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FMTV Family
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Amateurs discuss tactics, professionals discuss logistics. A military force can have all of the flashy combat vehicles it wants, but without a solid underpinning of medium and heavy trucks to handle logistics, that combat force is either dependent or hollow. This truth has been vividly illustrated in Iraq, where the priority level placed on raising the Iraqi Army’s combat power has made it dependent on the mature American logistics force in theater. Discussions of “independent operational capability” for Iraqi units revolve primarily around this logistics gap. While some units are capable now, Iraq is just beginning to implement the logistics tail that will give most of its units this ability to operate independently.

The 14 variants in the Family of Medium Tactical Vehicles (FMTV) form the core of the USA’s new state-of-the-art medium military transport truck fleet. Which in turn forms the core of the “mature logistics capability” seen in the Iraqi theater and elsewhere. FMTV trucks are all automatic transmission, and range from 2.5-ton cargo and van models to 5-ton cargo, tractor, van, wrecker, tanker, specialty, and dump-truck models in various 4×4 and 6×6 configurations. Some models also have attached trailers that increase their carrying capacity. Even so, the use of common engines, transmissions, drivelines, power trains, tires, cabs, et. al. create over 80% parts commonality between FMTV models. Where possible, commercial components are used for added savings.

In addition to their role as the backbone of the US Army’s truck fleet, FMTV trucks serve as the base for key weapons systems like the future MEADS air-defense system and the new HIMARS air-portable multiple rocket launchers. They also serve as the base for BAE’s Caiman MRAP blast-resistant vehicle, which adds armor and a blast-resistant capsule for carrying troops. As of June 1/08, the US military has ordered 2,862 Caimans for use on the front lines.

There have been 3 main phases of the FMTV program, including the last “SO23” open competition in 2003. All told, approximately 48,000 FMTV trucks in various models have been delivered to the US Army. As a 4th phase re-compete looms, a multi-billion dollar order will bridge the gap and inaugurate the US Army’s Long Term Armoring Strategy (LTAS) for its vehicle fleets. The initial contract for 10,000 trucks has finalized negotiations, and the US Army has just added another 10,000 trucks as the contenders maneuver for the next-phase FMTV award in 2009…

• FMTV Features and Developments [updated]
• FMTV Program: Long-Term Future [updated]
• FMTV Program: Production and Sustainment [updated]
• Contracts & Key Events
• Additional Readings

FMTV Features and Developments

FMTV A1P2 w. LTAS
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These trucks are at least as sophisticated as modern commercial vehicles. In addition to the Anti-Lock Braking System (ABS), FMTV trucks feature a Central Tire Inflation System (CTIS), exhaust retarder, extensive electronics, and other key features. A cab-over design, in which engine, fluids and hydraulics are all accessible in one place under the cab, is in place to make regular maintenance much easier and faster. After a series of accidents involving the FMTV A0 model trucks, modifications were made to reinforce the vehicles’ drivelines and u-joints. The subsequent A1 models ad their upgrades have been in production since 2000.

All FMTV trucks com with a 2 year full warranty, and a longer systemic warranty for any problems found to be the result of a systemic design or materials flaw. Beyond that, service contracts are required to see to the fleet’s ongoing health. The best place to manage these issues, however, remains the design phase.

One under-appreciated feature of the FMTV family is their array of embedded sensors and diagnostic systems, which monitor and report on various mechanical and electrical systems. These sensors all run through an ultra high speed J1939 electronic databus that makes the new Interactive Electronic Technical Manual (IETM) possible, and allows for both rapid fault diagnosis and connection to troubleshooting guides and parts ordering. This saves money by removing some unnecessary precautionary maintenance work, while preventing small problems from snowballing or creating breakdowns during a mission.

Full J1939 databus compliance across the vehicle is also appearing in other trucks like Oshkosh’s heavy HEMTT A4, but FMTV is currently unique in having this capability across the entire active fleet. The next step would involve a fully multiplexed system to increase bandwidth, and make it easier to take the next step into proactive “impending fault” diagnosis (prognostics) which learns about that particular vehicle over its lifetime and predicts problems in advance. BAE has invested private funds and some government funds in this area, but the design freeze going into the coming FMTV re-compete will forestall such discussions until a new winner has been declared.

On the materials side, some changes were made in the program’s early years, after corrosion resistance throughout such a long life cycle was shown to be an issue. A special e-coat facility at Sealy, TX is part of BAE’s purpose-built production infrastructure, and is used in conjunction with double-sided, galvanized, all-steel cabs; stainless steel exhaust systems; chip resistant coatings; and many other material and design upgrades. These efforts have helped to make FMTV is the first tactical vehicle ever to reach the 22-year mark in accelerated corrosion tests at the Aberdeen Test Center.

As a result of these measures, the current operational availability rate for FMTV trucks is an impressive 93%. That’s higher than any other vehicle in the US Army’s inventory – and likely higher than any vehicle in its history. In addition, tested data shows 20,000 miles between hardware failures, as opposed to the 3,500 miles originally expected.

The newest addition to the FMTV fleet is the FMTV A1P2 version, which is delivered ready to accept the LTAS armoring kits that form the core of the US military’s long-term plans to protect its logistics vehicles in theater.

FMTV Program: Long-Term Future

MEADS elements
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Over the longer term, the Army’s plans for its FMTV fleet move beyond acquisition, to maintenance, sustainment, and protection.

The original design requirement was a 20 year service life under heavy driving in difficult conditions, an appreciably difficult goal when one compares that requirement to expectations for one’s car.

Within that time span, mileage is actually less important in many cases than hours driven, as difficult off-road terrain can consume more hours and put on a great deal more wear in far fewer miles. While figures vary greatly for the different FMTV variants, DID has been quoted figures of around 10 hours per day as average for FMTV trucks in theater. Those trucks are not being rotated in and out, due to the transportation load it would create; instead, troops are generally rotated to the equipment in theater.

Even so, BAE representatives confirmed that the Army’s 20-year goal is still in place for its fleet. At present, there are no plans to recapitalize part or all of the FMTV fleet early. Instead, vehicles returning from combat theaters are RESET to like-new condition in partnership with the Red River Army Depot. BAE spokesmen place the current FMTV RESET rate at a very low 300-400 vehicles per year, with many of the vehicles brought in for accident or battle damage rather than high wear.

That kind of damage has become the US military’s biggest long-term issue, as it contemplates its truck fleet.

The steady employment of IED land mines in theater, coupled with a global communications net that has diffused bomb-making expertise and the concept of their use, ensures that land mines will be a major feature of future conflicts around the world. For several years now, the US military has moved to react quickly by purchasing add-on vehicle armor for its Hummer and trucks from various manufacturers, including Plasan Sasa (Marines MTVR medium trucks), and new BAE subsidiary Armor Holdings.

LTAS concept
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Over the longer term, a more organized approach was needed. Hence the Long-Term Armor Strategy (LTAS), which began issuing contracts in 2008 but has been in the works for several years now. The concept is that American trucks et. al. would be designed to quickly add standard configurations of removable armor: an “A-kit” for light threats, and a “B-kit” for heavier threats. Mine resistance is limited to some extent by the truck’s fundamental design, but add-on armoring does provide some protection against smaller devices, and lessons from the derivative Caiman MRAP design have informed the process.

LAS “A-kit” production is currently up to the relevant equipment suppliers for Hummers and trucks: AM General, BAE Systems, Oshkosh, and Navistar. BAE has received an initial contract for LTAS “B-kit” production, but the US Army has not made its final decision regarding how many it wants to order, especially with protection technologies evolving quickly and the current front-line situation calming down.

The FMTV A1P2 is the latest version in the family, and will be delivered in a design that’s ready to accept LTAS armoring. This seems like a minor change, until one realizes the implications of the potential extra weight. BAE Systems representatives have told DID that about 50% of the vehicle parts change in the A1P2 version, including higher capacity axles, new cab lift and cab tilt mechanisms, and a new, higher capacity air-over-hydraulic braking mechanism that replaces the previous hydraulic system.

Many FMTV trucks under the current interim contract will be sent from Sealy, TX to BAE’s facility in Cincinnati, OH to have this armor added prior to delivery. The original requirement was for armor that could be installed by soldiers in the field with few extra tools, but in practical terms the armor’s weight requires lifting equipment to mount. This means installation at production and maintenance locations, or in rare cases installation in the field with the help of engineering vehicles.

FMTV Program: Production and Sustainment

USMC HIMARS
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FMTV trucks entered service in 1996, and production has gone through 3 phases to date. The first 2 multi-year contracts were sole-source production phases, based on Stewart & Stevenson’s contract win. The third “SO23” contract was competed based on a set design blueprint, and ran from FY 2003-2008. All 15,500 trucks ordered under this phase will be delivered by November 2009, and the current inventory now stands at around 48,000 vehicles. This phase is now the responsibility of BAE Systems, following its $4.5 billion acquisition of Stewart & Stevenson’s parent Armor Holdings in May 2007.

Production has ramped up sharply over the last few years. Initial rates of production were approximately 2,400 trucks per year, but that rate has now accelerated to 7,200 (about 32/day) and is expected to reach over 8,000 per year (about 42/day) during FY 2009.

Heavy use in theater and casualties of chance or battle have contributed somewhat to this production ramp-up, but other factors also play a major role. One is the desire to grow the US Army by over 60,000 soldiers. The importance of logistics means that more soldiers will need more trucks, especially as the regular army focuses on assuming more of the sustainment role that has traditionally been assigned to the National Guard and Reserves. Meanwhile, those military reserve forces are driving 30 and even 40 year old trucks that are reaching the end of any useful life cycle, and must be replaced quickly.

Caiman MRAP
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Armor Holdings had anticipated many of these requirements, and began preparing its Sealy, TX facility about a year in advance to handle increasing production demands. Those moves have already paid off, leading to fast fulfillment of key MRAP and FMTV orders. The facility went from contract award to full-rate Caimin production, on a weekly rather than the standard monthly delivery schedule, in 43 days.

FMTV’s next phase will begin soon.

A “build to print” RFP from the US Army is expected around July 2008. It will offer the blueprint for the FMTV A1P2 series, to be competed among various manufacturers on the basis of cost, expected delivery time, evaluated contractor risk risk, etc., with an award around early 2009. Until then, the blueprint design is frozen.

BAE is touting the strength of its workforce and its embedded knowledge that goes beyond the blueprints, and into production processes, efficiency, and proven flexibility. The delivery record for FMTV and its derivative Caimin MRAP vehicles has been excellent; indeed, Caimin was the #1 MRAP vehicle in its ratio of on-time to promised deliveries. Then, too, there is the specialized infrastructure like BAE’s Sealy e-coat facility, and privately developed off-blueprint additions like “miles to go on this tank” indicators and other enhancements. All of this will make BAE hard to beat in the re-compete.

Nothing is impossible, however, and BAE can expect motivated competitors. Oshkosh produces the USMC’s MTVR medium trucks, and the Army’ FHTV heavy trucks; but they have fallen short of their expected success in the lighter MRAP and JLTV competitions. That makes them an experienced large-scale truck producer with strong military ties, available capacity, and something to prove. Truck manufacturer Navistar is also a large-scale producer for the US Army and other militaries. In contrast to Oshkosh, they won more prime contract orders than any other MRAP manufacturer. The new FMTV contract would kick in just as Navistar’s high-volume MRAP production line is expected to begin closing, which makes it a tempting bid target.

If the winner is anyone other than BAE Systems, the demands of production ramp-up mean that they will probably be unable to take over the contract until the end of 2010. Hence the need for an interim deal to bridge that gap. It is detailed below, and DID will continue to cover contracts and options awarded under this interim arrangement.

Contracts & Key Events

FMTV Load Handling System

Nov 12/08: BAE Systems announces a $1.6 billion contract from the U.S. Army to build another 10,000 FFMTV trucks and trailers for delivery during 2009 and 2010. This award is in addition to a finalized $2.1 billion contract for 10,000 vehicles, plus program support, engineering, integrated logistics support, configuration management and field service support. This latest contract brings the total 2008 award value for FMTVs in 2008 to $3.7 billion.

BAE Systems will manufacture all of these FMTVs in the Long Term Armor Strategy (LTAS) configuration.

Sept 29/08: BAE Systems Tactical Vehicle Systems Limited Partnership in Sealy, TX receives a $442.5 million firm-fixed-price contract modification, which finalizes the June 2008 order at about $2.1 billion for 10,000 FMTV trucks, program support and Federal Retail Excise Tax (FRET). Work will be performed in Sealy, Texas, with an estimated completion date of Dec 31/11. One bid was solicited and one bid was received by U.S. Army TACOM in Warren, MI (W56HZV-08-C-0460).

June 2/08: BAE Systems Tactical Vehicle Systems Limited Partnership in Sealy, TX received a $1.656 billion firm-fixed price and cost-reimbursement contract for 10,000 FMTV trucks, program support and federal retail excise tax. Work will be performed in Sealy, TX and is expected to be complete by Dec 31/10. One bid was solicited on Nov 5/07 by the U.S. Army TACOM in Warren, MI (W56HZV-08-C-0460).

BAE’s says that the posted figure is an initial amount, and announces a possible value of up to $2.2 billion pending negotiations to finalize the contract. The contract also contains an option year for another 10,000 trucks, whose exact cost would also be determined when this contract is finalized. BAE Systems release.

May 5/08: Stewart & Stevenson Tactical Vehicle Systems Limited Partnership, Sealy, Texas, was awarded on May 1, 2008, a $54,312,842 firm-fixed price and cost-reimbursement contract for adding 370 supplemental family of medium tactical vehicle variants to the contract. About 100 of these trucks will be equipped per the US Army’s LTAS configuration.

Work will be performed in Sealy, Texas and is expected to be complete by Nov. 15, 2008. Contract funds will not expire at the end of the current fiscal year. Two bids were solicited on Aug. 15, 2008, and two bids were received. U.S. Army TACOM, Warren, Mich., is the contracting activity (DAAE07-03-C-S023), and the current value of this 2003 contract is now about $3.6 billion. BAE Systems release.

April 2/08: Stewart & Stevenson Tactical Vehicle Systems Limited Partnership, Sealy, Texas, was awarded on March 31, 2008, a $43,579,276.55 firm-fixed price contract for adding long-term armor strategy A1P2 cabs to 730 family of medium tactical vehicles. Work will be performed in Sealy, Texas. Contract funds will not expire at the end of the current fiscal year. Work is expected to be completed by Nov. 15, 2008. Two bids were solicited on Aug. 15, 2002 and two bids were received. U.S. Army TACOM, Warren, Mich. is the contracting agency (DAAE07-03-C-S023).

April 09/07: The Pentagon’s current Selected Acquisition Report cites the FMTV program for cost changes:

“Program costs increased $3,351.9 million (+19.2 percent) from $17,450.1 million to $20,802.0 million, due primarily to the addition of Long Term Armor Strategy (LTAS) A-Cab (+$1,257.1 million) and associated LTAS installation kits (+$1,319.1 million). There were also increased recurring costs for planned model mix changes (+$672.8 million) and the application of revised escalation rates (+$64.6 million). These decreases were partially offset by an acceleration of the annual procurement buy profile (-$149.7 million).”

Additional Readings

• Global Security – Family of Medium Tactical Vehicles (FMTV). Includes more detailed information re: FMTV variants, as well.

• US Army Fact Files – Family of Medium Tactical Vehicles (FMTV)

• DID FOCUS Article – RESET of the US Army’s Vehicle Fleet Continues

• DID (March 28/08) – Iraq’s Military Requesting $1.39B in Weapons, Vehicles, and Equipment.

• DID (May 9/07) – BAE to Acquire Armor Holdings for $4.53B

• Army Logistician (Sept-Oct 2005) – Resetting the FMTV