Published on: April 22, 2025 / update from: April 22, 2025 - Author: Konrad Wolfenstein
Efficient maintenance logistics in the military with GS1 Datamatrix and Telemainttenance - Logistics Modernization of - Image: Xpert.Digital
The transformation of military maintenance logistics: GS1 Datamatrix and Telemainttenance
Optimized operational readiness: How new technologies change defense logistics
Modern defense logistics are faced with the complex challenge of keeping highly developed weapons systems and equipment in globally distributed and potentially endangered areas of application. A profound transformation is emerging: The integration of the GS1 Datamatrix as a standardized identification carrier combined with telemaintness solutions fundamentally revolutionizes the military maintenance logistics. This combination enables more precise identification of components, accelerates repair processes and significantly improves the operational readiness. The German Bundeswehr and international armed forces in particular are increasingly implementing these innovative technologies to optimize maintenance processes and ensure the availability of critical systems even under challenging conditions.
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Basics and importance of the GS1 Datamatrix in military logistics
The GS1 Datamatrix has established itself as a key technology in modern defense logistics. As a standardized 2D barcode, it offers an exceptionally high data capacity with high fault tolerance and thus enables a robust method for the clear identification of military components and digital data linkage.
Technical specifications and properties
The GS1 Datamatrix is based on the ISO version ECC 200 of the Data Matrix icon (ISO/IEC 16022) and supports the numbering structures of the GS1 system. The use of the REED solomone error correction algorithm, which keeps damaged symbols to a certain extent, is a particular strength-a decisive advantage in military use scenarios. Each symbol consists of square modules within a single -sided search pattern, whereby a light zone is necessary on all sides that a module must be wide.
The minimum module size should be 0.38 mm, which ensures reliable mechanical recording. In the first place, the FNC1 sign announces data according to the GS1 data designer concept and thus ensures the compatibility with the GS1 system. The possibility of the reverse (inverse) reflection is particularly advantageous, which means that symbols are either dark on light or bright on dark.
Implementation in the Bundeswehr
The Bundeswehr has set clear requirements for the labeling of products and materials. According to the technical delivery condition TL A-0032, supply items that are delivered to the Bundeswehr must be clearly and as permanently identified with a GS1 data carrier. The GS1-128 line code must be used to identify products, although alternatively the GS1 DataMatrix can also be used if this is necessary for reasons of space.
The labeling takes place according to a standardized scheme, which, for example, includes the GTIN (Global Trade Item Number) and a serial number. According to GS1 rules, a typical code contains elements such as: the data designer for the GS1 standard, the labeling GTIN for the supply article, the GLN (global location number) of the manufacturer, an identification number and the serial number of the specific part.
Telemaintenance: a paradigm shift in military maintenance
Telemainttenance: A paradigm shift in military maintenance - Image: Xpert.digital
Telematenance has established itself as a transformative approach in military maintenance and enables remote diagnosis and support by experts without having to be physically on site.
Concept and technological foundations
The basic principle of telemaintenance is based on a secure communication connection between technicians on site and distant experts. This connection can be transferred to real time audio and video data so that specialists can assess the situation from a distance and give instructions. Modern systems also enable the exchange of documents, the setting of markings on images and the use of augmented reality (AR) in order to visually convey complex instructions.
The integration of mixed reality technology is particularly innovative, which allows the distant expert to see the system to be waiting from the point of view of the technician and to give precise visual instructions. This creates intuitive and efficient collaboration over any distances.
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International application and successes
The US Army has already successfully used Telemainttenance in the Ukraine conflict . After the Russian invasion in February 2022, American specialists supported Ukrainian troops remotely in the maintenance of M777-Haubitzen. General Charles Hamilton, head of the Army Materiel Command, described this capacity as a “Game Changer” for the fight.
Due to the success, the US Army plans to implement telemaintenance in the Indo-Pacific area, which is logistically considered particularly challenging. In addition, the technology is to be tested in various exercises and integrated into the military doctrine and training.
Application in the German Bundeswehr
The Bundeswehr is increasingly relying on telemaintership solutions for its complex weapon systems. A remarkable example is cooperation with Rheinmetall for the maintenance of the A400M transport aircraft. In December 2021, Rheinmetall received an order in the low double-digit million range for the delivery of modern training rigs and augmented reality systems for the training of maintenance and repair staff.
These combined systems enable comprehensive, integrated training of the essential maintenance procedures with all work steps, regardless of the original air vehicle. As a result, the availability of the A400M fleet remains unaffected by the training, which improves the operational readiness of the Air Force.
Synergies between GS1 Datamatrix and Telemainttenance
The combination of GS1 Datamatrix and Telemaintenance creates significant synergies that raise military maintenance logistics to a new level.
Operative advantages of integration
The integration of the GS1 Datamatrix in Telemainttenance processes significantly improves the data quality, accelerates diagnosis and repair processes and increases the surgical flexibility of maintenance. The clear identification of components using the GS1 Datamatrix enables targeted access to the maintenance history or construction plans of the specific component.
This leads to reduced downtime and potentially lower costs, since experts can support quickly and precisely without physically being on site. The combination also enables improved logistical intelligence, since data about life cycle, maintenance history and availability of spare parts are accessible in real time.
MBDA Germany as a pioneer
With the use of the GS1 Datamatrix, MBDA Germany has created an innovative telemaintness service that offers a secure and inexpensive solution for the maintenance and maintenance of highly complex systems. The company develops, produces and supports air defense and steering aircraft systems for the Bundeswehr and is faced with the challenge of waiting for these high-tech products worldwide, often under extreme environmental influences.
The Telemainttenance platform developed by MBDA Germany enables them to be in contact with mobile data communication via audio and video by means of mobile data communication. Images from the affected machine or the component are recorded via a camera and the GS1 Datamatrix is read by scanner in order to enable an exact identification of the assembly.
This solution was successfully tested under real operating conditions on the Hamburg frigate and has demonstrated its practicality in complex scenarios.
Practical applications and case studies
The combination of GS1 Datamatrix and Telemainttenance is practical application in various military areas.
Maintenance and modernization of the Taurus marching aircraft
The Bundeswehr and Taurus Systems GmbH have signed a contract for the maintenance and modernization of the Taurus marching aircraft. The measures ensure the operational readiness of these high -precision spacers up to at least 2045.
In addition to maintenance, a comprehensive modernization is also carried out as part of “basic overhaul 2” in order to meet the increasing requirements for modern weapons systems. Taurus thus remains a key element of the Air Force and NATO, which, with its range of over 500 kilometers and high precision, makes an important contribution to deterrent and state and alliance defense.
Use of telemaintenance in Ukraine
The US Army has successfully used the telemaintance ability that she initially developed in a parking lot in Poland to support Ukrainian troops. Hamilton reported on a case in which Ukrainian soldiers have led to the repair of an already damaged device in order to make it operational again.
The virtual maintenance support has been significantly expanded since then. The army built up an independent facility and a spare parts warehouse. Ukrainian soldiers can now communicate with employees in US depots, which gives maintenance technicians access to specialist engineers and original manufacturers.
Mixed reality collaboration for the Bundeswehr
For missions in the field camp, to the lake or in disaster areas, the Bundeswehr implemented the remote support system “T-Maintenance XR” in combination with the Genoa Rendezvous long-distance maintenance solution. This enables technicians on site, directly, intuitively and safely over any distances to work with an expert via mixed reality collaborative.
A special advantage of this system is the possibility of making rare expert knowledge available quickly in a wide variety of places, often only for a short time and for important details. Safe remote support meets the highest demands on IT security and offers simple integration into existing networks and reliable control options.
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Data security and interoperability: challenges for modern military solutions
Despite the many advantages, military organizations face some challenges when implementing these technologies.
Data security and system interiority
A central challenge is to guarantee data security when transmitting sensitive military information. This is particularly critical, since telemaintenance systems often have to operate over long distances and potentially unsafe networks.
The interoperability between different systems and platforms is also a challenge. Military organizations often use a variety of devices and systems of different generations and manufacturers, all of which have to be integrated into a uniform maintenance system.
Further development and future potential
In the medium term, MBDA Germany strives for the expansion of your telemaint dance solution for further maintenance-intensive areas such as machine and plant engineering. The use of the GS1 Datamatrix as a globally proven, sophisticated identification standard offers the best conditions for this.
The increasing distribution of augmented reality and artificial intelligence opens up further opportunities to improve telemaintenance. For example, future systems could automatically diagnose problems or propose preventive maintenance measures based on the analysis of historical data.
The US Army plans to not only use telemaint dance in various geographical regions, but also to integrate in training centers in order to make it an integral part of your doctrine and training methods.
Efficiency increase through technology: modern approaches in military logistics
The integration of GS1 Datamatrix and Telemainttenance marks a paradigm shift in military maintenance logistics. This combination offers significant advantages in terms of efficiency, cost reduction and operational readiness and is therefore a decisive factor for modernizing defense logistics.
The successful implementations at the US Army, the Bundeswehr and companies such as MBDA Germany show the enormous potential of these technologies in practical applications. Especially in times of global inserts and complex weapon systems, the ability to make expert knowledge available quickly and safely at any place in the world is invaluable.
Despite challenges such as data security and system interior operability, the advantages through improved logistical intelligence, reduced downtime and potentially lower costs outweigh. With progressive technological development, especially in the field of augmented reality and artificial intelligence, military maintenance logistics should make further significant progress in the coming years.
The GS1 Datamatrix as a robust identification standard and telemaint dance as a flexible remote maintenance solution will remain central components and strengthen the defense capacity of modern armed forces.
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