Sunday 29 April 2012

Cost concerns over F-22 Raptor modernization plan

The U.S. Air Force expects to invest $9.7 billion into their fleet of F-22 jet fighters to develop and retrofit new capabilities into the complex stealth aircraft, an action the service did not anticipate for the program, putting the Raptor under the congressional microscope.

Fighter aircraft modernization is not new within the Department of Defense (DOD). In fact, the Air Force and Navy have modernized many of their fighter and attack aircraft over the past several decades, like the F-15, F-16 and F/A-18 programs. These programs each began with the expectation that their aircraft would be upgraded over time, the F-22 did not.

The F-22A began as a single-step program and did not anticipate the need for future modernization. Concerns over the mounting cost of the F-22A modernization prompted an examination by Government Accountability Office (GAO).

The GAO released their report on Thursday that examined the history of the modernization programs of the F-15, F-16, F/A-18, and compare those legacy programs with the F-22A modernization program. The F-117A stealth fighter was not included in the report because of the highly classified nature of the program.

To identify differences and similarities between the F-22A modernization program and those of the selected legacy programs (F-15, F-16 and F/A-18), the GAO reviewed official service history documents and current and historical program documents; analyzed program cost, schedule, performance, and quantity data; and spoke with current and former Air Force, Navy, and contractor officials.

F-22A program

The Air Force’s F-22A Raptor is the only operational tactical aircraft incorporating a low observable (stealth) and highly maneuverable airframe, advanced integrated avionics, and a supercruise engine capable of sustained supersonic flight.

From the outset, the Air Force’s F-22A development strategy was to pursue a quantum leap in capability in a single development program, referred to as a single-step approach, to develop and field a stealthy aircraft with advanced capabilities to replace its aging F-15C/D fleet and perform air superiority missions.

The F-22A acquisition program began in 1991 with an intended development period of 12 years and planned a procurement of 648 aircraft. The system development and demonstration period eventually spanned more than 14 years, during which time threats, missions, and a number of requirements changed. As a result, development costs substantially increased and procurement quantities greatly decreased—resulting in the procurement of only 179 aircraft, plus nine development aircraft. The final Lockheed Martin-built F-22 rolled off the assembly line in December.

Modernization

In 2003, the Air Force established a F-22A modernization program primarily to develop and insert new and enhanced ground attack capabilities that were considered necessary to meet current and future threats. These upgrades were not part of the initial development program. The modernization program is broken into four phases, known as increments, with each phase being made up of multiple projects:

    Increment 2, the initial phase of modernization, addressed some requirements deferred from the acquisition program and added new ground attack capability. It has been fielded.
    Increment 3.1 began fielding in November 2011 and adds enhanced radar and enhanced air-to-ground attack capabilities.
    Increment 3.2A is a software upgrade to increase the F-22A’s electronic protection, combat identification, and capability to receive data over DOD’s Link-16 data network.
    Increment 3.2B is expected to increase the F-22A’s geolocation, electronic protection, and Intra Flight Data Link capabilities and integrate AIM-9X and AIM-120D missiles.

Some of the key content originally planned for Increment 3.2B has been deferred, the estimated cost of the overall modernization program has doubled, and the schedule has slipped by seven years—which program officials attribute to requirements and funding instability. The most recent program schedule indicates that 3.2B will begin fielding in 2017.

“Based on F-22A flight hour data provided by the program office our analysis indicates that a large number of aircraft are likely to have flown more than 1,500 hours, or nearly 20 percent of their 8,000-hour service lives, before the Increment 3.2B upgrades are fielded,” the GAO says.

Taking these modernizations and comparing them to the older F-15, F-16 and F/A-18 programs is not easy.

“Accurately identifying and comparing the total cost of each [aircraft] modernization program is difficult,” the GAO says in their report. “Each of the programs, including the F-22A, initially managed and funded modernization as a continuation of its baseline program, so modernization costs and funding were not clearly identified in selected acquisition reports or budget documents."

“The F-22A program is more complex and costly than the legacy programs, primarily because the new capabilities have to be retrofitted onto complex, stealth aircraft that have integrated avionics systems, which, according to program and contractor officials, adds labor hours and cost,” the GAO report says. “Legacy modernization programs were less complex, and thus less costly, and incorporated mature technologies onto new production aircraft.”

Development of the F-22A took more than 14 years, encountered significant cost increases and quantity reductions, and has not yet fully met established requirements, specifically those related to reliability and maintainability, the GAO report says.

All of the legacy programs encountered difficulties during their initial development programs, yet they all delivered initial increments of operational aircraft within five to seven years.

"When the F-22’s mission changed in 2003, the resources—primarily technology and funding—needed to meet the new requirements had not been fully developed or identified," the report says. "As a result, the cost, schedule, and performance projections for the F-22A modernization program were not well founded and, over time, costs have doubled and the delivery of the full required capability has been delayed by more than seven years.

"As DOD pursues more complex and costly fighter aircraft to meet the advanced threats of the future, it is increasingly important that programs begin planning for incremental modernization at the earliest possible point."

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