. United States General Accounting Office Testimony Before the Subcommittee on Military Acquisition, Committee on Armed Services, House of Representatives For Releaseon Delivery Expectedat 1090 a.m., EST, Thursday FebruaryIO,1994 Y MILITARY AIRLIFT The C-17 Program Status and Proposed Settlement Statement of Frank C. Conahan, Assistant Comptroller General, National Security and International Affairs Division OS89Y4/ GAO/T-NSIAD-94-115 I Mr. Chairman and I am pleased program. for of the Subcommittee: Members to be here today to discuss Based on the continuing the status work that of the C-17 we have been doing the House and Senate Committees on Armed Services, provide updated performance Defense's information issues on C-17 cost, and our observations (DOD) proposed settlement Douglas Corporation, schedule, we will and on the Department agreement with the prime contractor of McDonnell on the C-17 aircraft. RESULTS IN BRIEF Since last March when I testified, experience cost, program costs for continue the 120 aircraft acquire unit schedule, by $1.3 billion. the C-17 also continues additional restriction after to increase. C-17 estimate DOD estimate In addition, Delivery are being delivered acceptance. may be cause for in the Fiscal The act prohibits $43 billion work or known deficiencies government slippage Total to the average is paying McDonnell Douglas to build and aircraft amounts of unfinished corrected problems. to grow; the current the government again slipped and performance program now exceeds the last 210 aircraft price the C-17 program continues schedules with increasing that must be More important, invoking a funding Year 1994 Defense Authorization DOD from obligating have Act. funds for more than four to C-17s in any given aircraft in the prior the contract Estimates Also, of flight test Furthermore, that rates while involving problems continue. software and inadequate In addition 1 month of to our review, the life cost-effectiveness. the wing, payload/range is fixing flaps, and slats, immature mission built-in-test (BIT) other computer capability. the Defense Science Board (DSB) the C-17 program last summer. The DSB rightly recognized a number of problems which beset the program: contractor performance, poor Air This planned to demonstrate the contractor These include too much concurrency, all than expected. must achieve is key to its Finally, problems within less the C-17 cannot meet current specifications. unless appear to be optimistic. is significantly and maintainability cost advantage assessed completion because the aircraft reliability to the act, date. C-17 reliability technical year subsequent 6 months are delivered delivery is important cycle fiscal overly ambitious greater poor coat and schedule than anticipated complexity, goals, and Force management. In December 1993, the Secretary of Defense announced a decision to stop the C-17 program at 40 aircraft made significant improvements. investments On January unless the contractor in management and productivity 6, 1994, DOD and McDonnell 2 Douglas r agreed to a settlement designed to ensure a viable 120 aircraft program. However, DOD has not established specific schedule, and performance criteria which to evaluate improvements in the contractor's against performance and which will enable DOD to make an informed decision on whether to continue the program beyond 40 aircraft. In addition, schedule calls to be made before for this these investments estimated that decision can be assessed with these investments costs by $1.4 billion cost, the program's the effects any certainty. The DSB could decrease total or, under a worst-case program cost growth to about $800 m illion program scenario, lim it for the 120 aircraft program. Congress should realize significantly deciding that the first from the provisions whether the settlement 40 C-179 will in the settlement. two issues must be addressed, information is needed on the details delay and disruption the government for revising its claims identify against Before is a good deal for the government, potential not benefit F irst, more complete of the contractor's claims and the consideration contract McDonnell Douglas. specifications due and waiving Second, analysis to the m inimum number of C-17s needed to meet specialized requirements should be completed as soon as possible. The cost to the government may be more than the settlement specifies. The DSB estimates of consideration 3 for changes in of payload/range specifications of aircraft ranged from $750 million hand, the potential claims based on the contractor's $1.25 billion. settlement proclaimed the $237 million claim that contractor and government without Congress to decide (COEA) sponsored significantly strategy by DOD, there DOD has acknowledged that would represents analysis to execute difficult be requirement for analysis that can now meet can get the job done. a settlement of C-17's until with the another and nondevelopmental effectively delay making a mix of aircraft for meeting November 1995. on the quantity leave the government with C-17 the COEA identified and to launch a new study to determine for a mixed force was done. on both the effectiveness that on the most cost-effective will it cheaper alternatives a decision in the at a lower cost than the full decision Delaying or price are alternatives By doing so, DOD will airlift recognized We to endorse the settlement. aircraft. its could, at $234 million, cost and operational shortfall On the other add up to about information claims, However, DOD has decided contractor valued delivery have been validated. in claims additional whether Based on a recent DOD's airlift estimate, for which no legal We believe late given up by the contractor because one claim, a contractor for to $3 billion. None of these estimates also question program. and waived claims of C-178 until another 4 $5 billion November 1995 invested in this problem-plagued additional At that program information time, upon which DOD will the settlement estimated program cost In 1987, we reported1 close for costs, that routine its direct environment, costs, doubts about the C-17's requirements airfields solution performance, program, cost-effectiveness. strategy to fill and raise We believe for the airlift shortfall According meets DOD's minimum airlift to provide certain such as the ability and airdrop these capabilities uncertainties acquisition aircraft and was used The changed world at a lower cost than the full fleet, the program came the C-17 program were terminated. The C-17 is intended the airlift of the total objectives pursue an acquisition would occur if to the COEA, this concurrent wide-body if less than anticipated serious that requirements in wartime. delays DOD should vigorously decision. about $21.3 billion, or about 50 percent airlift delivery in this more the C-17 was the most cost-effective lengthy nondevelopmental to make an informed cost and performance rising little for only 40 of the 120 planned C-17s. to meet U.S. to meeting in our opinion, have obligated including alternative with, outsized cargo. are necessary in the program, C-17 program. unique capabilities to land on small, If it is decided to austere that and outweigh the enormous and, therefore, the proposed lMilitarv Airlift: Air Force Analysis Suoports Acuuisition C-17 Aircraft (GAO/NSIAD-87-97, Mar. 20, 1987). 5 of settlement cost, we believe goes forward, and performance schedule, criteria in the contractor's performance, to make an informed decision beyond 40 aircraft. legislatively on whether existing that that amended or revised in the settlement that specific improvements will to continue be needed the program Congress should statutory specify requirements to the C-17 program remain in effect specifically nothing (1) all to evaluate information We also believe that applicable DOD should establish legislatively unless and (2) there is commits the government to buy more than 40 aircraft. BACKGROUND The C-17 military Air transport, to airlift substantial refueling. The Air airlifter payloads planned 1990, the Secretary aircraft. Through fiscal appropriated for the is being designed over long ranges without Force is intending and the cornerstone Force originally of future the C-17 to be its airlift forces. to buy 210 C-17 aircraft. core The Air However, in of Defense reduced the program to 120 year 1994, the Congress has over $15 billion for the C-17 program, (1) $5.5 billion for research, (2) $9.8 billion for procurement; military and produced by the McDonnell Douglas Corporation, Force April being developed development, test and evaluation; and (3) $163 million construction. 6 including for Although costs, some of these funds have been used to cover government such as management and testing, been for Douglas. and provided parts of 26 production scheduled with C-17 aircraft the advance procurement (P27 through that contracts funds have of McDonnell year 1994, the Congress has authorized Through fiscal the procurement aircraft and production development the majority P34). (Pl through funds for another Advanced procurement need to be ordered the year before P26) eight involves production buying is to start. c In addition aircraft to the development and low-rate initial Force has awarded three of 14 additional McDonnell aircraft for for The Air and plans of the test aircraft. production aircraft remaining production to award another The test a test of 6 aircraft, the Air contract The Air aircraft and five eight contract P9) of the 20 of the testing. have been delivered 7 for Force has accepted and 9 (Pl through Command, production advance procurement are being used in flight aircraft initial Force has also awarded in March 1994. aircraft which included low-rate Douglas an advance procurement production Mobility production contracts aircraft. six more aircraft delivery contract, The four to the Air UPDATE ON COST, SCHEDULE, AND PERFORMANCE ISSUES Total C-17 program costs billion estimate for more than DOD's last continue to grow; the current the 120 aircraft estimate schedules have again slipped completion remain optimistic. $43 program is now $1.3 billion to acquire 210 aircraft. and estimates of flight Delivery test Cost Issues For the fiscal total year 1991 President's budget, program costs would be $41.8 billion aircraft. estimated Three years that total later, inflation billion estimated Budget Office total 210 budget, decreases buy decreased reduction the was offset program cost would increase in program costs by by $13.2 The C-17 Program Director recently another billion, from $39.5 to $43 billion. estimate to acquire 120 aircraft now exceeds the last estimate to acquire 210 aircraft by $1.3 billion. Thus, the total 8 for DOD An August 1993 study showed that However, this in cost growth. that that program costs would be $39.5 billion and the reduced aircraft $15.5 billion. to acquire in the 1994 President's reduced C-17 program of 120 aircraft. Congressional DOD estimated $3.5 program cost DOD Production Cost Growth Continues In March 1993, we testified production costs deteriorated. the value of cost for continued of to increase performed work efficiency. development Index (CPI), per dollar and lot III which measures expended, is an indicator decline contracts. under the new lot and as efficiency There has been a further the development lot contractor The Cost Performance the efficiency for that in the CPI In addition, IV contract is higher, while the trend IV is downward. Since March 1993, the cumulative decreased slightly decrease, the Defense Plant increased the government's development from 0.67 to 0.66. contract $1.4 billion CPI for the development In part Representative due to this Office (DPRO) estimate-at-completion from $7.9 billion over the contract price about of $6.7 billion. CPI for the lot downward trend from 0.91 to 0.85 from March to November 1993. the DPRO increased contract another which approximates its $100 million, showing the same downward III III from $1.1 billion the contract than the lot also showed a EAC for the lot ceiling As of November 1993, the cumulative was better contract the The cumulative Again, III (EAC) for to $8.1 billion, ceiling contract CPI for contract, trend since 9 price production to $1.2 billion, of $1.215 billion. the lot but the lot contract IV contract IV CPI is award in May 1993, Even though the cumulative is no better 80 percent will than the contractor's expended level, make a profit principal for $119 million the government more to build IV as compared to lot that improved is paying III at the the contractor $100 million. However, the financial the contractor the same number of aircraft price at the target comparison and ceiling for the lot position about under lot I Unit III, IV, and prices. Table 1: Price Comparison for Production (Dollars in Millions) I on lot and III. 1 shows the unit V contracts IV is decreasing the DPRO projects of approximately IV is that lot performance reason for the contractor's on lot Table CPI trend price Lots III, I IV and V Total price II Lot Number of aircraft Target Ceiling III' 4 $237.8 $281.5 IV 4 267.4 301.2 1,069.7 1,204.g V 6 270.7 303.7 1,624.3 1,821.g 29.6 19.7 Price increase Lot III to IV Target Ceiling $951.2 $1,126.0 118.5 78.9 'Lot III engine prices have been excluded for purposes of comparison. Engines are government furnished equipment on lots IV and V. 10 Normally, one would anticipate improve would and the decline aircraft 1, contract as the production matures, design from production shown in table that lot the average unit to production aircraft processes unit lot. prices prices However, as have increased, not decreased. Productivitv In the past, Remains Inadeauate efficiency, increased disruptions but the rate the C-17 program had experienced and that this needed improvement work force, were displaced quarters a little in the learning of a recent this improvement bumping. that not sufficient 11 on commercial the C-17 assembly During the first were displaced. of II personnel curve. As a the assembly work force January showed improvement lots had not to prevent in assembly personnel between production was still of to the program since turnover DPRO analysis curve rate through three-quarters had been newly assigned effects or 42 percent of 1993, 1,567 workers over workers with objectives. severe bumping would continue 1992, 1,448 workers, result, was improving of improvement because of bumping by senior achieving three aircraft, curve, production enough to meet program cost and schedule We noted that During McDonnell Douglas' as measured by the learning each successive projects that we reported and III, to achieve 1992. The were reflected in in the learning but that the cost and schedule goals for lot declined not The displacement III. significantly in the be a significant third obstacle of C-17 assembly quarter of to improving workers 1993 and should the learning curve in the future. In April that 1992, we reported out-of-position learning work. curve. has since the aft fuselage of the aircraft five level, at fuselage and efficiency, major assembly tools to 51 percent The contractor of the required was done out-of-position the five in the contractor's which in the DPRO's being accomplished learning would have been greater 12 if a out-of- are used to reported that for work to assemble as the fuselage major assembly tools. in the amount of out-of-position improvement work on to 5 percent of production fuselage. assembly moved through improvement reduced out-of-position from 13 percent indicator For example, PlO, 21 percent than the to the low the amount of out-of-position amount of work is still manufacture believed together). is a better posftion, decrease was a major contributor at the major assembly tool significant the aft ,at other (where major sections wings are joined opinion work-- work performed P4 to PlO decreased major join However, officials The contractor For example, aircraft contractor work station-- designated that curve reflects While a work at major join, more work had been the completed in-position as the major sections from one assembly tool Last year, the impact of assembly quality measured by off-standard on cost and schedule hours (primarily from approximately aircraft delivered, established costs were about $44 million for all rate 1993, the Acting for Production not being achieved. that if Deputy Assistant mid-1993 review the contractor and quality assurance planned production continued processes, schedule including Scrap, assembly, This adds about $7.3 million per year. Secretary of Defense a 50 percent reduction it its current observed manufacturing could not maintain and at the same time reduce cost. 13 be tied decision. of the C-17 program, with per aircraft over a 12 month period to the next major C-17 program funding The DSB, in its but the goals of 6 equivalent costs five on the 10th production Resources recommended that in scrap rework and repair hours have for the first departments, in 1993. at a production In August off-standard shows improvement, by the company are still rework and repair aircraft 40 percent, to about 34 percent This trend as for rework and repair) Since then, trends. declined aircraft. moved to the next. discussed we of the aircraft the unit Schedule Issues During 1993, the contractor lot aircraft, II late. the Air even after delivery schedule missed the scheduled aircraft delivered for lot delivery III aircraft, extended because the Fiscal the contractor lot (PlO through Year 1994 Defense Authorization the Secretary Act imposed a of Defense from subsequent to the act, One milestone is that to obligating month of the contract This requirement aircraft unless acceptance. missing with while have been in the 6 must be delivered P7 through increasing that within 1 P9; however, the amounts of unfinished had to be corrected For example, minor inspection fasteners, delivered year date. was met for aircraft work or known deficiencies on P9 included aircraft, new funds, delivery were delivered government a number of milestones all of This is significant 1 month late. prohibits that P16) is at risk funds for more than four C-17s in any fiscal months prior III and the DPRO are forecasting obligating met. the in 1993 by a month, at least that about 5 months for two of the three each of the next seven aircraft being delivered The last aircraft. Force significantly Both the System Program Office requirement five P5 and P6, were each delivered Also, contract delivered items, the uncorrected deficiencies such as loose screws and major deficiencies 14 after included a cargo ramp that would not unlock contractor involved and open. At the time of our review, had not yet quantified the number of work hours in completing this work. officer withheld million on P9 for the unfinished These aircraft waivers. $10,000 for P7, $65,000 for P8, and over $3 For example, defines officer contract other things, the Air with as acceptance performance, that relatively required reliability, The government involving, among or maintainability. Both had hoped to reduce the number to deliver the aircraft. the number of major waivers constant for which the of an item not conforming requirements Force and the contractor however, a number of major about $7 million. or configuration of major waivers during work at the time of delivery. P9 had 126 major waivers withheld a major waiver with However, the contracting were also delivered contracting the We found, granted from P5 to P9, the five remained aircraft delivered 1993. Estimated Date For Completinq Flicht Test is Optimistic In March 1993, we reported slipped probability it will believe at least 13 calendar of additional complete even this the flight that the C-17 flight months to January slippage. test test program had 1995 with a high The Air Force now estimates program by March 1995. is an optimistic estimate. 15 We In April the 1993, the Air original month) schedule ending believe that in March 1995.2 the flight to the 135 aircraft-month out that it is difficult test Air test which (42 calendar Force and contractor program is generally schedule. to determine program from month) program, 1993, to a 135 aircraft-month tracking flight the test (27 calendar 80 aircraft-month ended in November officials Force rebaselined However, they point the exact status program due to the uncertain nature of the of developmental testing. The Air Force and the contractor judge the status flight hours milestones. of the test {time about 73 percent the required schedule. The Air test Overall, aircraft the assumed 40-flight identified flight milestones, 1993, overall and about hour average rate requirement credit ‘For test purposes, an aircraft one aircraft for one calendar approximately test 69 percent of flight for completion hour efficiency 69 percent behind schedule. per aircraft From April through rate below per month of the December averaged 51.3 month is defined month. 16. credit which is ahead of which is slightly program as scheduled. flight and flight have averaged a monthly as a necessary test hours, points, to Force has completed points Force has completed of key flight task), 1994, the Air flight of indicators such as test a specific of the 6,899 test 1,885 credit test program, to perform As of January use a variety as the use of percent, which is below the 62-percent assumed for the remainder Force program. Additionally, experiencing example, as of January available test test half Of the remaining lost problems from completing 17 aircraft-months to manage the flight month schedule, (45 calendar it test has developed month) schedule 565 days were conditions kept the program at risk. to increase program from 135 to 152 aircraft-months. plans days, missions. The DSB found the 135 aircraft-month recommended adding test test completion Although the Air January of Air Force has identified believe may present Force the 135 aircraft- a preliminary 152 aircraft-month which extends the flight test planned (In March 1993, we projected until July Force and contractor 1994, show the test test program against program would not be completed While a series Air date. It the flight program to June 1995-- 3 months beyond the currently flight For because the aircraft test and other intended down time. (1,315 days) of the days (2,836 days) were lost were being worked on. aircraft the Air program is still amount of aircraft 1994, nearly because technical rate of the 135-month rebaselined the flight a significant efficiency 1995). reports, program is generally the following a substantial risk program as scheduled: 17 areas the of through on schedule, concern that to the completion of the we the , -- Software immaturity operationally -- Paratroop -- Completion mission Air has restricted representative and airdrop a-pilot of developmental testing systems and some significant (such as completion scheduled at the end of the test Force operational concerns independently reliability, not improve. Air if maintenance. selected field landings} and officials during ability 33 have also able to be operational testing, estimated percent the aircraft that of flfght test aircraft BIT system and inadequate manuals are key contributors to the Air Force's regarding its maintain operational to independently testing. 18 does the contractor technical during a (PM&A) evaluation to maintain The lack of a working ability are the Air Force may have to Force personnel about critical aero performance and availability that schedule. program. the aircraft their provides crew. the Air Force may not They indicate a waiver currently that for of short reports maintainability, requirement. request test maintain flight problems could delay the test milestones expressed assessment of the the aircraft concern Performance Issues In March 1993, we reported that and range specifications. Since then, these specifications contractor to levels believe operational configured both the Air can be achieved. In addition, (IOC), Finally, values Force and the initial which is scheduled because the Air aircraft. reliability DOD has proposed relaxing that capability 1995, may slip the C-17 could not meet payload for January Force may not have 12 similarly test to be about half results to date show of expected requirements. SDecifications In March 1993, we reported payload weight, engines that the C-17 could not meet its and range specifications aircraft then, that increase to meet specific in aircraft fuel be fully Mobility Command has asserted proposed specification requirement capability expected objectives, will and failure expectations. that, of achieving. although Since several performance not be significantly mission. 19 of the operational and mission degraded. requirement to levels The Air changes do not meet current aircraft in of the C-17 specifications capable to meet the threshold payload/range because of growth drag, consumption DOD has proposed relaxing the C-17 will primarily The C-17 is for the Command's key Table 2 shows that current the proposed specification C-17 operational maximum payload, objectives heavy I Heavy logistics Maximum payload Medium II loaistics Ferry I a.,--:-, range bAn objective or objectiveb II requirement - Threshold Objective Objective 110/3,200 .i;:1;&; .::$,:~,~~{ .'..::.:,. .:.;'::.'i, : ,:j::: ...A...... :.:;;;i& Objective II c Current 130/3 ,200 value is an acceptable the basic aircraft does not meet contracted DOD now defines miles. miles) I I ; Proposed ..>I ~:'~~~:~~~~~J:;~~~ Objective Although design the C-17's (heavy logistics) currently missions. and Proposed Range and Payload Requirements 'A threshold is the minimum acceptable operational identified by the Air Mobility Command. mile logistics, (Thousand pounds/nautical II II the and ferry medium logistics, Table 2: Comparison of Current Specifications with Operational rrr for changes do not meet requires operational of the C-17 is nearly payload/range primary mission, mission The settlement proposes complete, the specifications. specification 130,000 pounds 3200 nautical revising 20 requirement. as the 3,200 nautical The contract the C-17 to carry requirement this specification to 120,000 pounds, while requirement mile mission increase, the C-17's are still and failure consumption aircraft expectations. miles-- below the threshold The DSB recommended that and range performance to an operational to fuel miles. requirement, are feasible Differing consumption C-17 payload methodology assumptions rates. for weight are included between While the growth or reduced in the more stringent Using the operational a 123,330 pound payload In other words, but it would still specification and, if requirement. any margins that C-17 would deliver performance. shows how the C-17 would actually methodology. traditional drag fuel be changed from a traditional eliminates engine performance aircraft the method for calculating methodology it for the 101,796 pounds 3200 nautical carry methodology. these methods pertain operational growth, to improve payload/range the C-17 will contract weight reasons McDonnell Douglas has proposed several implemented, nautical The primary to the DSB, these initiatives still on the 3200 nautical of the engine to meet specific initiatives According perform, Command's threshold performance is only 93,345 pounds. shortfall low-risk Mobility is 110,000 pounds. The DSB found that payload the Air it fall of 130,000 pounds. 21 a distance would achieve short methodology, the of 3,200 the threshold of the current In agreeing to these reduced standards, contractor to implement -- Use the Pratt commercial the following DOD directed initiatives. & Whitney 94 commercial improvements the to increase engine that specific includes fuel consumption by 0.4 percent. -- Implement aircraft low risk weight -- Reduce total -- Increase weight was necessary gross weight to allow been unsuccessful weight at reducing official, reduction initiatives to implement. Program and contractor flight has demonstrated testing 2 percent. achieved These officials by the additional while that believe McDonnell initiatives, the net aircraft many of the proposed payload the key heavy logistics to a contractor Douglas has been pursuing of these initiatives to meet even the revised including to fuel. implementation for the aircraft According by 5,000 pounds, for additional successful and range specifications, believes drag by one percent. maximum takeoff The DSB found that to reduce initiatives by 1,500 pounds. aircraft 585,000 pounds, mission. reduction weight it has and would be too expensive officials stated that drag can be reduced at least that the increased payload drag reduction would offset any lost 22 payload capacity should the weight reduction measures be unsuccessful. Planned IOC May Slip The current Mobility program plan calls Command to declare 12 similarly configured which follows. during IOC in Janu,ary 1995. aircraft to support In preparation 1993 will yet unspecified for design. retrofitted with undergo major wfng and fuel retrofits are scheduled The DSB, however, retrofit in flight to provide evaluation. 5 months, all of the design test, 12 similarly It, while high risk, believe agreeing them into to keep the January that it the production aircraft for the contractor's 1995 date as a target 23 them aircraft IOC and the PM&A the start However, Air is achievable. time to evaluate recommended slipping that and The was insufficient changes in the aircraft, configured therefore, and slats spend in December 1994. there from January to June 1995. officials, new flaps P9) will system modifications. that and incorporate delivered them to an as (P5 through to be completed concluded the RM&A evaluation to configure aircraft Five This requires IOC, the aircraft undergo modifications up to 3 months being will for the commander of the Air of IOC Force retrofit plan is plan They, therefore, for starting IOC. C-17 Reliabilitv RMhA is critical to peacetime and the ability budgeted and Maintainability to keep operations levels. The Air after the start evaluation The RMhA evaluation flying hours. availability, wartime and support Force plans costs to conduct However, we believe that near an RM&A of IOC between February is a 30 day evaluation utilization, and July requiring if about 1,750 C-17 reliability not improve sufficiently in the next few months, the Air should the RM&A evaluation consider delaying until 1995. does Force reliability improves. Aircraft testing has revealed expected based on contractual maintainability concluded likelihood that that C-17 reliability growth curves, is less although is substantially better than expected. based on current reliability values, of the C-17 successfully completing The DSB the a mission does not meet requirements. Table 3 shows that test actual aircraft reliability hours and 25 hours of initial substantially below the expected at 1,202 flight squadron operations reliability. 24 than is Table 3: Actual C-17 Reliability and Expected Reliability measure Ynherent maintenance is unscheduled maintenance component due to its own internal failure. required on a bCorrective maintenance is the sum of inherent, induced and no defect maintenance actions. Induced maintenance is unscheduled maintenance on a component due to some induced condition rather than an inherent failure. No defect maintenance results from a false indicator or isolation reading. C-17 reliability failures data show that have occurred reliability numbers. corrective solutions improve reliability. addition, there with a large variety no one particular item driving This means the contractor for a substantial In other data to track or operating with restrictions. 25 trends the low have to find is no simple components because they are seldom used, failed yet installed, will number of failures words1 there is insufficient of different for to fix. In some but not fixed, not While reliability performance maintainability appears to be substantially However, some Air higher Air Force flight than expected the maintenance flight test that maintenance expected. than that believe the due to employees provide both at squadron operations at Charleston are concerned given the These officials manuals, aircraft numbers are partially contractor and at the initial of the aircraft better officials test maintainability support Force Base. immaturity is less than expected, that BIT system and the incomplete repairs by Air Force personnel will take longer. Other Technical As we reported Issues last the C-17 program. performance, year, technical These problems increased problems continue may result program cost, in and/or to occur decreased extended in aircraft program schedules. Built-in-Test The C-17 has been experiencing rates. BIT provides line-replaceable requires However, the Air for electronic units. a BIT false excessively fault The C-17 air alarm rate high BIT false isolation vehicle alarm to individual specification of not more than 5 percent. Force has experienced 26 BIT false alarm rates as high as 97.9 percent Charleston Current Air for production immaturity operating at Force Base. problems with maintenance aircraft BIT provide personnel extremely troubleshooting of BIT software the BIT system itself, limited capability the aircraft. has limited and additional the ability In addition, to fully problems may exist system that have yet to be identified, It also impacts maintenance training as part of initial operations. to be accomplished This problem, if not corrected, significant impact on the ability operational testing The contractor action 1994. squadron have a to pass and plan to reduce the number of BIT false 1994, show the number of false highest the critical for developing However, BIT data, the number occurring to its within x agreed to take responsibility alarms by January with of the aircraft test and RMQA evaluations. managing a corrective January will to as of the end of alarms is still at Charleston Air very high, Force Base increasing level, Wina Failure In October 1992, both wings on the static approximately retrofitting static testing 128 percent the static in July during article's 1993. test a 150-percent wings, article failed load test. the contractor In September 1993, the left 27 at After resumed static wing failed the outer again at 144 percent. part However, based on an engineering Douglas and an Executive was appointed results, by Secretary concluded test. The team's that Independent of the Air final report the production Basically, Some Air wings. and stiffeners with this to various approach. the contractor, the wing to eliminate stiffeners by using the test is retrofitting involves steel straps to the wing and spars on the wing. however, were not entirely Therefore, at its stronger load as a part own expense, agreed to redesign straps components to build as soon as possible, of the proposed and the wing. The new but not later than one-fourth of the P29. 120 C-17 aircraft fleet ribs retrofit the need for supplemental wing is to be incorporated If the contractor this Force and DOD officials, settlement, aircraft Force to review the wing by adding stainless satisfied Review Team, which has not been issued. wing failure, stringers on analysis, the wing had passed the 150 percent Due to the 1992 static reinforcing damage occurred of the wing where the upper spar cap did not meet specifications. McDonnell The initial will DOD officials currently materials-- are purchased, have wings using the supplemental warn of possible implemented stainless solution steel approximately corrosion straps problems with because of attaching straps and stiffeners. dissimilar and aluminum stringers. 28 the They stated life that potential corrosion and Slat limit the service Redesian In March 1993, we testified susceptible the skin C-17 flaps and weaken the structure. the slats ribs and slats and the flaps The hinge fairings temperature composite skins aircraft P2 and are currently to the weight retrofit on the flap flaps to titanium undergoing will of the aircraft. Pll edge to are being changed to high flight and slats with on test testing. add approximately 1,100 pounds will in-production both the new flaps production has in the the trailing have been installed and slats existing the contractor Redesigned flaps and substructures to receive by changing materials. titanium The redesigned the material were which can ripple Since then, by changing and skins, titanium. aircraft that to heat damage from engine exhaust, redesigned will could of these wings. Flap slat problems be the first and slats. aircraft with The contractor the new flaps slats, Main Landina The C-17 continues gear. Gear and Tires to experience These problems interference, include and (3) tire problems with (1) retraction, wear. Testing 29 the main landing (2) post has shown that, on and occasion, level the main landing flight and while ground maneuvering allows gear. banking. and braking, interference landing gear has not retracted the large during in heavy-loaded shock strut compression between the post and axle beam of the main The Air Force has also life does not meet specification test data to reflect experienced In addition, satisfactorily found that even after adjusting a more normal operational during the tire service the actual mission profile than tests. EVOLUTION OF C-17 SETTLEMENTAGREEMENT Concern over continuing problems resulted procurement Fiscal funds and imposing the release reporting Defense Acquisition effectiveness, requirements. Acts requirements, of Defense for Acquisition the program and report Defense for Acquisition DOD and cost and Subsequently, the tasked the DSB to back on what had to be done to put The DAB conducted the DAB have not yet been officially In December 1993, the Secretary The required an extensive of the program between August and December 1993. of of Board (DAB) review and affordability. the C-17 program back on track. results various on the adequacy of the C-17's Under Secretary review and performance in the Congress restricting a special operational evaluate schedule, Years 1993 and 1994 Defense Authorization to conduct report C-17 cost, The reported. of Defense and Under Secretary announced a decision 30 to stop the C-17 of program at 40 aircraft unless management and productivity proposal to resolve contractor. proposed improvements. C-17 issues On January They also outlined between the government a and the 6, 1994, McDonnell Douglas agreed to DOD's which according specific authorizing provides for: -- a provisional and appropriations schedule and at cost, program, and (d) satisfy to deliver (c) successfully all other of approval, which McDonnell Douglas an ability RM&A requirements -- a settlement enactment major management and manufacturing (b) demonstrate resolving terms requires 2 year program during changes, including to its legislation must (a) introduce complete contract process aircraft on the flight test specifications and between the government and McDonnell Douglas all outstanding C-17 business and management issues as the date of the agreement. The estimated million. made significant settlement. The.settlement, of the contractor cost to implement The government's which is to settle is shown in table claims. the proposed settlement share is $348 million, A breakout 4. 31 is $802 $237 million of proposed settlement of costs Table 4: Estimated Settlement Government Item Flight costs test extension Redesign wing Computer Aided Design/Computer (Dollars Douglas $61.5 $61.5 0 32.0 20.0 20.0 15.0 15.0 2.5 2.5 0 100.0 Aided Manufacturing Management Information System Advanced Quality System Product improvement projects Other Nonrecurring engineering 32 in millions GAO'S ASSESSMENTOF THE SETTLEMENT The proposed settlement recommends changes designed completion of a viable lZO-aircraft settlement only makes sense in the context program and not a 40-aircraft analysis First, program. program. of the proposed settlement, DOD has not established performance objectives that program is to continue analysis claims of the value McDonnell evaluate claims, the validity estimates specifications continues and without Also, and unfiled, the program, the an in-depth to settle all attempting or to establish Third, cannot be realized to DOD agreed to pay without exposure. the and agreed to waive $237 million of such claims improvements schedule, and continue of the claims. of the government's productivity concerns. Second, in an effort the contractor filed of our must be met by McDonnell Douglas if Douglas an additional outstanding cost, beyond 40 aircraft. against the of a 120-aircraft On the basis specific reduced payload/range potential We believe we have several improve the management environment government to ensure to realistic the impact of unless the program beyond 40 aircraft. DOD Has Not Established Cost Or Schedule Criteria The settlement demonstrate letter an ability states that to deliver McDonnell Douglas must aircraft 33 on schedule and at cost, ; as well other as successfully contract complete specifications, the flight including However, DOD has not established criteria it intends For example, delivering aircraft "at cost.'* costs be established unit The settlement aircraft states beginning discussed Force is accepting P16--are told the delivery P7 shall remain the same. aircraft with several lots. under contract for However, as I the Air work or uncorrected at least through 1 month late. DOD was being given to slipping months. settlement can be implemented, schedule may slip. If obligation for specific the next seven aircraft--P10 consideration this beyond 40 or goals schedule, unfinished being delivered schedule year schedule to meet delivery us that targets for C-17 production in order of to continue The DSB recommended that proposed from a fiscal cost or schedule define not the delivery In addition, at risk officials that with earlier, deficiencies. any specific DOD does program and all RM&A requirements. to use to decide whether aircraft. target test Thus, even before it the appears the delivery happens, DOD may have to seek relief 1994 congressional requirement of funds for C-17 production aircraft restricting referred the to earlier. DOD officials proceeds of criteria evaluation told us a decision beyond 40 aircraft pertinent the C-17 program would not be based upon any single or key parameters. of all on whether It will data, be a judgement based on an We believe 34 set this situation 1 provides DOD too much latitude and undermines accountability. new program environment such, we believe that will in determining program performance The DSB reported there that to create was a need for accountability. DOD should clearly spell out specific As criteria be used to recommend to the Congress whether program should a the C-17 proceed beyond 40 aircraft. Claims Resolution to Settlement Was A major objective of the settlement claims. Prior Kev filed to the settlement 12 claims against When the settlement been resolved; contracting Contract states an additional disruption $472 million. none of these claims under consideration or in litigation that had by the at the Armed Service Board of McDonnell Douglas was planning in claims to the DSB, these claims to the program caused the $1.25 billion 1993, the Air Force Principal said that against by the government. in claims I want to before Subcommittee on Defense, Deputy Assistant 35 and was never filed In testimony he knew of no basis to submit the government. were based on delay by any government entity. Committee on Appropriations, Contracting McDonnell Douglas had totaling agreement was signed, $1.25 billion emphasize that reviewed the government, contractor Appeals. The settlement According agreement, they were either officer was to resolve or the House in March Secretary for for these claims, In the DSB's opinion, the $472 million provides that in claims DOD will modifications, full-scale the government was liable filed contract. Douglas agrees to release claims may have as of January 6, 1994, the settlement, whether $234 million filed or not. requested components. The DSB concluded of this without DOD performing As part of the settlement, various specifications aircraft. claim. Douglas' that the decision and the delivery for specifications and delivery is difficult estimated to estimate. the value Members' estimates effort government schedule for P6 and prior claims to these waivers and contract We were told that 36 modifications assumptions. to $3 billion. the magnitude the contractor. due the members of a DSB team different ranged from $750 million against contract The consideration based on several against claim of the claim. schedule. was made to establish claims should pay 100 to pay this analysis to meet the original failure agreeing the the government also agreed to revise the contractor for that a package of wing the government or price C-17 settlement, assertion The government also agreed to waive all government from all Of the $237 million We question a legal of the of the date the company to subcontract percent further the government was based on McDonnell government prices for the $237 million, McDonnell it contract and ceiling In return of The settlement payment through the target development $237 million by the contractor. make this increasing for No of the specific DOD officials told us that avoiding primary factor Officers rights protracted in the claims the contractor was a settlement. of the government or modify of entirety, existing the government without consideration. Clearly, e contracts obtaining considering valid to the legal the settlement 1 in its both McDonnell Douglas and the government have agreed to make concessions. DOD has been unable, specific consideration agreeing to waive its the Air existing however, to identify Force will receive in return contractual rights the for and to modify contract. We believe contentious that, in an overriding relationship and to continue claims both parties establish without establishing have against value true cost of this settlement that the contract specification methodology by the C-17's to maintain to eliminate between the government the realistic operational effort of the claims is not known. revisions for calculating current the 120 aircraft performance program. 37 the government the value each other. the and the contractor the C-17 program to 120 aircraft, has made concessions driven with and employees of the government may not waive contract detriment this litigation of potential Without any effort of both parties, In addition, the we believe and the change to an payload and range were capabilities to in an effort Benefits From Productivitv ImDrovements Are Uncertain According is antiquated problems and lacks limit Design/Computer Information an effective the efficiency DSB recommended that McDonnell improvements these improvements is $175 million. of this could decrease years before realized. projects completed The first until program cost growth program. resulting specific from changes will product be improvement to be December 31, 1995, and the second package will until any benefit a year later. Given these time frames, from these programs will the Congress will production that program cost by $1.4 limit benefits of proposes be faced with beyond a 40 aircraft of The DSB estimated and management process installment costs to be proposed by McDonnell Douglas is not scheduled be completed if total other so as to The estimated cost. scenario, It improvements practices The settlement for the 120-aircraft productivity the System along with business to about $800 million could take several As such, (CAD/CAM), a Management to modernize under a worst-case These implement Computer Aided the government pay $37.5 million or, system. of the C-17 program. these improvements infrastructure of the C-17 program. Aided Manufacturing improve the efficiency billion quality System, and an Advanced Quality productivity that corporate to the DSB, McDonnell Douglas' occur prior the decision not little to 1996 when on proceeding with program. 38 1 actions Similarly, intended to modernize manufacturing and management structure impact during the first engineering implementation Finally, quality will have only limited While the CAD/CAM system for two years. changes may be fully McDonnell Douglas' functional by 1996, full of the system is not proposed to start the Advanced Quality that control will System will take several until 1997. be a phased change in years to implement. ALTERNATIVES TO THE C-17 DOD's settlement letter need to consider commercial production as part wide-body of a successful Based on congressional direction, conducted alternatives to determine the Secretary of Defense, C-178 and C-5Bs, the job done. a combination This total aircraft In general, 3Primary authorized aircraft. to the C-17. 'Total aircraft inventory and training aircraft, authorized showed that wide-body 39 As announced by a combination aircraft For wide-body the total aircraft backup and training including was aircraft. of C-17s and commercial fleet, of can get alternative aircraft.3 do not include is the entire a COEA be wide-body and 49 commercial combination program. that the most cost-effective 47 C-17s aircraft airlift DOD directed the analysis primary Based on this or new C-58 strategic of 40 C-173 and 47 commercial inventory, are needed.4 aircraft or C-178 and commercial represents the to McDonnell Douglas also discusses backup wide-body $7 aircraft, life-cycle cost savings when compared to a fleet billion In connection with were estimated of 120 C-17s. the settlement, DOD announced that program would not proceed beyond 40 aircraft Douglas made significant disconnect with based on primary the analysis inventory believe authorized of 40 C-17s, this assessing aircraft the COEA, since to include information the proposed unless program improvements. announcement is based on total McDonnell inventory, aircraft. the C-17 Because DOD's the alternatives there is a examined were As such, DOD needs to update an alternative based on a total or 34 C-17 primary authorized is needed to assist settlement at about aircraft. We the Congress in and determining program should proceed beyond a total aircraft aircraft whether inventory the C-17 of 40 aircraft. Although DOD has acknowledged alternatives that settlement with determine making a decision DOD will settlement its airlift the contractor aircraft. program cost for are significantly has decided cheaper to execute and to launch a new study for a mixed force By doing so, DOD will on the most cost-effective requirement have obligated costs, there can get the job done, it the optimum strategy nondevelopmental meeting that until or about 50 percent effectively mix of aircraft including of the total only 40 of the 120 planned C-17s. 40 to of C-17s and November 1995. about $21.3 billion, a At that the estimated delay for time, In 1987, we reported alternative close that to meet our airlift to meeting its maintainability delivery in wartime. in this about its acquisition schedule, undermine commercial Act made available procurement cargo variant according to an procurement complementary request lift as well serious delays doubts about continue, uncertainties and in our credibility. to acquire Year 1994 Defense Authorization to initiate wide body military as a complement to the C-17. Force official, DOD has determined C-17 aircraft than the procurement wide body aircraft. Congress to transfer as and lengthy significant to DOD up to $400 million Air and direct an update on DOD's plans of two additional to intertheater raise and performance The Fiscal aircraft routine environment, development, a nondevelopmental of especially Even though the C-17 is 9 years we provide aircraft. program came planned reliability performance, program, the program's You also asked that the objectives, its The changed world engineering cost, if and was used for cost-effectiveness. full-scale opinion, through less than anticipated concurrent the C-17's into achievable capability, costs, requirements cost and performance the cost advantages rising the C-17 was the most cost-effective the C-17 program. 41 Instead, that would contribute of They told $300 million or commercial the more additional us that DOD plans of undesignated to funds to The Air calls Force has developed for military spending up to $100 million or commercial been presented In our opinion, it developmental decision and cost-effectiveness these efforts suggests that nondevelopmental Mr. Chairman, DOD will cargo. An Air is scheduled military that answer any questions related for November 1995. depend on the outcome of that assess the operational utility in moving military Force official estimated or a small that fraction acquisition of plan to compete the C-17 against and/or concludes which has on the number of non- DOD's preliminary is preparing that a nondevelopmental seems to be closely cost around $5 million, available. it will strategy The strategy, of wide body aircraft will the $100 million to procure a decision aircraft In the interim, bulk and oversize that appears that airlift acquisition wide body aircraft. to the Under Secretary, to the C-17 milestone decision. a preliminary commercial my statement. wide-body I will aircraft. be happy to you or members of the Subcommittee may have. (707046) 42