An interesting example is the use of a hazard warning switch in a vehicle used for security patrols. In civilian applications, the hazard warning lights might be switched on a few times a year. The Military users, however, switched them on every time they stopped traffic, maybe ten to twenty times a day. The result was monthly failures and big bills as the switch was part of a more sophisticated steering column module. An accurate analysis of usage patterns would have identified this issue prior to deployment and prevented it before vehicles reached the field.

“Real-world testing is a major focus of our investment,” adds Elmes. “If testing doesn’t simulate the real field conditions and the way the vehicle will actually be used, it will probably miss something important. Get it right and you have the data needed to develop a cost-effective and highly successful MCOTS vehicle.”

Another saving with MCOTS is type approval and health and safety. In an increasingly litigious society, the duty of care of any employer is commercially as well as morally critical. “Commercial vehicles have already undergone multi-million pound development programmes. They provide a relatively quiet cabin, low pass-by noise, low emissions and appropriate attention to occupant protection during an accident. These are valuable attributes for military users. An MCOTS builder needs a depth of expertise to retain as much of this as possible through the transformation.”

Having rigorously defined the requirement, identified a base vehicle and researched the areas requiring modification, the MCOTS version must be built. It is unlikely that the original vehicle manufacturer will be interested in making anything other than small modifications - of the type found on police cars, for example, with upgraded brakes, clutch and suspension - without an order for a very substantial fleet. But specialist companies are geared-up to do this cost-effectively for much smaller numbers.
Millbrook Special Vehicle Group is one of Europe’s leading providers of engineering consultancy and low-volume manufacturing expertise for the military and service vehicle industries. With its substantial workshops and a low-volume production line, the group can provide build and up-fit programmes for new or existing fleets as well as refurbishment programmes to extend the life and capability of older vehicles.

“The military vehicle industry is currently grappling with the implications of MCOTS,” concludes Millbrook’s Julian Bryan. “The potential for cost saving is huge, but delivering reliable solutions requires a deep understanding of how the vehicles are used and a fresh approach to how vehicles are designed, developed and purchased. There will be a new generation of military vehicle specialists with the ability to provide the complete spectrum from bespoke to lightly modified. It’s an exciting opportunity for UK industry to lead the world and for the MoD to acquire more for less.”