapidly build 55 LCSs by 2016, then stop building
small combatants until 2030 - Start building the expensive DD(X)s/CG(X)s well
over a decade before the first the
Ticonderoga-class CGs are scheduled to retire,
and slowly move toward a steady-state build rate
of only two large surface combatants a year
(reached in 2017) - There will be seven DD(X)s and three CG(Xs) in
the fleet before the first Tico retires, causing
the battle line to drive to 95 ships (seven over
requirement) - Then, in the later 2020s/early 2030s, try to
simultaneously recapitalize the amphibious,
combat logistics force, support vessels, SSGNs,
SSBNs, DDGs and LCSs (which have a 25-year design
life and must be replaced) - The result is that a graph charting the number of
ships in the TSBF looks like a roller
coaster, going from 281 today to 329 in 2019 to
292 in 2031 steady-state is 293
ships (-18 combatants and 4 SSGNs)
19Hard to See Any Industrial Base Stability in This
Plan (Unless Stability is Defined as Developing
a Number and Sticking to It)
- How do you size the plant and workforce when
- Dont get to two submarines per year until FY 12
(if then) - No auxiliaries authorized from FY12 though FY 16
- No medium size amphibious ships authorized from
FY11 through FY 17 - If we build the tenth LPD-17 if not, add two
years - No large deck amphibious ships authorized from FY
13 through FY 23 - Build large surface combatants at a rate of 1.44
ships for the next ten years, then jump to 2
per year - How will we retain the industrial plant and
workforce required to build the large fleet
numbers in 2020, much less respond to a concerted
maritime challenge from China? - Clear that further consolidation will be
required how far do we go? - Where is Congress in the debate?
20Moreover, How Do We Retain Our Design Teams?
- Consider the British experience with the Astute
SSN - We must not become fully pre-occupied by the
industrial base at the expense of our
intellectual capital in submarine design. One
only has to look at the UKs automotive and
aerospace industries to see that it is the
high-value design and intellectual capabilities
that have been retained while most manufacture
has gone overseas. And while the UK is likely to
want to retain an indigenous submarine
manufacture capability, we must protect the
design resource that ultimately underpins the
industrial activity. (emphasis added). - Given our huge maritime lead, but lack of a
robust commercial shipbuilding industrial base,
is pursuing prototypes and having design
competitions aimed at changing the rules of the
game more important than shifting to a new large
surface combatant now? - The U.S. submarine design base is already at
risk - We are locking in on a surface combatant design
long before the outlines of any maritime
challenge is clear - What about the design teams for auxiliaries and
amphibs?
21Finally, If RD Goes Down and Stays Down, Will We
Be Prepared to Respond to New Challenges?
Future Seabasing Operation
22- Perhaps We Need to Rethink Our Basic Assumptions
and Plans Before Take-off
Industrial Base
Navy Plan
- If we are indeed on the verge of a disruptive
maritime competition with China, perhaps we
should consider a strategy of the second move
less emphasis on expensive new designs that
extend an already huge lead and more emphasis on - Strong RD
- Maintain industrial base using proven designs
(i.e., the DDG-79 and LPD-17) - Maintain design teams with prototypes
- Change the rules of the game!
23- I am now going to pick up my ball point.
- If you have any questions whatsoever, please
direct them to Allison and Mike. - I will be out of my office until 2020.
24 25The Programmed Surface Battle Line Will Be,
Without Doubt, the Most Powerful in the World, if
Not in History
- These 84 combatants will carry among them
- 8,468 strike-length VLS missile cells plus 400
Harpoon ASCMs - Each individual cell is capable of carrying four
10-inch diameter local air defense/terminal
missiles or one 13-inch diameter area air
defense/ATBM missile or anti-submarine rocket or
one 21-inch land attack missile or ballistic
missile interceptor - This is a larger missile load than that found on
366 surface combatants in the next 17 largest
navies (15 of which are either allies or
strategic partners) - 106 5-inch naval guns
- 112 helicopter hangers capable of handling a
MH-60R/S - Moreover, they will be joined by an increasingly
capable allied AEGIS/VLS fleet - JMSDF minimum of six Kongous, with 552 VLS cells
- South Korean Navy three KDX-IIIs with 216 VLS
cells (?) - Australian Navy three AWDs with 216 VLS cells
(?) - Spanish Navy six F-100s with 288 VLS cells
- Norwegian Navy five Nansen-class with 40 VLS
cells (space for 80) - These 23 AEGIS/VLS combatants will be joined by
dozens more allied combatants armed with hundreds
more Mk-41 VLS cells
26Moreover, the Combatants Will Be Quite Modern,
With Decades of Service Life Left
- The oldest Ticonderoga-class CG in the battle
line, the USS Bunker Hill (CG-52), was
commissioned in 1986, and is scheduled to retire
in 2021 after 35 years of service - The last Tico is scheduled to retire in 2029
- The oldest Burke-class DDG in the battle line,
the USS Arleigh Burke (DDG-51), was commission in
1991, and will retire in 2026 after 35 years of
service - The last Burke should retire around 2046
- As far as the overall fleet, these 84 ships will
have been commissioned over a period of 25 years
(1986-2011) at an average rate of 3.36 ships per
year (ten ships every three years) - The average age of the fleet will only be 12.5
-13 years oldless than the average age of the
DoNs aircraft fleet! - By the end of 2026, there will be 11 Ticos and 62
Burkes remaining in the fleet - By the end of 2031, there will be 44 Burkes
remaining
27From a Standpoint of Competitive Strategy,
Improving the 84 AEGIS/VLS Ships is Far More
Important to the Navys Future Than Building
Seven DD(X)s
- Seven DD(X)s represent 245 years of future battle
force service 84 AEGIS/VLS combatants represent
2000 years of future battle force service - The technologies pioneered by the DD(X) program
are not unique, and can be transferred - According to the Navy, the AEGIS/VLS ships can
hold their own against the DD(X). For example,
Navy officials say - A DDG is more capable than a DD(X) in blue water
area air defense - The DD(X) is more capable than the DDG in
littoral air defense - The ships are equally capable in ASW and blue
water counter-cruise missile missions (depends a
lot on the scenario and threat) - Moreover, the advantages of the DD(X) will
largely disappear in a fully networked setting - For example, adding the SPQ-9B and the Advanced
Hawkeye to the mix helps to close some of the
gaps filled by DD(X) - A battery of 106, 5/62s capable of firing
ERGM/BTERM spread across 84 platforms is more
flexible than and a battery of 14, 6 AGSs on
seven platforms - Given the lower cost of the DDG (can buy two for
the price of one DD(X)) and the fact that it is a
better bet should China mount an open-ocean
maritime challenge, it is important
that the DD(X) not rob money from the DDG/CG
modernization programs
28The Current CG/DDG Modernization Plan Focuses on
Improving the Capability of the Surface Battle
Network and Reducing Fleet OS Costs
- Includes a HME and SMARTSHIP phase
- All electric auxiliaries
- Structural modifications
- Habitability/quality of life upgrades
- Integrated Bridge Systems
- Shipboard LANs and fiber optic networks
- Saves 24 enlisted billets per CG, 40 billets per
DDG (Savings of 3,000 total billets - Includes combat system upgrade phase
- Common Cat-3 compliant hardware/software
- AEGIS Open Architecture (AOA)
- VLS Open Architecture
- Common configuration replaces multiple baseline
configurations - Common Mk-160 gun computing system
- May result in even more manpower savings (up to
30 per DDG) - Will improve total force networking and enable
more rapid force improvements
29The CG Modernization Plan is Further Along Than
the DDG Modernization
- Current plans call for spending 228 million per
CG - Allows for robust combat capability improvements
- Surface Grid Lock System Auto Correlation and
Common Data Link Management System (AAW) - SQQ-89A(V) 15 (ASW)
- Provides several important self-defense
improvements - SPQ-9B and ESSM
- CIWS Blk 1B
- Non-cooperative ID systems
- DDG Modernization Program is in the early stages,
but current planning figures are relatively
modest - Currently funded for only 78 million per ship
- Allows far less in the way of combat capability
upgrades. For example - CEC is not included, nor are SPY-1D improvements
- SPQ-9B and ESSM are not included
- SQQ-89A(V)15 is not included
- The relatively low projected costs for the DDG
modernization is troubling, given that a key
assumption of the current shipbuilding plan is
that OS costs will remain flat - Will there be the flexibility to expand the scope
of the effort?
30A Different Competitive Approach Would be to
Focus in the Near Term on CG/DDG Modernization
and to Simultaneously Position the Navy to
Respond to a Maritime Challenge
- Build two DD(X) technology demonstrators, and
shift money toward CG/DDG Modernization Program - Start new design effort for CG(X)
- Maintains design teams keeps DD(X) RD stream
intact - First step expand the scope of the CG/DDG
Modernization Program to outfit all 84 AEGIS/VLS
ships with - AEGIS OA, VLS OA, CEC, common system signal
processors - Mk160 Mod X GCS, 5/62s, and magazine mods to
handle ERGM/BTERM - SPQ-9B and ESSM
- CIWS 1B with full sensor integration
- A common non-cooperative ID systems
- A common, upgraded ESM system
- SQQ-89A(V)15
- Would make 84 compatible and interchangeable
nodes in a vast mobile missile field that can be
tailored to any current threat, and rapidly
modernized to meet emerging threat
31Second Step Would Be To Expand the Combat System
Upgrades to Enable the Fleet to Meet the Pacing
Threats
- Pacing threat one ballistic missiles and MaRVs
- Make every ship in the battle line capable of
making mid-course and terminal intercepts of
ballistic missiles - Currently, 18 of the 84 ships (21 percent) are
receiving upgrades to the combat systems to
tackle this threat in a cooperative program with
MDA - Radar improvements, BSP, SM-3 interceptor
- Why not expand program for all 84 ships?
- Simultaneously pursue a terminal interceptor
(either PAC-3 SME or SM-6?) - Pacing threat two SSN-27 Sizzler
- Three-stage missile sea skimmer to 20 kilometers
from target pops up for final target
acquisition launches a final supersonic combat
stage - CEC Advanced Hawkeye F/A-18F Block II Navy
Integrated Fire Control Counter-air (NIFCA)
SM-6 ERAM SPQ-9B/ESSM - Other improvements?
- Pacing threat three silent diesel submarines
- SQQ-89A(V)15 with MFTA
- Full MH-60R integration
- UUVs
32Third Step Would Be Setting Aside Money For a
Competitive Fleet-wide Improvement Program
- The Navy would promulgate desired combat
capabilities vendors would nominate systems
highest payoff systems would be pursued out of a
management reserve - C4I Improvements
- i.e., Common Radio Room
- Force Protection Improvements
- i.e., Typhoon remote cannon mounts
- AAW Combat System Upgrades
- i.e., Radar transmitter upgrades
- ASW Combat System Upgrades
- i.e., Mk 54 torpedo integration
33Optional and Most Ambitious Step Would Be to
Pursue Major System/Hull Rebuilds
- Primary goal provide shipyards with additional
work during a period of depressed construction - i.e., Provide all Flight I/II Burkes with an
ability to hanger and operate UAVs or
helicopters - i.e., Introduce major radar improvements
- i.e., Transfer DD(X) technologies (autonomic fire
suppression system?) - Could be complemented by a low-rate production
program of one DDG-79 per year, building to
the 88 ship requirement, and then replacing the
oldest DDG-51s on a one-for-one basis
34Know When To Hold Em
- Play the hand youve got!
- The 84 AEGIS/VLS combatants soon to be in the
fleet will constitute the most capable battle
line in the world by a wide margin - As important as the DD(X) may be, keeping the 84
AEGIS/VLS ships in service for 35 years will be
far more so - This will require sustained maintenance HME
upgrades and combat systems upgrades designed to
tackle the pacing threats - If paying for the DD(X) and CG(X) starts to rob
or divert money from the CG/DDG modernization
effort, plans for a 313-ship Navy will be put at
grave risk - Best case, the Navy builds to 70 large
combatants18 below requirement - If DD(X)s and CG(X)s retire earlyor provide no
useful combat capability to the battle forcethe
number will fall much lower