Case Study

Custom Asset Visibility Solution for UK Ministry of Defence Osprey Body Armor Initiative 

An ingenious approach enhances mission readiness and soldier safety

Project Overview:  As part of Operation Herrick (UK operations in Afghanistan between 2003 and 2014) the UK MoD mandated the deployment of Osprey body armor for all combat soldiers. While each body armor plate was rigorously tested for reliability, the plates were not individually identified or tracked, creating an information gap that posed unnecessary potential cost and injury risk. Camcode Global implemented a comprehensive labeling and software solution that ensured precise tracking and management of these critical soldier safety assets.

Challenges

The absence of individual tracking for each Osprey body armor plate prompted the MoD to require all existing and new body armor to be marked with an Item Unique Identification (IUID) label. This was to be done when the plate passed through refurbishment and production lines at contractor facilities. This task involved marking 20,000 new body armor plates and 80,000 legacy plates that had previously only been identified by their lot and batch numbers.

System Complexity
Data for each plate had to be managed across three separate systems—the testing facility’s internal IT system, MoD’s Equipment Management system, and the Logistic Information System.
Manual Processes
Receiving and re-issuing actions were labor-intensive, time-consuming, and plagued by data errors, leading to mismanagement of the plates and potentially unnecessary purchases or, worse, injury or death.
Extreme Conditions
To survive the asset’s lifespan, the marking solution needed to be able to withstand hostile conditions, survive explosive environments, and endure X-ray testing.
Legacy Assets & New Assets
Consistently marking 20,000 new body armor plates along with 80,000 existing body armor plates required a coordinated approach.

Camcode Global’s Role

The UK MoD selected Camcode Global to help achieve MoD’s goals for Osprey body armor identification and tracking with an IUID solution that would create a shared data key for use across all ERP systems. 

Camcode Global conducted an exhaustive assessment of the body armor, testing various materials to determine the optimal marking that would endure throughout the asset’s lifespan so that the label data would remain scannable. Activities included:

  • Meticulous Material Selection: After thorough assessment, Camcode Global engineers selected a polyester label with a specific over-laminate and developed a proprietary adhesive. Collaborating with the Army, engineers also determined the ideal label placement on the plates, for both durability and scanning access.
  • Contractor Collaboration: Camcode Global collaborated with the contractor to devise a method for marking new plates at the manufacturing facility. 
  • Software Integration: A Camcode Global data specialist created a comprehensive lookup table of all Osprey body armor pieces produced to date, enabling the UK MoD to reserve items in their IUID registry. This lookup table was integrated with Camcode Global software, allowing the contractor to generate and install compliant IUID labels during production.
  • Training & Inspections: Camcode Global installed a marking system at the facility and trained contractor staff on proper production, installation, and procedures. Regular inspections at the facility ensured adherence to standards.

Key Benefits

  • Efficiency: Manual processes were streamlined.
  • Readiness: Better visibility into body armor condition supported mission readiness. 
  • Soldier Safety: With individual identification of each plate tied to its test data, failing plates could easily be removed from inventory. 
  • Compliance: The solution achieved UK MoD’s requirements for IUID marking.
Through its collaborative process and unique expertise, Camcode Global helped UK MoD maximize the effectiveness of its initiative to deploy and mark Osprey body armor plates. Precise tracking and management of critical assets ultimately enhanced operational efficiency, mission readiness, and soldier safety.