Lessons Learnt In Military Vehicle Capability Development And Acquisition?
Developing and acquiring military vehicle systems is a complex undertaking, demanding strategic foresight, engineering precision, and adaptive problem-solving. Over the past 20 years, numerous projects have highlighted both successes and challenges in delivering effective military capabilities. In Australia, key projects such as the M113 upgrades¹, the Bushmaster Infantry Mobility Vehicle², the Australian Light Armoured Vehicle (ASLAV) program³, and the Land 400 Phase 2 initiative⁴ offer critical insights into capability development. Meanwhile, in the U.S., programs like the Optionally Manned Fighting Vehicle (OMFV)⁵ and the Joint Light Tactical Vehicle (JLTV)⁶ showcase lessons in systems engineering and acquisition strategies. This blog post draws on these projects to highlight key technical challenges and lessons that can inform and improve future military vehicle capability development and acquisition processes to meet evolving demands in modern combat and operational readiness.
Managing Evolving Requirements and Scope Changes
One of the most significant challenges in military capability development is managing changing requirements and project scope. The M113 Armored Personnel Carrier upgrade, initially planned as a minor enhancement, evolved into a comprehensive overhaul due to shifting operational needs and strategic priorities¹. This led to delays, budget overruns, and increased complexity. Similarly, the U.S. OMFV program faced challenges due to evolving requirements that strained project focus and resources⁵. Both examples underscore the importance of a robust requirements management framework capable of adapting to change without destabilizing the project. Effective systems engineering demands early and continuous stakeholder engagement, disciplined change control, and a clear understanding of evolving mission needs to prevent scope creep.
Complex Systems Integration
Integrating new technologies and capabilities with existing platforms presents one of the most persistent challenges in military vehicle projects. The M113 upgrade and the OMFV program highlighted the complexities of merging modern systems—such as weapons, advanced electronics, and extended hulls—with legacy platforms¹⁵. Similarly, the JLTV program had to balance protection, payload, and mobility while integrating seamlessly into existing tactical systems⁶. GAO findings on the OMFV highlighted that integration efforts require clear methodologies, validated data, and objective force structure analyses to ensure reliability and compatibility⁵. Overcoming these challenges requires a holistic approach, involving comprehensive planning, rigorous testing, and proactive risk identification. Integration must be treated as a core element of systems engineering from the outset, ensuring interoperability and compatibility with existing military frameworks.
Designing for Survivability and Protection
The need to design systems that offer superior protection and survivability is a critical challenge for defense engineers. The Bushmaster Infantry Mobility Vehicle was developed to counter IED threats found in conflict zones like Afghanistan and Iraq through its innovative V-shaped hull design². This approach, which required extensive testing and refinement, highlighted the importance of adapting designs based on real-world feedback. Similarly, the JLTV program prioritized survivability against modern threats such as mines and roadside bombs while maintaining essential mobility⁶. GAO assessments of next-generation vehicles emphasize that design choices must accommodate future upgrades to remain effective over time⁵. This underscores the value of iterative design, real-world validation, and flexibility to address evolving combat demands.
The Importance of Test and Evaluation
Effective test and evaluation are critical components of military vehicle capability development and acquisition. Projects such as the Bushmaster Infantry Mobility Vehicle demonstrated that iterative testing and real-world validation are essential for refining designs and adapting systems to combat conditions². Similarly, GAO assessments of U.S. programs like the OMFV highlighted the importance of clear methodologies, data validation, and quantifiable metrics during testing to ensure reliable integration and performance verification⁵. Comprehensive test and evaluation processes help identify and mitigate technical risks early, enhance system reliability, and ensure that military vehicles meet stringent operational requirements before deployment. By prioritizing rigorous testing, defense organizations can achieve higher levels of performance, safety, and mission readiness.
Balancing Cost, Schedule, and Technical Performance
Balancing cost, schedule, and performance is a perennial challenge in military vehicle capability projects. The Land 400 Phase 2 initiative sought to deliver advanced combat reconnaissance vehicles while managing performance specifications within budget and schedule constraints⁴. Similarly, the Bushmaster project experienced cost overruns due to design modifications and evolving needs², while the JLTV program faced cost management challenges related to its ambitious requirements⁶. GAO reviews of next-generation combat vehicles stressed the importance of accurate cost estimation, transparent budgeting, and aligning requirements with available resources to ensure program viability⁵. Systems engineers must engage in transparent communication, risk analysis, and agile decision-making to optimize trade-offs without compromising mission-critical capabilities.
Addressing Technological Obsolescence and Upgrades
Modernizing legacy systems to remain effective in future operational contexts is an ongoing challenge. The ASLAV program sought to extend vehicle lifespans by integrating new technologies across multiple phases³. The U.S. OMFV program, which aims to replace the Bradley Fighting Vehicle, grapples with designing future-proof systems capable of accommodating rapid upgrades⁵. GAO findings emphasized the importance of modular open systems architecture for facilitating future integrations and upgrades, ensuring adaptability to emerging needs⁵. Addressing technological obsolescence requires forward-thinking lifecycle planning, modular design, and continuous technology readiness assessments to keep systems operationally relevant.
Ensuring Reliability and Maintainability
Reliability and maintainability are critical to the operational success of military vehicle systems. The M113 upgrades highlighted how modifying mechanical and electronic components can introduce new maintenance challenges, ultimately affecting operational readiness¹. Similarly, the Bushmaster project encountered significant reliability issues early on, with mechanical failures and manufacturing defects threatening its deployment². These challenges were addressed through close collaboration between defense stakeholders and industry partners, involving iterative testing, design refinements, and improvements to manufacturing processes. This collaborative approach transformed the Bushmaster into a highly dependable platform capable of enduring harsh combat conditions².
GAO assessments emphasized that designing systems for long-term reliability, maintainability, and modularity is essential for reducing lifecycle costs and maximizing operational readiness⁵⁷. To achieve this, there must be a strong focus on reliability engineering during capability development and acquisition, ensuring high levels of system availability and minimizing lifecycle costs. Defense projects should incorporate modular designs for easier repairs, establish robust supply chains, and provide comprehensive training to maintain operational effectiveness throughout the system’s lifecycle.
Common Technical Lessons Across Multiple Vehicle Projects
While each military vehicle project is unique, recurring lessons emerge across programs, including the M113 upgrades, the Bushmaster, the Land 400 Phase 2 initiative¹²³⁴, and U.S. efforts such as the OMFV⁵ and JLTV⁶. Robust systems integration is essential to ensure that new technologies work seamlessly with existing platforms and doctrines. GAO assessments of the OMFV emphasized that transparent methodologies and data validation processes are critical for ensuring reliability⁵. Adaptable and modular designs that accommodate evolving threats and enable upgrades without complete overhauls were highlighted across these projects, with the OMFV’s modular open systems architecture serving as a prime example⁵. Furthermore, the need for disciplined project management and cost-performance trade-offs, as demonstrated by the JLTV program⁶, reinforces the importance of a holistic and agile approach to systems engineering in military vehicle development and acquisition.
Harnessing Lessons for the Future
The challenges encountered in military vehicle capability development and acquisition highlight critical lessons for systems engineers, defense professionals, and technical leaders. Successfully addressing evolving requirements, managing complex integrations, balancing cost and performance, and ensuring long-term reliability are central to delivering effective military vehicle capabilities. Through disciplined requirements management, iterative design, proactive risk mitigation, and comprehensive lifecycle planning, military vehicle systems can be developed with the precision, adaptability, and resilience needed to meet both current and future challenges. By applying these lessons, defense professionals can transform complex projects into mission-ready solutions, ensuring their capabilities remain effective and adaptable to the ever-changing demands of modern conflict.
Empowering Defense Professionals, Technical Leaders, and Systems Engineers through Specialized Education and Training
At the Eggler Institute of Technology, we empower defense professionals, technical leaders, and systems engineers to excel in systems engineering, capability development, and acquisition. Our specialized military vehicle technology education and training course equip individuals with the knowledge, skills, and practical tools to navigate the complexities of military vehicle projects. By focusing on real-world applications, industry best practices, and collaborative approaches, we prepare leaders to drive capability development and acquisition success—ensuring that defense organizations can meet the challenges of today and anticipate the needs of tomorrow. You can learn more about our courses here.
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Footnotes
- Australian National Audit Office (ANAO) Reports on M113 Upgrades
- Australian Strategic Policy Institute (ASPI) Monograph: The Bushmaster – From Concept to Combat
- ANAO Reports on ASLAV Program
- ANAO Report on Land 400 Phase 2 Procurement
- U.S. Government Accountability Office (GAO) Reports on Optionally Manned Fighting Vehicle (GAO-23-106549)
- GAO Reports on Joint Light Tactical Vehicle (JLTV) (GAO-20-579).
About the Author
Mark Eggler, BE (Hons), MSc.
Mark has over 30 years experience as a senior program manager, project manager and professional systems engineer working on complex military projects. He has worked for the Australian Department of Defence and international OEMs on large scale military vehicle acquisition programs and now teaches technical leadership, systems engineering and military vehicle technology courses worldwide.
