SWG Program Update

21 February 2013
Lieutenant General Chris Bogdan, USAF
Program Executive Officer
F-35 Lightning II Program

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

F-35 Program Status

Bottom Line Up Front
F-35 Program on Realistic Baseline and Stable for past 2.5 years
Slow but Steady progress being made

Program Executive Officer Assessment

Affordability is #1 concern
Development: No more money, no more time
Production: Prices coming down slowly
Operations and Sustainment: MUST reduce life cycle costs

Schedule
90% remaining in Production Delivery Schedule is stable
10% remaining in SDD

Moderate Confidence we will meet our 2015 capabilities (Block 2B)

Some risk to delivering 2018 capabilities (Block 3F)

NO showstoppers for known Technical Issues

Systems Engineering process/discipline producing better results
Technical Solutions in Work

Transparency, Accountability, Discipline

Too Many Opinions, Not Enough Facts
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

F-35 Program Status

(PEO Assessment)
Development

SDD Cost: $55.2B (TY$) SDD Cost to Go: $5.8B Schedule: No Major Slips since 2011
Testing: Efficiency: G
Effectiveness: Y
Software: Y
Other Technical Issues: Y

Production

A/C Cost: 4% Reduction from LRIP 4 to 5 A/C Schedule: Tracking to Post Strike Plan
A/C Quality: Improving
A/C Concurrency: Projected costs reduced ~30%; Actual costs well below projected
Engine Cost: 4% (CTOVL/CV) / 18% (STOVL) Reduction from LRIP 4 to 5
Engine Schedule: Average 60 days ahead of need
Engine Quality: Quality escapes a concern

Sustainment
O&S Costs (20 yrs production, 30 yrs sustainment):
2011 OSD Estimate: $617B

2012 Program Office Estimate: $549B

(BY12$)

A/C Availability: Y Readiness drivers identified with corrective actions

ALIS: 1.0.3 delivered to Edwards, Eglin, Nellis, Yuma; still too many workarounds
Site Activations: 4 sites to 17 sites in 5 years
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

F-35 Basics
CY2012

CY2013

Development
Schedule

Delivery
Schedule

2A

CY2014

CY2015
2B

Fleet Release

3i

A= 18
B= 16
C= 8

A= 11
B= 17
C= 1

A= 23
B= 6
C= 4

Yuma

3F

Luke

Iwakuni

CY2018
Fleet Release

Fleet Release

A= 93
B= 16
C= 9

A= 106
B= 19
C= 14

Italian AF Main
Operating Base (MOB)

Nellis

Eglin

CY2017

Fleet Release

A= 54
B= 13
C= 6

Edwards

Base Stand Up

CY2016

Hill

A= 134
B= 29
C= 20

Norway
MOB
Misawa JP

Grottaglia

Ogden
Cherry Point

LHD-2
Beaufort

Israeli Main
Operating Base

LHD-1
LHA-6

CVN-72

LHD-8

F-35 Weapon System Capabilities:

Block 1 A/B
-Initial Simulated Air-to-Air
-Initial Simulated Air-toGround
-Air Refueling

Block 2 A/B

Block 3 I/F

Block 4 A/B

-Initial Warfighting Capability

-Initial Deployment
- Initial Weapons Employment

-Exportability
-Full Warfighting Capability
-Internal/External Weapons

-Follow-On-Development
-Added Weapons
-Improved Capability
-Enhanced Reliability &
Maintainability

Development Schedule: .99 Earned Value SPI (Steady)

Development Cost: .99 Earned Value CPI (Steady)
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

Developmental Flight Test

Efficiency
Facts About 2012:
1,167 Test Flights, 18% more than planned
9,319 Test Points, 10% more than planned

Successes:
High AoA including first Intentional Departure and Attained 75 deg AoA
First Airborne Separation of GBU-12, GBU-31, AIM-120, Paveway IV training mode, AIM-120 sim
launch against tracked target
CY2012
Flight
Efficiency
CY 12
TestTest
Efficiency
First Flight with Live Countermeasures
100% Complete Clean Wing Flutter
Planned Test Points
2870
F-35A Flight
First Night Refueling
Science
Actual Test Points
2573
Air Start Testing Complete

But, Issues:
Weapons Bay Flipper Door
STOVL Operations Due to
Aux Air Doors
Spin Chute Modification Delays
CTOL Air-Refueling Stop

F-35B Flight
Science

Planned Test Points

F-35C Flight
Science

Planned Test Points

Mission
System

Planned Test Points

2482

Actual Test Points

2443

2138

Actual Test Points

2247

1971
2056

Actual Test Points

12/31/2012
0

500

1000

1500

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

2000

2500

3000

3500

Developmental Flight Test

Effectiveness
Durability Test Status

Flight Science

Blk 1B

700 KCAS / 1.6M

40k ft
50 deg AoA / 7.0g

AIM-120
GBU-12
GBU-31 / GBU-32

1474 Hours

FS496 Bulkhead
Cracking (B Model)

Redesign / Retrofit
Cut In BF24

2117 Hours

Fwd Root Rib

(A Model)

Redesign / Retrofit
Cut In AF31

Blk 3F
AIM-9X
SDB-I
JSOW
Gun
Paveway IV

5830 hours

Avionics Bay Floor

Cracking (C Model)

Redesign / Retrofit
Cut In TBD

400 KCAS / 0.8M

39k ft
18 deg AoA / 4.5g

Blk 2B
Corrective Action

Redesign / Retrofit
Cut In LRIP7

500 KCAS / 0.9M

39k ft
18 deg AoA / 5.5g

550 KCAS / 0.9M

40k ft
18 deg AoA / 5.5g

Major Finding

FS472 Bulkhead
Cracking (B Model)

F-35B
Envelope

Blk 2A

Hours

7000 Hours

F-35A
Envelope

450 KCAS / 0.9M

40k ft
18 deg AoA / 4.5g

550 KCAS / 1.2M

40k ft
50 deg AoA / 5.5g

Y
Plan: 73%
Act: 68%

700 KCAS / 1.6M

50k ft
50 deg AoA / 9.0g

Plan: 64%
Act: 64%

630 KCAS / 1.6M

50k ft
50 deg AoA / 7.0g

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

F-35C
Envelope
N/A

450 KCAS / 0.9M

40k ft
18 deg AoA / 4.5g

550 KCAS / 1.2M

40k ft
50 deg AoA / 6.0g

Y
Plan: 65%
Act: 62%

700 KCAS / 1.6M

50k ft
50 deg AoA / 7.5g

F-35 Technical Issues

As of 14 Feb 13

Issue
BK-1 Fueldraulic Line Failure
Gen II Helmet
(Jitter, Green Glow, DAS, Acuity, Schedule,
Export)

F-35C Arresting Hook

(Prob of Engagemt, Loads, Landing Spot - SW)

Software
(Delivery Timeline, Management of Capability
Content)

ALIS Maturity
(Unreliable
software)

health management, immature ALIS

Lightning Protection
(Cant operate near thunderstorms)

F-35B STOVL Ops

(Clear fleet for vertical takeoff/landing)

Fuel Dump
(Airframe wetting)

Next Key Milestone

Status /
Trend

Return to production
effort ongoing

19 of 38 Test Flights Complete

Green Glow and DAS Latency DONE
DoD/Service Review of Suitability 6 March

CDR: 16 Apr 13

Redesign Ongoing
Ground Test at Lakehurst 4Q2013
Carrier Qualification 3Q2014

AS Block 3 CDR:
30 April 13

New systems engineering rigor to manage SW

build
Block 2B Mission Systems SW Build Plan
developed

AS Block 3 CDR:
30 April 13

New systems engineering rigor

Incremental software fixes
End-to-End Testing

AS Block 3 CDR:
30 April 13

Key Accomplishments
All F-35B cleared to fly after mod
Flights resumed on 14 Feb

Conducted Pre-CDR TIM, 23-24 Jan 13

CDR: 26-28 Feb 13

BF-19 mod finished

FRR completed: 24 Jan 13

Interim Flight
Clearance with
NAVAIR Leadership

Design downselect:
Mar 2013

Flight test: trade study design

solution review

Acronyms:; SW: software; CDR: critical design review; TIM: technical interchange meeting; FRR: flight readiness review
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

F-35 Production Quality

(Thru December 2012)
F-35 Nonconformance Hours by TVE
(Excludes Fab)
Data as of: 12-10-12

F-35 LM touch Labor Hours

CTOL

Projected

STOVL

CV

LRIP 1

Scrap, Rework, Repair Hours

AF-25

AF-24

BF-22

AF-23

AF-22

BF-21

AF-21

BF-20

CF-05

BF-19

BF-18

BF-17

AN-01

AF-20

BF-16

AF-19

AF-18

BK-02

AF-17

AF-16

BK-01

AF-15

BF-14

AF-14

BF-13

BF-12

BF-11

BF-10

BF-09

BF-08

AF-13

BF-07

BF-06

AF-12

AF-11

AF-10

AF-09

BF-15

LRIP 4

Aircraft

(60 days after First Flight)

35

16.0%

LM Ft Worth SRR

30

14.0%

25

12.0%

10.0%

20

8.0%

Defects

LMFW
LMFW
Strike
Strike

6.0%

15
10
5

Suppliers to LM FW SRR

2.0%

AF-9
AF-8
A
A
A
A
BF-6
BF-8
BF-7
BF-9
B
B
B
A
A
A
BK-1
B
B
B
B
BK-2
B
B
B

Percentage of Total Assembly Hours

LRIP 3

Delivered Aircraft Quality

18.0%

Percentage of Total Assembly Hours

LRIP 2

TVE

Aircraft

4.0%

AF-08

AF-07

AF-06

Hours
Hours

Labor Hours

Actual

Hours Expended On Quality Defects

AF-9 AF-8 AF-10 AF-11 AF-12 AF-13 BF-6 BF-8 BF-7 BF-9 BF-10 BF-11 BF-12 AF-14 AF-15 AF-16 BK-1 BF-13 BF-14 BF-15 BF-16 BK-2 BF-19 BF-20 BF-21
OQPL 23 24 24 31 29 18 27 25 22 11 11 7 4 4 6 5 9 9 7 6 1 2 1 3 1

0.0%

2011

Jan-12

Feb-12

Mar-12

Apr-12

May-12

Jun-12

Jul-12

Aug-12

Sep-12

Oct-12

Nov-12

Dec-12

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

F-35 Production Line Status

(As of 14 February 2013)
Total Assembly: 500 Manufacturing Days
Ahead of Schedule

Aft Fuselage (BAE)

Tails (BAE)

Total Assembly ~1 day behind

Field Ops ~16 days behind

1 day ahead

*20 M days margin not included

Wing
LM Ft Worth

7 days behind
Weight on
Wheels

Final

Finishes
Flight line / Field Ops

DD250
Roll-out

LM Marietta
Alenia

Mate

16 days behind

2 days ahead
Ahead of Schedule

Center Fuselage
NGC

1 day
behind

Forward Fuselage
LM Ft Worth
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

Airframe Production Costs

CTOL

CV
$250

$250

$200

CV SAR 11
CV Settlement
CV EAC

CTOL SAR 11
CTOL Settlement
CTOL EAC

$220
$215

$200

$176

$159

$150

$155
$141

$127

$131

$123

$122
$106

$110

$100

$155

$150

Target
$77

URF TY$M

URF TY$M

$171

$141

Target

$126

$91

$100

$50

$50
FY07
LRIP 1
2 CTOL

FY08
LRIP 2
6 CTOL

FY09
FY10
FY11
FY12
FY13
FY14
FY15
FY16
FY17
LRIP 3
LRIP 4
LRIP 5
LRIP 6
LRIP 7
LRIP 8
LRIP 9 LRIP 10 LRIP 11
7 CTOL 10 CTOL 22 CTOL 18 CTOL 19 CTOL 19 CTOL 32 CTOL 48 CTOL 48 CTOL

STOVL

FY07 FY08
LRIP 1 LRIP 2

FY09
LRIP 3

FY10
LRIP 4
4 CV

FY11
LRIP 5
7 CV

FY12
LRIP 6
7 CV

FY13
LRIP 7
4 CV

FY14
LRIP 8
4 CV

FY15
LRIP 9
6 CV

FY16
FY17
LRIP 10 LRIP 11
9 CV
14 CV

Cost Performance

$250
STOVL SAR 11
STOVL Settlement

Contract

STOVL EAC

URF TY$M

$200

$161
$150

$158

$135
$127

$100

$131

$130

$118

$108

$113

Target
$87

F-35 LRIP 1 (Cost Plus)

F-35 LRIP 2 (Cost Plus)
F-35 LRIP 3 (Cost Plus)
F-35 LRIP 4 (FPIF)
F-35 LRIP 5 (FPIF)
F-35 LRIP 6 (FPIF)

Increase
Over Target cost
11.8%
17.2%
22.3%
8.7% (50/50)
45/55 over target share ratio
0/100 over target share ratio

$50
FY07
LRIP 1

FY08
FY09
FY10
FY11
FY12
FY13
FY14
FY15
FY16
FY17
LRIP 2
LRIP 3
LRIP 4
LRIP 5
LRIP 6
LRIP 7
LRIP 8
LRIP 9 LRIP 10 LRIP 11
6 STOVL 7 STOVL 16 STOVL 3 STOVL 6 STOVL 6 STOVL 6 STOVL 6 STOVL 9 STOVL 14 STOVL

- Month-end December 2012 CPR

- Production Basic Build Effort Only

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

10

Engine Production Costs

CTOL
$30$30

CV

CV Engine
CTOL
Engine

$30

EAC CTOL/CV
EAC
CTOL/CV

CV Engine

EAC CTOL/CV
Settlement CTOL/CV

Settlement CTOL/CV

Settlement
SAR 12 CTOL/CV
CTOL/CV

$25
$25
U
R
F

$25$25

U
R
F

U
R
F

$22
$22
$20
$20

$20$20

T T
Y Y
$ $
M M$15$15

T
Y
$
M

$20
$20
$19
$19
$18
$18

$25

$15
$15
Target
$12
$12

$10$10

SAR 12 CTOL/CV

$25
$22
$20
$20
$20
$19
$18

$15

$15

Target
$12

$10
LRIP
LRIP
LRIP
LRIP
LRIP5 5 LRIP
LRIP6 6 LRIP
LRIP77 LRIP
LRIP88 LRIP
LRIP99 LRIP
LRIP10
10 LRIP
LRIP11
11
LRIP
1 1 LRIP
2 2 LRIP
3 3 LRIP
4 4 LRIP
FY07 FY08
FY08 FY09
FY09 FY10
FY10 FY11
FY11 FY12
FY12 FY13
FY13 FY14
FY14 FY15
FY15 FY16
FY16 FY17
FY17
FY07

STOVL
$50

LRIP 1
FY07

LRIP 2
FY08

LRIP 3
FY09

LRIP 4
FY10

STOVL Engine

EAC STOVL
Settlement STOVL

Contract

SAR 12 STOVL

T
Y
$
M

$45

F135 LRIP 1 (Cost Plus)

F135 LRIP 2 (Cost Plus)
F135 LRIP 3 (Cost Plus)
F135 LRIP 4 (FPIF)
F135 LRIP 5 (FPIF)
F135 LRIP 6 (FPIF)

$39

$40

$37

$35

$32
$31
LRIP 1
FY07

LRIP 2
FY08

LRIP 3
FY09

LRIP 4
FY10

LRIP 7
FY13

LRIP 8
FY14

LRIP 9
FY15

LRIP 10 LRIP 11
FY16
FY17

Increase
Over Target cost
4%
13%
11%
3% (50/50)
0/100 over target share ratio
0/100 over target share ratio

Target
$30

$33
$30

LRIP 6
FY12

Cost Performance

$46
U
R
F

LRIP 5
FY11

LRIP 5
FY11

LRIP 6
FY12

LRIP 7
FY13

LRIP 8
FY14

LRIP 9
FY15

LRIP 10 LRIP 11
FY16
FY17

- Month-end December 2012 CPR, with JPO VACs ($ M)

- Production Effort Only

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

11

Concurrency
Concurrency is defined as the overlap of the development, test, production, fielding, operations
and sustainment phases of an acquisition program
Concurrency introduces risk of discoveries during production requiring retrofit of delivered a/c
Fixes rolled into Production line Timelines decreasing (18 mos to 13 mos)
Retrofit aircraft already produced requires modifications (Mod plan created and regularly updated)
Lockheed Martin sharing in Concurrency costs (LRIP 5 and beyond)

Concurrency Changes are identified during Flight Test, Qualification Test, Ground Test
Projected Concurrency Cost by LRIP Lot

High-Level Mod Schedule

Group 1 Mod Examples:

Forward Root Rib (STOVL/CTOL)
Station 3/9 Aft Rib (STOVL/CTOL)
FS 496 Bulkhead (STOVL)

Increased Discipline in Estimating & Controlling Concurrency Costs

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

12

F-35 Sustainment
Requirement

Current Actual

Status Against the

Plan

By Variant
(CTOL/STOVL/CV)

By Variant
(CTOL/STOVL/CV)

By Variant
(CTOL/STOVL/CV)

(6.0/4.0/4.0)

(1.66/1.44/1.53)

(290/220/250)

(45.1/21.0/22.7)

Fault Detection Rate (%)

98

79.80

Electronic Fault Isolation (%)

90

70.00

False Alarms (MFHBFA)

50

.45

Maintenance Man-Hours / Flight Hour Unsch. (MMH/FH(U))

(6.0/6.0/6.0)

(6.10/4.09/3.77)

Elapsed Maintenance Time (MTTR)

(2.5/3.0/2.5)

(12.97/11.97/5.21)

Metric

Reliability & Maintainability

MFHBFDC (Airframe)
MFHBFDC (Engine)

Prognostic / Health Monitoring

Mean Downtime (Supply and Maint)

MFHBFDC = Maintenance flight hours between failure

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

13

F-35 Sustainment
Air Vehicle Availability
100%

Eglin CTOL AVA

Eglin STOVL AVA

Eglin FLEET AVA

80%

Good

60%
40%
20%
0%

Non-Mission Capable - Supply

50%

CTOL NMC-S

STOVL NMC-S

FLEET NMC-S

Non-Mission Capable - Maintenance

100%

10%
0%

FLEET NMC-M

60%

Good

Good

20%

STOVL NMC-M

80%

40%
30%

CTOL NMC-M

40%
20%
0%

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

14

F-35 Operational Training

ATC Student Throughput
140

Pilot Training

120

Pilots
Planned

100
80
60
40

Pilots
Graduated

20
Oct-14

Sep-14

Aug-14

Jul-14

Jun-14

May-14

Apr-14

Mar-14

Feb-14

Jan-14

Dec-13

Nov-13

Oct-13

Sep-13

Aug-13

Jul-13

Jun-13

May-13

Apr-13

Mar-13

Feb-13

Jan-13

Dec-12

Nov-12

Oct-12

Sep-12

Aug-12

Jul-12

Jun-12

May-12

Apr-12

(End of Month)

1800

Maintenance Training

1600

Maintainers
Planned

1400
1200
1000
800
600

Missed planned target due to:

1) IATO security shutdown in Dec 2011
2) ~60 % Services seat fill rate

Maintainers
Graduated

400
200
0
Dec-12

Jan-13 Feb-13

Mar-13

Apr-13

May-13

Jun-13

Jul-13

Aug-13

Sep-13

Oct-13

Nov-13

Dec-13
(End of Month)

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

15

F-35 Sustainment Strategy

F-35 Program Office will be Product Support Manager
Product Support Integrator Not Yet Determined
LM and P&W have not earned right yet

Inject Competition where Feasible Industry Day Results

Support Equipment
ALIS Administration

Global Supply Chain

Training Center Operations

Improve Reliability and Maintainability of Weapon System

Repair Contracts
Robust R&M Team
Deep Dive of top 20 Air Vehicle Depot Level Reparable (AVDLR) Costs
R&M Sensitivity analysis of top 50 AVDLR

Cost per Flying Hour Estimating

ALIS Improvements

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

16

F-35 PEO Planning Priorities

Year Long Continuing Resolution/Sequestration

Preserve System Design and Development to the

maximum extent possible
Keep Initial Operational Capability Options open with
Block 2B
Wholeness: Support and sustain all delivered aircraft
Preserve efficiencies in production to the maximum
extent possible.
Reductions will decrease LRIP 7 quantities, increasing unit
recurring flyaway cost

Maintain production capacity to the maximum extent

possible.
Reductions will decrease investments in tooling, redesigns for
obsolete parts, and cost reduction initiatives

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

17

Partner Challenges
Cost Visibility
JPO directing LM/PW to adjust Cost Reporting

Reprogramming Labs
Partner/FMS Reprogramming Labs late to need; working to recover schedule

Airworthiness Requirements
Single Airworthiness Process / Data for all Partners
Partner unique needs accommodated (funded) on a case-by-case basis

Transition to pooled training (2013-2014)

Pooling Implementation Agreements and Contract signatures pending

Long-Term Training and infrastructure for CONUS-based

international training and basing
Working with Partners on requests for long-term support and U.S. military
construction projects

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

18

Summary
Program Making Steady Progress
Realistic Plan
Driving Stability into the Program
Schedule/Capabilities Holding Steady

Affordability is Critical for US and Partners

Technical Issues are being worked
New Culture for Industry, Program Office, DoD
Enterprise
Look Forward, Not Back
Transparency, Accountability, Discipline
Too many opinions, not enough facts

F-35 Program MUST deliver on its Promises

Hold ME accountable
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

19

Questions?
DISTRIBUTION
STATEMENT
A. Approved
forpublic
public release;
distribution
is unlimited.
DISTRIBUTION
STATEMENT
A. Approved
for
release;
distribution
is unlimited.

20