Two-level maintenance: modularity and the transformation of Army maintenance.

Today's Army is transforming because of the pressures of strategic challenges, combat experiences and technological changes. The goal of the Ordnance Corps' Task Force Modularity is to restructure Army maintenance so tactical-level combat units are more mobile and self-sustaining than ever before.

The Ordnance Corps has been undergoing its own transformation for the past 17 years in response to a growing need for a more versatile and efficient maintenance system. The limitations of the old system are echeloned and redundant maintenance activities that are restricted to actions specified at a particular level. The time spent sending equipment from one activity to the next created longer repair cycles, lower operational readiness rates and, consequently, decreases in combat power.

The solution, first conceived in 1988 by Brigadier General Leon E. Salomon, then Chief of Ordnance, is to merge the four-level maintenance system into a streamlined two-level system focused on reducing repair cycle times.

[FIGURE 1 OMITTED]

In the old four-level maintenance system, each maintenance activity was responsible for restoring equipment to the maintenance element's capability, and when factors, such as time or tools and equipment became a roadblock, the equipment was sent to the next higher level. Units spent a lot of time evacuating equipment to higher maintenance levels, waiting for that item to be repaired and then waiting for it to be sent back through the appropriate channels. This process often was prolonged when dealing with large or expensive equipment.

Transforming Maintenance. An integrated concept team (ICT) to transform Army maintenance included personnel from the Army Materiel Command (AMC); Department of the Army (DA) G3; DA G4; Training and Doctrine Command (TRADOC); National Guard Bureau (NGB); Combined Arms Support Command (CASCOM); Office of the Chief of Army Reserves (OCAR); Assistant Secretary of the Army for Acquisition, Logistics and Technology (ASAALT); and others. The ICT was chartered by TRADOC to research and develop the two-level maintenance concept. The objective was to reduce redundancy and combat inefficiencies. Based on the concept of "Fix Forward/Repair Rear" coined by the 1998 Chief of Ordnance, Brigadier General Thomas R. Dickenson. Figure 1 shows how the system is transformed.

The change to the two-level maintenance system goes into effect as each division becomes modular.

The old organizational motor pools and direct support (DS) activities essentially have been combined into Field Maintenance, characterized by a repair-and-return-to-user system. Its maintenance relies on line replaceable unit (LRU) and component replacement, battle damage assessment and repair (BDAR), recovery and services. Field Maintenance is performed at all levels of the Army.

Sustainment Maintenance is the second level of maintenance, essentially representing a combination of the old general support (GS) and depot-level activities. It is a repair-and-return to the Army supply system activity that can be brought as far forward as required, based on the mission, enemy, terrain and weather, troops, time available and civilian considerations (METT-TC), but it normally is found above the brigade combat team (BCT) level.

Sustainment Maintenance relies on end item and component repair with some component replacement, whereas Field Maintenance relies only on component replacement.

The most important part of maintenance modularity for the tactical leader is its positive impact on operational readiness. The Army has transitioned to this new system because it provides more maintenance capability to the company level. Company commanders have direct access to the mechanics performing all on-system maintenance. Testing equipment, recovery equipment and higher mechanic skills have been placed at the lowest possible levels, so equipment can be returned to fully mission capable (FMC) status faster.

Maintenance Organization. In the brigade, each maneuver battalion has an attached Forward Support Company (FSC) to perform field-level maintenance. (See Figure 2.) Each FSC has a Maintenance Platoon that provides the battalion recovery support, automotive and tracked-vehicle repair and ground-support equipment repair.

A Field Maintenance Team deploys with each maneuver company and provides automotive and track-vehicle repair support. Each team will have an M88 recovery vehicle and a forward repair system, heavy (FRS-H). If the equipment cannot be brought to FMC status on site, the Field Maintenance Team recovers it to the Base Maintenance Section of the FSC.

All ground support equipment repairs will be conducted at the FSC located with the battalion headquarters. The FSC Base Maintenance Section also will perform maintenance for the battalion headquarters.

Currently, low-density military occupational specialties (MOS), such as those for electronics, missile and armament repair, are in the Brigade Support Battalion (BSB) within the Field Maintenance Company (FMC). These assets can and will detach from the BSB and attach to the FSC or even a Field Maintenance Team, when necessary.

For the two- and three-star units of employment (UEx), field maintenance will be conducted by Support Maintenance Companies (SMCs). The SMC has platoons for automotive, ground support equipment, missile and electronics repair as well as an attached test, measurement and diagnostic equipment (TMDE) section.

When a piece of equipment cannot be fixed by on-system repair, it must be returned to the UEx-level to a Component Repair Platoon (CRP) or Component Repair Company (CRC). Sustainment Maintenance is performed at the three-star UEx level; however, teams may be detached from the CRC and attached to the SMC operating in the UEx.

[FIGURE 2 OMITTED]

Merging Maintenance MOS. Before Force XXI, the Army had separate mechanics for the turret and hull of tracked vehicles as well as separate mechanics at each level of maintenance. As the Ordnance Corps transitions toward a two-level maintenance system and combines echelons, MOS mergers are necessary. Trained personnel now can repair a system in one location with units having to evacuate equipment less often.

Under the two-level maintenance system, one MOS maintains the tracked-vehicle system while another maintains wheeled vehicles. (See Figure 3.) These merged MOS are called multi-capable maintainers (MCMs) and can perform all field-level repairs for their maneuver companies wherever they are on the battlefield.

The communications and electronics repair field also has had MOS mergers, increasing the individual mechanic's and maintenance activity's versatility.

Leaders may be concerned that MOS merging and brigade restructuring lead to a decrease in the ratio of mechanic-to-equipment. However, considering critical systems across the Army, there is little change. The key is retaining basic systems design, so the number of mechanics available remains relatively constant. The new ratio of equipment-to-mechanics is almost the same as under the old system with a slight reduction in managerial overhead because shop offices at different levels are combined.

The overriding theme of two-level maintenance and modularity is mobility and versatility. The many benefits of the changes are obvious. Previously, most major end items were repaired at the unit and DS level. Maneuver battalions and brigades now can repair their equipment efficiently at the unit level. As improvements in equipment reliability, maintainability, diagnostics and prognostics continue, the Army's ability to maintain equipment efficiently and reduce repair cycle time will continue to increase combat power for today and tomorrow.

For more information on the Ordnance Corps' transformation to two-level maintenance and maintenance modularity, see www.us.army.mil and follow the links to TRADOC, CASCOM and the Directorate of Combat Developments (DCD), Ordnance (OD).

Captain Alyssa Y. Astphan, Ordnance Corps (OD), until recently, was a Project Officer in the Future Development Ordnance Branch of the Combined Arms Support Command (CASCOM), Fort Lee, Virginia. Currently, she is a student in the Combined Logistics Captain's Career Course at Fort Lee. In her previous assignment in the 595th Maintenance Company, 501st Corps Support Group, 19th Theater Support Command, in Korea, she was the Company Executive Officer, Maintenance Control Officer and Platoon Leader. Her next assignment will be with the 2d Brigade Combat Team, 10th Mountain Division (Light Infantry), Fort Drum, New York.

By Captain Alyssa Y. Astphan, OD

Four-Level Maintenance  Organization       Direct Support

Abrams                  63E, 45E           63H, 45K
Bradley                 63T, 45T           63H, 45K
Artillery               63D, 45D           63H, 45K
Wheel                   63B, 63S           63W, 63G
Track                   63Y                63H, 63G

Two-Level Maintenance   Field Maintenance

Abrams                  63A, 45K
Bradley                 63M, 45K
Artillery               63D, 45K
Wheel                   63B
Track                   63H

MOS Legend:
45D = Self-propelled Field Artillery Turret Mechanic
45E = Abrams System Maintainer
45K = Armament Repairer
45T = Bradley System Maintainer
63B = Light Wheel Vehicle Mechanic
63D = Self-Propelled Field Artillery Repairer
63G = Fuel and Electrical Systems Repairer
63H = Track Vehicle Repairer
63M = M2/3 Bradley Fighting Vehicle System Maintainer
63T = Bradley System Mechanic
63W = Wheel Vehicle Repairer
63Y = Track Vehicle Mechanic

Figure 3: Maintenance Military Occupational Specialty (MOS) Mergers. The
functions and capabilities of all the maintenance MOS still exist; they
just have merged. For example, 63Gs are being phased out with the MOS
tasks migrating to 63Bs and 63Hs.