Navy Grapples with Shipbuilding Delays: A Look Under the Hood

A recent 45-day Navy shipbuilding review, initiated by Secretary Carlos Del Toro, has exposed concerning delays across several key programs.

According to reports released on Tuesday, April 2, these delays threaten to impact the Navy’s ability to maintain its technological edge and operational readiness.

Here’s a deeper dive into the challenges plaguing the Constellation-class frigates, Columbia-class submarines, and the broader shipbuilding landscape.

Constellation-class Frigates: A Case of Growing Pains

The most significant setback is the Constellation-class frigates, which were envisioned as agile and heavily armed additions to the fleet.

The lead ship, Constellation (FFG-62), could face a three-year delay, pushing delivery from 2026 to 2029.

Detailed design of of 🇺🇸US Navy's FREMM-based FFG 62 Constellation class frigates underway.

USS Constellation due in service by 2026. pic.twitter.com/A3OP43pqyX

— Navy Lookout (@NavyLookout) January 13, 2022

This delay stems from a confluence of factors:

Incomplete Design

The frigate’s design, based on the Italian and French FREMM parent design, is still under development.

While the initial plan leveraged an existing platform, extensive modifications to meet Navy requirements, such as tougher survivability standards, have significantly increased design complexity.

This has driven down commonality with the original FREMM to under 15 percent, essentially creating a new ship design.

Finalizing the detailed design this year is crucial to stay on track, but challenges remain.

Workforce Woes

Fincantieri Marinette Marine shipyard in Wisconsin, tasked with construction, is facing a critical workforce shortage.

The yard is juggling the demanding task of completing Littoral Combat Ships (LCS), building frigates for Saudi Arabia, and constructing the Constellation-class frigates simultaneously.

This multifaceted workload, coupled with difficulties in attracting and retaining skilled workers, has significantly hampered progress.

The Navy has acknowledged this challenge, allocating $50 million to incentivize the workforce at Marinette.

Rapid Prototyping, Slow Reality

The Constellation-class program was born out of the Navy’s rapid requirements process, aiming for quicker delivery.

However, this approach appears to have underestimated the complexity of adapting an existing design for US needs.

The extensive modifications have created a new design with its own set of challenges, highlighting the need for a more balanced approach between speed and thoroughness.

Columbia-class Ballistic Missile Submarines: A Race Against Time

The Columbia-class program, tasked with replacing the aging Ohio-class ballistic missile submarines, is also facing delays.

The lead boat’s delivery is expected to be pushed back by 12 to 16 months, potentially slipping from October 2027 to late 2028 or early 2029.

This delay has significant implications, as the Columbia-class submarines are crucial for maintaining a credible nuclear deterrent.

Key contributors to the delay include:

Module Integration Hurdles

The Columbia-class boasts a modular construction approach, where different sections are built in separate shipyards and then assembled.

However, delays in delivering the bow section, constructed by HII’s Newport News Shipbuilding in Virginia, have disrupted the overall schedule.

This highlights the importance of seamless coordination between shipyards involved in complex projects.

Supply Chain Jitters

Delays in parts shared with the ongoing aircraft carrier construction program have also impacted the Columbia-class schedule.

This underscores the vulnerability of shipbuilding programs to broader supply chain disruptions.

Beyond the Headlines: A Ripple Effect

While the Constellation-class and Columbia-class programs have garnered significant attention, the shipbuilding review revealed delays in other critical areas.

The Enterprise aircraft carrier is expected to be delivered 18 to 24 months later than planned, impacting the Navy’s future carrier strike group capabilities.

Additionally, both Block IV and Block V Virginia-class attack submarines are facing delays, raising concerns about the Navy’s underwater dominance.

A Cause for Concern, But Not Despair

The shipbuilding review serves as a wake-up call for the Navy.

The identified delays highlight the need for a multi-pronged approach to get these programs back on track.

This could involve:

• Strengthening Workforce Development: Programs that incentivize skilled workers to join and stay in the shipbuilding industry are crucial. Collaborations with educational institutions and targeted recruitment efforts are essential.
• Streamlining Design Processes: While rapid prototyping has its merits, ensuring thorough design work upfront can prevent downstream delays. Striking a balance between speed and thoroughness is key.
• Supply Chain Resilience: Building a more robust supply chain that is less susceptible to disruptions is critical. Diversifying suppliers and exploring alternative sources for vital components can mitigate risks.

The Navy has acknowledged the challenges and is actively working on solutions.

While the delays are concerning, they are not insurmountable.

By taking decisive action, the Navy can ensure its shipbuilding programs deliver the critical capabilities needed to maintain its maritime dominance.