Memorandum from UNITE
This response is submitted by Unite. Unite is
the UK's largest trade union with almost 2 million members across
the private and public sectors. The union's members work in a
range of industries including manufacturing, aerospace, shipbuilding
& repair, financial services, construction, transport, education,
health and not for profit sectors.
EXECUTIVE SUMMARY
— The Ministry of Defence must seriously
consider replacing the current ageing Puma with sixteen new Merlin
Mk3a aircraft.
— This proposal will rationalise the
Medium Support Helicopter fleet from 3 types to one, reducing
costs and making economic and financial sense to the Treasury
and the tax payer.
— Unite has serious concerns about
the safety of Puma, the main concern being its poor engine response.
— If the programme is implemented,
any transition period will not impact upon operational capability,
as there will be no loss of aircraft as they enter into an upgrade
programme.
— The proposal for Merlin will ensure
a bigger footprint for UK based companies. As well as providing
contracts for Augusta Westland, the engines will be manufactured
by Rolls-Royce.
— The procurement of Merlin would
ensure the maximum retention and creation of jobs for workers
based in the UK.
— The key technical skills required
to make these complex pieces of machinery will be retained in
the UK and will ensure skills shortages and skills gaps are controlled.
— The proposal could deliver acquisition
savings of more than £300 million against the Future Medium
Helicopter Tranche 1 and Life Extension Programme budgets.
1. INTRODUCTION
1.1. Over the past three decades the UK Aerospace
industry has undergone a series of significant changes and strategic
re-structuring. The two most important changes have been the rapid
globalisation of manufacturing industry and the changes to production
and capability in the face of the UK armed forces being involved
in two major military conflicts.
1.2. The sector is the second largest in
the world and is a significant driver of regional, national and
global economic growth and productivity. The industry generates
£38.6 billion worth of revenue and exports of £4.34
billion.[13]
The Aerospace sector employs a workforce of over 124,000 people
and supports a supply chain of over 100,000 people. Unite represents
around 100,000 workers within the Aerospace industry.
1.3. The sector has a number of large key
companies but also has a diverse and strategically important supply
chain of small and medium sized enterprises (SMEs). These workplaces
are incredibly important to the success and productivity of the
Aerospace sector and Unite acknowledges the key role SMEs play
in ensuring that the UK Aerospace sector remains one of the most
successful in the world.
2. PUMA LIFE
EXTENSION PROGRAMME
(LEP)
2.1. Unite believes the Puma LEP is a stop-gap
measure to provide an interim "Battlefield Medium Support
Helicopter" capability before the MoD can procure a new helicopter
when funds become available in 2022.
2.2. Unite has concerns that there are serious
issues around the safety of Puma. The main concern with the current
Puma is its poor engine response. A demand by the pilot for too
much power too quickly causes the rotor speed to drop resulting
in a consequent loss of lift. To overcome some of these known
failings the Ministry of Defence (MoD) has decided that the aircraft
needs a new more powerful engine. This in turn will require a
new cockpit because of the need to fit modern digital engine controls.
2.3. Unite believes this will not solve the
problem. Although some handling characteristics will be improved
other poor safety features cannot be rectified. For example, the
aircraft has a high centre of gravity and, when combined with
a short wheel base and tricycle undercarriage, this makes the
aircraft prone to rolling over especially in high winds and when
operating from uneven landing sites. It is this feature that makes
the aircraft unsuitable to operate from the back of ships.
2.4. Added to this, Unite believes the aircraft
has not been designed to meet modern safety standards. It is only
built to a 6g crash case, whereas the Merlin for example is designed
to survive a 16g crash. Roughly translated this means that only
40% of Puma crashes would be survivable whilst with Merlin the
crew and passengers would survive in excess of 90% of all crashes.
As well as this, the Puma LEP upgrade does not include the fitting
of modern crashworthy seating.
2.5. Unite believes these safety issues cannot
be resolved. Crashworthiness is all about achieving a balanced
design where no one feature compromises the capabilities of others.
A crashworthy seat is great to have but only if the basic airframe
does not collapse in a crash. Optimised crashworthy design cannot
be achieved retrospectively on a legacy platform. Partial incorporation
of crashworthy design features may be a benefit to survival rates
but are likely to generate significant design change and weight
growth penalties that must be factored into the overall operational
performance.
3. CAPABILITY
3.1. The capabilities that are needed now
are vastly different to those envisaged 50 years ago when the
cold war was the greatest threat to UK national safety and security.
What this has created is a scenario where it is the technological
advantage that is needed by the UK armed forces.
3.2. This level of technological change and
expansion has created new ways of working and the creation of
new industries and new technologies. Part of this creation has
been developed by the small and medium sized enterprises (SMEs)
in the sector. This is where the technological innovation is to
be found and where there are significant levels of intellectual
property and the ability to provide solutions for the big companies
that dominate the UK Aerospace sector.
3.3. Through life capability is vitally important
at this crucial time. There has been a critical change of approach
regarding national security within the UK, the USA and other areas
around the world. This impacts significantly on Unite members
and the strategic long term objectives of the companies they work
for. Unite is keen for the present government to focus on capability
as an issue within the sector.
3.4. Strategic and focused investment will
secure the jobs, skills, livelihoods and communities of the workers
in the sector. The Aerospace sector is a unique niche sector.
The workers within the sector are highly skilled, highly educated
and have undergone extensive training. The work they do is not
undertaken anywhere else in the UK and is of vital importance
to the UK economy and the UK balance of payments.
4. AIRCRAFT PROCUREMENT
4.1. Unite believes it is highly likely
that, should the Puma Life Extension Programme commence, a good
deal of emergent after-work will be identified, which could have
a detrimental impact on controlling costs. Experience gleaned
from an earlier programme to upgrade South African Pumas for the
MoD showed that of the originally procured 6 aircraft only 4 could
be made suitable for operational service. There are also known
issues with the top deck structure which supports the main rotor
gearbox and engine where repair costs are high.
4.2. Unite is clear that capability is of
strategic importance where government procurement is concerned.
The MoD has a poor record of implementing procurement contracts
on time and ensuring that strategic military equipment is available
for the armed forces. The National Audit Office has provided evidence
to show that delays in procurement can end up costing the UK government
and the UK tax payer far in advance of the original budget.
4.3. Quentin Davies, Minister for Defence,
Equipment & Supply (DE&S) recently announced a study into
the potential procurement of new aircraft in place of both the
Puma and Sea King Life Extension Programmes (LEPs). There are
major benefits associated with the introduction of further numbers
of helicopters to enhance the existing fleet of helicopters currently
used by the MoD. Unite believes the most pragmatic alternative
to having two LEPs is to increase the current Merlin Fleet by
44 aircraft.
5. SKILLS AND
TRAINING
5.1. It is clear that the Aerospace sector
is one where the employees are highly qualified and highly skilled.
However, a number of key reports have indicated that a shortage
of skilled employees may be hampering growth in manufacturing
industry as well as limiting the potential for any changes in
highly technical operational processes. Unite believes that procurement
decisions by the MoD must take into account training, skills and
ensuring the key skills in the sector are retained. Long gaps
in the awarding of contracts can generate serious problems with
skills retention and skills shortages.
5.2. Unite is keen to see that companies
within the sector do not become complacent about training their
existing workforce. It is vital for workers to continue their
training and development while in work and it is the employer's
responsibility to ensure that the workforce has this opportunity.
Skills gaps can become a serious issue within manufacturing companies
and as such could seriously affect productivity.
5.3. The present government has made it clear
that they want to see a highly educated and highly skilled workforce
for the future growth and prosperity of the UK economy. There
are two key factors driving demand for skills within this sector.
5.3.1. Replacement demand—where
job opportunities are created by retirement, occupational mobility
and where there are skills shortages within the sector.
5.3.2. Structural change driven
by international competition—the important role of skills
in improving productivity relative to international competitors
cannot be underestimated. Structural change within the sector,
such as the huge changes in technology and the products required
by the armed forces, are broadening the types of skills required
within the sector.
5.4. Unite believes that ensuring strong
workforce skills is a matter of shared responsibility between
government, employers, unions and individuals. It is clearly documented
that trade unions have played a pivotal role in encouraging workers
and employers to participate fully in the learning agenda, this
role can now be extended to include on the job training and skills
development for all workers.
UNITE RECOMMENDATIONS
— The Ministry of Defence must give
serious consideration to replacing the current ageing helicopters
with modern aircraft that will have up to a 40-year operational
expectancy, and which are designed to contemporary safety and
survivability standards.
— As an element of the proposal, replace
the current Puma capability with 16 new Merlin Mk3a aircraft within
the same budget and profile.
— Rationalise the Medium Support Helicopter
fleet from three types to one, with the removal of costs associated
with the support and maintenance of the current Puma and Sea King
Mk4 aircraft.
— Unite believes the transition period
will incur no impact upon operational capability as there will
be no loss of aircraft as they enter into an upgrade programme.
The Puma fleet will diminish significantly as aircraft are returned
to Romania for structural rework followed by new electrical and
avionic equipment being installed.
— The proposal could deliver acquisition
savings of greater than £300 million against the Future Medium
Helicopter (FMH) tranche 1 and Life Extension Programme budgets.
— By increasing the fleet size of
an already utilised aircraft, this will reduce the direct cost
of ownership of the Merlin helicopter by 28% through economies
of scale and also build on significant UK investment in the Merlin
helicopter.
— Implementing the programme will
remove or significantly reduce the requirement for further investment
in training, infrastructure, independent test and evaluation,
trials and MoD Project Team costs, while avoiding the costs, risks
and delay associated with bringing new aircraft types into service.
— Accepting the upgrade of Merlin
will ensure a bigger footprint for the UK workforce as Rolls Royce
will be supplying the engines.
— Unite believes the implementation
of the upgrade will provide for the retention and creation of
jobs in the aerospace sector.
— All equipment procured by the MoD
must be manufactured in the UK, using UK based workers.
26 June 2009
13 SBAC-UK Aerospace Survey 2008. Back
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