Overview

Many organisations upgrade from Windows CE to Android because of the lack of security support for Windows CE, which has been gradually phased out over many years and finally ended on 10 October 2023.

However, as this migration for a defence organisation’s logistics operations reveals, the benefits can extend far beyond security to overall efficiency and business continuity.

For our client, the results were transformative. Mobile computers could be used securely in even challenging, disconnected military environments. Meanwhile, routine duties such as asset verification checks were 80% faster and pallet receipts 90% faster.

These results were achieved in a timely and efficient way using CoreXA, Nuffield Technologies’ modular framework for building line-of-business mobile apps.

Challenges

Several years ago, Nuffield Technologies helped the client transition from legacy paper-based, manual processes to a barcode-enabled, mobile computing solution. By extending their existing desktop systems with a new mobile capability, we enabled 100% accuracy of equipment checks and significantly faster mobile logistics processes.

This solution introduced:

• a rugged handheld computer (Motorola MC9090) for reliable field data capture
• a barcode scanning app ensuring 100% equipment and location confirmation
• offline-first integration with the core logistics system, syncing data when connectivity allows.

Together, these innovations significantly reduced the time it took two people to conduct a full inventory verification check of an equipment store from one day to three hours.

Says Helen Craig, Nuffield Technologies MD, ‘The system was a success and continued to deliver benefits for many years. However, over time, obsolescence crept in. It became clear an upgrade was required.’

Of particular concern was the continued use of the legacy Windows CE operating system. With reduced mainstream support and a timeline for fully discontinued security support on the horizon, security updates were provided under a costly extended support agreement. It was imperative to introduce a modern, secure OS that would deliver for many years to come.

Ageing technology was also an issue. The MC9090 fared poorly alongside the capabilities of modern barcode scanning sensors and its large size made it difficult to fit into storage racks. Meanwhile, the user experience of the app was falling far behind what most people would expect in the age of iPhone and Android devices.

Our Solution

Nuffield Technologies partnered with rugged device manufacturer Zebra Technologies to deliver an Android-based solution.

Android was chosen because of the:

• availability of ruggedised, MIL-SPEC-rated devices; we sourced and deployed more than 4,000 Zebra TC72 ultra-rugged touch computers
• customisability of the Android operating system, which made it possible to meet strict security requirements for operating mobile devices
• familiarity of this OS, reducing the need for training.

Windows CE to Android upgrades can be challenging for software developers. This is because the two operating systems have fundamentally different architectures, requiring extensive code rewriting and reimagining of application design, rather than simple porting.

More broadly, a study conducted by McKinsey discovered that 66% of enterprise software projects overrun on cost.

Nuffield Technologies has a history of successfully completing Windows CE to Android migrations, using its innovative modular CoreXA framework. For our defence client, this approach allowed for rapid app development by leveraging our own off-the-shelf modules and purpose-built code. Also, the .NET 6+ cross-platform compatibility enabled significant code reuse, ensuring a smooth transition.

Many of our client’s requirements for the migration concerned security. Moving to Zebra’s Android OS helped significantly, as security updates are available for the extended life of the device – 10 years. However, we also introduced a bespoke solution to reflect our client’s need for exceptionally hardened protection. A security layer built on Zebra MX locked-down devices, added essential features that were missing from the core operating system for example, the ability to share a single device with multiple users securely.

The solution could also be used in disconnected environments, without access to wireless communications. This is a crucial functionality for defence environments, where Wi-Fi and mobile networks are not always available.

The migration also provided a welcome opportunity to upgrade devices to meet modern expectations. Windows CE was released long before smartphone adoption, and software design standards for mobile devices have changed dramatically. Using CoreXA, we provided a contemporary and simple user experience and interface.

The Zebra TC72 devices were hi-spec rugged mobile computers, conforming to MIL-STD 810G, with robust sealing to keep out moisture and dust. They were complemented by modern barcode scanners from Zebra, with capabilities that far exceeded the client’s current expectations.

Summing up our approach to the migration, Helen Craig says, ‘Given that it was not always possible to maintain connectivity, smart workarounds were needed to make sure mobile apps were always accessible. And, when it comes to the mobile computers used by teams, it’s imperative to think about the ruggedness and reliability of those devices, which must provide high levels of performance and uptime despite the often difficult operating conditions in defence scenarios.’

As well as delivering the migration, Nuffield Technologies provided comprehensive ongoing security via Zebra’s LifeGuard for Android, which provides extended security updates to keep devices working for longer, reducing the total cost of ownership. We also delivered a comprehensive support package to ensure the devices could be repaired where possible and then returned to the defence organisation, reducing electronic waste.

The Results

Our client is now using a secure OS with regular updates that are compliant with their information security requirements. Our bespoke solution also ensures teams can work efficiently and securely in Wi-Fi free environments.

The overall user experience has improved – for instance, the client’s mobile inventory management system features a modernised user interface, helping to speed up work and reduce cognitive load on users.

Zebra TC72 mobile computers prove durable and adaptable. Particularly useful are the swappable batteries, which can be swapped out while the TC72 is being used, to increase device uptime in the field and prolong device operational life.

The improved barcode scanner on the TC72 enables faster and more accurate scanning – even on damaged barcodes, or on equipment stored in low-light environments. The compact size of the device means it can scan in small spaces, such as weapon racks. Also, the upgraded software enables continuous scanning, so a complete rack of equipment can be recorded in one sweep rather than individually scanning each item as before.

In initial field trials, one TC72 user scanned all items in a complete store in 30 minutes. This was a significant improvement on the initial paper-based process, which took two people one day; and the previous Motorola MC9090-based solution, which took two people three hours.

Benefits / Outcomes in brief

• More secure, reliable mobile work experience
• Time savings in excess of 80% when conducting stock checks
• Time savings in excess of 90% when receiving pallets
• Dramatically reduced total cost of ownership – between 42.5% and 60.5% per year compared to consumer devices
• Better, more intuitive user experience
• High degree of device uptime
• 10-year device life

Says Helen Craig, ‘For defence forces and critical infrastructure projects, maintaining security and business continuity is paramount. The challenge lies in compliance – meeting stringent digital information security requirements while managing mobile devices in secure environments. Legacy systems like Windows CE cannot offer the protection required. In contrast, Android is a modern OS that receives regular updates to address emerging threats. The new platform, combined with bespoke software development, delivers a robust, security-hardened solution to ensure compliance and operational resilience.

‘As our work for our client shows, the essential move to Android can also be the catalyst to updating technology and finding more efficient and compliant ways to work.’

Nuffield Technologies is proud to have provided this migration solution for its defence organisation customer, which delivered a secure, modern OS and a step-change in digital capability for its stores management.