Defense Acquisitions
Key Considerations for Planning Future Army Combat Systems
Gao ID: GAO-09-410T March 26, 2009
The Future Combat System (FCS) program--which comprises 14 integrated weapon systems and an advanced information network--is the centerpiece of the Army's effort to transition to a lighter, more agile, and more capable combat force. The substantial technical challenges, the cost of the program, and the Army's acquisition strategy are among the reasons why the program is recognized as needing special oversight and review. This testimony is based on GAO's March 12, 2009 report and addresses knowledge gaps that will persist in the FCS program as Congress is asked to make significant funding commitments for development and production over the next several years.
The Army will be challenged to demonstrate the knowledge needed to warrant an unqualified commitment to the FCS program at the 2009 milestone review. While the Army has made progress, knowledge deficiencies remain in key areas. Specifically, all critical technologies are not currently at a minimum acceptable level of maturity. Neither has it been demonstrated that emerging FCS system designs can meet specific requirements or mitigate associated technical risks. Actual demonstrations--versus modeling and simulation results--have been limited, with only small scale warfighting concepts and limited prototypes demonstrated. Network performance is also largely unproven. These deficiencies do not necessarily represent problems that could have been avoided; rather, they reflect the actual maturity of the program. Finally, there is an existing tension between program costs and available funds that will likely worsen, as FCS costs are likely to increase at the same time as competition for funds intensifies between near- and far-term needs in DOD and between DOD and other federal agencies. DOD could have at least three programmatic directions to consider for shaping investments in future capabilities, each of which presents challenges. First, the current FCS acquisition strategy is unlikely to be executable with remaining resources and calls for significant production commitments before designs are demonstrated. To date, FCS has spent about 60 percent of its development funds, even though the most expensive activities remain to be completed before the production decision. In February 2010, Congress will be asked to consider approving procurement funding for FCS core systems before most prototype deliveries, the critical design review, and key system tests have taken place. Second, the program to spin out early FCS capabilities to current forces operates on an aggressive schedule centered on a 2009 demonstration that will employ some surrogate systems and preliminary designs instead of fully developed items, with little time for evaluation of results. Third, the Army is currently considering an incremental FCS strategy--that is, to develop and field capabilities in stages versus in one step. Such an approach is generally preferable, but would present decision makers with a third major change in FCS strategy to consider anew. While details are yet unavailable, it is important that each increment be justifiable by itself and not dependent on future increments.
GAO-09-410T, Defense Acquisitions: Key Considerations for Planning Future Army Combat Systems
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Testimony:
Before the Subcommittee on Air and Land Forces, Committee on Armed
Services, House of Representatives:
United States Government Accountability Office:
GAO:
For Release on Delivery:
Expected at 2:00 p.m. EDT:
March 26, 2009:
Defense Acquisitions:
Key Considerations for Planning Future Army Combat Systems:
Statement of Paul L. Francis, Director:
Acquisition and Sourcing Management:
GAO-09-410T:
GAO Highlights:
Highlights of GAO-09-410T, a report to Subcommittee on Air and Land
Forces, Committee on Armed Services, House of Representatives.
Why GAO Did This Study:
The Future Combat System (FCS) program”which comprises 14 integrated
weapon systems and an advanced information network”is the centerpiece
of the Army‘s effort to transition to a lighter, more agile, and more
capable combat force. The substantial technical challenges, the cost of
the program, and the Army‘s acquisition strategy are among the reasons
why the program is recognized as needing special oversight and review.
This testimony is based on GAO‘s March 12, 2009 report and addresses
knowledge gaps that will persist in the FCS program as Congress is
asked to make significant funding commitments for development and
production over the next several years.
What GAO Found:
The Army will be challenged to demonstrate the knowledge needed to
warrant an unqualified commitment to the FCS program at the 2009
milestone review. While the Army has made progress, knowledge
deficiencies remain in key areas. Specifically, all critical
technologies are not currently at a minimum acceptable level of
maturity. Neither has it been demonstrated that emerging FCS system
designs can meet specific requirements or mitigate associated technical
risks. Actual demonstrations”versus modeling and simulation
results”have been limited, with only small scale warfighting concepts
and limited prototypes demonstrated. Network performance is also
largely unproven. These deficiencies do not necessarily represent
problems that could have been avoided; rather, they reflect the actual
maturity of the program. Finally, there is an existing tension between
program costs and available funds that will likely worsen, as FCS costs
are likely to increase at the same time as competition for funds
intensifies between near- and far-term needs in DOD and between DOD and
other federal agencies.
DOD could have at least three programmatic directions to consider for
shaping investments in future capabilities, each of which presents
challenges. First, the current FCS acquisition strategy is unlikely to
be executable with remaining resources and calls for significant
production commitments before designs are demonstrated. To date, FCS
has spent about 60 percent of its development funds, even though the
most expensive activities remain to be completed before the production
decision. In February 2010, Congress will be asked to consider
approving procurement funding for FCS core systems before most
prototype deliveries, the critical design review, and key system tests
have taken place. Second, the program to spin out early FCS
capabilities to current forces operates on an aggressive schedule
centered on a 2009 demonstration that will employ some surrogate
systems and preliminary designs instead of fully developed items, with
little time for evaluation of results. Third, the Army is currently
considering an incremental FCS strategy”that is, to develop and field
capabilities in stages versus in one step. Such an approach is
generally preferable, but would present decision makers with a third
major change in FCS strategy to consider anew. While details are yet
unavailable, it is important that each increment be justifiable by
itself and not dependent on future increments.
What GAO Recommends:
In its March 2009 report, GAO suggested Congress consider not approving
full funds for the program until several conditions are met, such as
preparation of a complete budget for any program emerging from the
milestone review. GAO also recommends the Secretary of Defense, among
other things, ensure the program that emerges conforms to current
defense acquisition policy, such as technology maturity; any spin out
approach is based on fully tested results; and any incremental strategy
involves free standing, justifiable increments.
View [hyperlink, http://www.gao.gov/cgi-bin/getrpt?GAO-09-410T] or key
components. For more information, contact Paul Francis at (202) 512-
4841 or francisp@gao.gov.
[End of section]
Mr. Chairman and Members of the Subcommittee:
I am pleased to be here today to discuss the Department of the Army's
Future Combat System (FCS), a networked family of weapons and other
integrated systems. FCS is in the forefront of efforts to help the Army
transform into a lighter, more agile, and more capable combat force by
using a new concept of operations, new technologies, and a new
information network, linking whole brigades together in a system of
systems. Later this year, FCS faces a congressionally mandated go/no-go
decision review to determine the program's future. This review is
crucial, as production funding and commitments will build rapidly after
that point, limiting the government's ability to alter its course.
My statement today is based on the work we conducted over the last year
in response to the National Defense Authorization Act for Fiscal Year
2006, which requires GAO to report annually on the FCS program.
[Footnote 1] This statement discusses the knowledge gaps that will
persist in the FCS program as Congress is asked to make significant
funding commitments for development and production over the next
several years. For additional information on these issues, please refer
to our report released March 12, 2009.[Footnote 2]
Background:
The FCS concept is designed to be part of the Army's Future Force,
which is intended to transform the Army into a more rapidly deployable
and responsive force that differs substantially from the large division-
centric structure of the past. The Army is reorganizing its current
forces into modular brigade combat teams, each of which is expected to
be highly survivable and the most lethal brigade-sized unit the Army
has ever fielded. The Army expects FCS-equipped brigade combat teams to
provide significant warfighting capabilities to the Department of
Defense's (DOD) overall joint military operations.
Since being approved for development in 2003, the program has gone
through several restructures and modifications. In 2004, the program re-
introduced four systems that had been deferred, lengthened the
development and production schedules, and instituted plans to spin out
selected FCS technologies and systems to current Army forces throughout
the program's development phase. In 2006, the Army again deferred four
systems, among other changes. In 2008, the Army altered its efforts to
spin out capabilities to current forces from heavy brigade combat teams
to infantry brigade combat teams.
The FCS program began in May 2003 before the Army defined what the
systems were going to be required to do and how they would interact.
The Army moved ahead without determining whether the concept could be
successfully developed with existing resources--without proven
technologies, a stable design, and available funding and time. The Army
projects the FCS program will cost $159 billion, not including all the
costs to the Army, such as complementary programs. The Army is also
using a unique partner-like arrangement with a lead system integrator
(LSI), Boeing, to manage and produce the FCS. For these and other
reasons, the FCS program is recognized as being high risk and requiring
special oversight. Accordingly, in 2006, Congress mandated that DOD
hold a milestone review following the FCS preliminary design review.
[Footnote 3] Congress directed that the review include an assessment of
whether (1) the needs are valid and can best be met with the FCS
concept, (2) the FCS program can be developed within existing
resources, and (3) the program should continue as currently structured,
be restructured, or be terminated. Congress required the Secretary of
Defense to assess the program against specific criteria, including the
maturity of critical technologies, program risks, demonstrations of the
FCS concept and software, and a cost estimate and affordability
assessment, and to report on findings by the time of the milestone
review.
This statement is based on work we conducted between March 2008 and
March 2009 in accordance with generally accepted government auditing
standards. Those standards require that we plan and perform the audit
to obtain sufficient, appropriate evidence to provide a reasonable
basis for our findings and conclusions based on our audit objectives.
We believe that the evidence obtained provides a reasonable basis for
our findings and conclusions based on our audit objectives.
Significant Knowledge Gaps in Key System Development Areas:
Assessed against the criteria to be used for the milestone review, the
FCS program has significant knowledge gaps. Specifically, the program
has yet to show that critical technologies are mature, design issues
have been resolved, requirements and resources are matched, performance
has been demonstrated versus simulated, and costs are affordable. The
Army will be challenged to convincingly demonstrate the knowledge
necessary to warrant an unqualified commitment to FCS at the 2009
milestone review.
While best practices and DOD policy preference are for each of a
program's critical technologies to achieve a technology readiness level
(TRL) of 7 prior to entering development, the Army is struggling to
achieve a TRL 6, the level required for the milestone review, after
almost 6 years of development. Although the Army projects that TRL 6
will be achieved by the time of the review, the Army will be challenged
to do so. Dates for several key demonstrations have slipped, and
several ratings have yet to be validated by independent reviewers.
Furthermore, the Army's experience with maturing FCS technologies does
not inspire confidence that it will be able to execute the fast-paced
integration plans involved with advancing technologies to TRL 7 before
the production decision in 2013.
Design knowledge expected to be available at the time of the milestone
review may not provide the necessary confidence that FCS design risks
are at acceptable levels. The Army continues to set and refine
requirements in order to establish system designs, particularly at the
system level. Although the Army plans to have completed all system-
level preliminary design reviews before the milestone review, the
schedule to close out all the reviews may take more time than
anticipated, key risk items will have to be addressed, and design trade-
offs will be necessary. For example, the projected weight of the FCS
manned ground vehicles has increased, which could have a number of
effects on vehicle performance. In the coming months, the Army will
have to address these and other design and requirements conflicts. It
is important to note that DOD's updated acquisition policy calls for
holding preliminary design review at or near the time of the decision
to begin development, which in the case of FCS was in 2003.
The Army will be challenged to meet the congressional direction to
demonstrate--versus simulate-that the FCS warfighting concept will work
by the time of the milestone review. At this time, limited
demonstrations of select capabilities, including manned ground vehicles
and software, have been conducted, but no meaningful demonstration that
the FCS concept as a whole will work has been attempted. A thorough
demonstration of the FCS network, the linchpin of the FCS concept, will
not be attempted until 2012. There have been some demonstrations of
early versions of the lightweight armor and an active protection
system, but the feasibility of the FCS survivability concept remains
uncertain.
The Army is expected to update its cost estimate, currently $159
billion, for the milestone review.[Footnote 4] Last year, the Army
indicated its notional plans to increase estimates by about $19
billion, but has not said whether it would have to trade off
capabilities to accommodate the higher costs. The Army has also
indicated its willingness to reduce funding to current force systems in
favor of FCS. While the updated program cost estimate will be a better
representation of actual costs than previous estimates, the program
still has many risks and unprecedented challenges to meet, and thus,
the estimate will likely change again as more knowledge is acquired.
Army Plans to Proceed with Production Commitments before Solid Level of
Knowledge Demonstrated to Decision-makers:
At the milestone review, DOD will have to evaluate at least three
programmatic options to shape investments in combat systems for the
Army, each of which presents challenges. The first involves the FCS
program, which, as currently structured, has significant risks for
execution. Second, the decision to produce spin out systems to current
forces is expected to occur before full testing of production-
representative prototypes. Third, the Army is considering altering the
FCS strategy to follow an incremental approach, which is preferable to
the current approach, but presents other challenges.
The FCS acquisition strategy is unlikely to be executable within
current cost and schedule projections, given the significant amount of
development and demonstration yet to be completed. The timing of
upcoming commitments to production funding puts decision makers in the
difficult position of making production commitments without knowing if
FCS will work as intended. Under the current acquisition strategy, FCS
decisions are not knowledge-based, nor do they facilitate oversight.
For example, the Army has scheduled only 2 years between the critical
design review and the production decision in 2013, leaving little time
to gain knowledge between the two events. As a result, FCS will rely on
immature prototypes for making the decision to proceed into production.
Also, if the program receives approval to proceed at the milestone
review this year, the Army will have only 40 percent of its financial
and schedule resources left to complete what is typically the most
challenging and expensive development work ahead, as depicted in figure
1 below.
Figure 1: Remaining FCS Research and Development Funding and Key
Events:
[Refer to PDF for image: shaded line graph]
Fiscal year: 2003;
Percent of funds remaining: 99%.
Fiscal year: 2004;
Percent of funds remaining: 94%.
Fiscal year: 2005;
Percent of funds remaining: 83%.
Fiscal year: 2006;
Percent of funds remaining: 73%.
Fiscal year: 2007;
Percent of funds remaining: 61%.
Fiscal year: 2008;
Percent of funds remaining: 49%.
Fiscal year: 2009; Preliminary design review;
Percent of funds remaining: 39%.
Fiscal year: 2010;
Percent of funds remaining: 28%.
Fiscal year: 2011; Critical design review;
Percent of funds remaining: 18%.
Fiscal year: 2012;
Percent of funds remaining: 12%.
Fiscal year: 2013; Low-rate initial production;
Percent of funds remaining: 7%.
Fiscal year: 2014;
Percent of funds remaining: 3%.
Fiscal year: 2015; Initial operating capability;
Percent of funds remaining: 0%.
Source: U.S. Army (data); GAO (analysis and presentation).
[End of figure]
Historical experience and recent independent cost estimates on FCS
suggest that costs will grow beyond the Army's estimates. Our previous
work has shown the development costs for programs with mature
technologies increased by a modest average of 4.8 percent over the
first full estimate, whereas the development costs for programs with
immature technologies increased by a much higher average of 34.9
percent. Similarly, program acquisition unit costs for the programs
with the most mature technologies increased by less than 1 percent,
whereas the programs that started development with immature
technologies experienced an average program acquisition unit cost
increase of nearly 27 percent over the first full estimate. Our work
also showed that most development cost growth occurred after the
critical design review. Specifically, of the 28.3 percent cost growth
that weapon systems average in development, 19.7 percent occurs after
the critical design review.
Under the current strategy, the Army's plans for funding core
production efforts put congressional decision makers in a difficult
position in a number of ways. Facilitization costs begin in fiscal year
2011, the budget for which will be presented to Congress in February
2010, several months after the milestone review and prior to the
critical design review.[Footnote 5] In fact, there could still be
action items from the preliminary design review to complete at that
time. Further, when Congress is asked to approve funding for initial
low-rate production of core FCS systems, the Army will not yet have
proven that the FCS network and the program concept will work, a
demonstration that is expected as part of Limited User Test 3 in 2012.
This situation is illustrated further in figure 2 below.
Figure 2: FCS Program Events and Congressional Budget Decisions on
Production Funds:
[Refer to PDF for image: illustration]
Article delivery and testing:
NLOS-C: 2010;
MGV: 2011;
CI. IV UAV: 2012;
LUT 3: 2013.
FCS Program decision points:
PDR: 2009;
DAB: 2009;
CDR: 2011;
MSC: 2013.
Congressional budget decisions on production money:
FY 09 request -$154.6 million;
FY 10 request -$148 million;
FY 11 request -$677.8 million;
FY 12 request -$2.2 billion;
FY 13 request -$5.7 billion.
CDR = Critical Design Review;
DAB = Defense Acquisition Board Milestone Review;
LUT = Limited User Test;
NLOS-C = Non-Line-of-Sight Cannon;
MGV = Manned Ground Vehicle;
MSC = Milestone C;
PDR = Preliminary Design Review;
Cl. IV UAV = Class IV Unmanned Aerial Vehicle.
Source: U.S. Army (data); GAO (analysis and presentation).
[End of figure]
Significant production funds will also be spent on the Non-Line-of-
Sight Cannon and spin out systems between now and the FCS core
production decision in 2013. To meet congressionally required fielding
dates, the Army began building Non-Line-of-Sight Cannon prototypes last
year, but has encountered some setbacks due to development issues and
delays. The vehicles are planned to be used as training assets and will
not be fieldable systems. The Army is planning for a seamless
transition between these prototypes and production of the core FCS
systems, but given the financial investment from the Army and
consequently, the energized industrial base, this could create pressure
to proceed into core production prior to achieving a solid level of
knowledge on which to move forward.
Currently, the Army's efforts to field spin out systems relies on a
rushed schedule that calls for making production decisions before
production-representative prototypes have clearly demonstrated a useful
military capability. A shift in focus on the Army's efforts to spin out
capabilities to current forces from heavy brigade combat teams to
infantry brigade combat teams resulted in moving the production
decision from January 2009 to December 2009.[Footnote 6] However, only
one key test has been conducted under the new structure, and this event
was a shortened version of an event that was originally planned to
focus on the heavy brigade combat team. Additionally, testing completed
to date has involved surrogate or non-production representative forms
of systems, and the three tests scheduled for this year will follow the
same practice.
Army officials have said that they are considering an incremental or
block acquisition approach to FCS in order to mitigate risks in four
major areas: (1) immaturity of requirements for system survivability,
network capability, and information assurance; (2) limited availability
of performance trade space to maintain program cost and schedule given
current program risks; (3) program not funded to Cost Analysis
Improvement Group estimates and effect of congressional budget cuts;
and (4) continuing challenges in aligning schedules and expectations
for multiple concurrent acquisitions. Restructuring the FCS program
around an incremental approach has the potential to alleviate the risks
inherent in the current strategy and is an opportunity to apply recent
DOD policy updates, such as the creation of configuration steering
boards, and provide decision-makers with more information before
program commitments are made. On the other hand, an incremental
approach entails its own oversight challenges. First, it presents
decision makers with another FCS strategy to consider, possibly after
the fiscal year 2010 budget is submitted. Second, the approach must
ensure that each increment stands on its own and is not dependent on
future increments.
As DOD considers the current strategy, an incremental strategy, and its
production commitments, it will also have to continue to pay close
attention to the role being played by the FCS lead system integrator.
We have previously reported that the role of the integrator posed
oversight challenges. Since then, the Army has committed to using the
integrator for initial production, potentially a larger role than
initially envisioned.
Concluding Remarks:
The 2009 milestone review is the most important decision on the Future
Combat System since the program began in 2003. If the preliminary
design reviews are successfully completed and critical technologies
mature as planned in 2009, the FCS program will essentially be at a
stage that statute and DOD policy would consider as being ready to
start development. In this sense, the 2009 review will complete the
evaluative process that began with the original 2003 milestone
decision. Furthermore, when considering that the current estimate for
FCS ranges from $159 billion to $200 billion when the potential
increases to core program costs and estimated costs of spin outs are
included, 90 percent or more of the investment in the program lies
ahead. Even if a new, incremental approach to FCS is approved, a full
milestone review that carries the responsibility of a go/no-go decision
is still in order, along with attendant reports and analyses that are
required inputs. In the meantime, a configuration steering board, as
required by DOD policy, may help bridge the gaps between requirements
and system designs and help in the timely completion of the FCS
preliminary design reviews.
There is no question that the Army needs to ensure its forces are well
equipped. The Army has vigorously pursued FCS as the solution, a
concept and an approach that is unconventional, yet with many good
features. The difficulties and redirections experienced by the program
should be seen as revealing its immaturity, rather than as the basis
for criticism. However, at this point, enough time and money have been
expended that the program should be evaluated at the 2009 milestone
review based on what it has shown, not on what it could show. The Army
should not pursue FCS at any cost, nor should it settle for whatever
the FCS program produces under fixed resources. Rather, the program
direction taken after the milestone review must strike a balance
between near-term and long-term needs, realistic funding expectations,
and a sound plan for execution. Regarding execution, the review
represents an opportunity to ensure that the emerging investment
program be put on the soundest possible footing by applying the best
standards available, like those contained in DOD's 2008 acquisition
policy, and requiring clear demonstrations of the FCS concept and
network before any commitment to production of core FCS systems.
Any decision the Army makes to change the FCS program is likely to lag
behind the congressional schedule for authorizing and appropriating
fiscal year 2010 funds. Therefore, Congress needs to preserve its
options for ensuring it has adequate knowledge on which to base funding
decisions. Specifically, it does not seem reasonable to expect Congress
to provide full fiscal year 2010 funding for the program before the
milestone review is held nor production funding before system designs
are stable and validated in testing.
In our report released March 12, 2009, we raised several matters for
congressional consideration. We suggested Congress consider restricting
budget authority for fiscal year 2010 until DOD fully complies with the
milestone review requirements and provides a complete budget
justification package for any program that emerges. In addition,
Congress could consider not approving production or long lead item
funds for core FCS until after the critical design review is
satisfactorily completed and demonstrations have provided confidence
that the FCS system-of-systems operating with the communications
network will be able to meet its requirements.
We also made several recommendations to the Secretary of Defense
including ensuring that the FCS program that emerges from the milestone
review conform with current DOD acquisition policy and directing the
Secretary of the Army to convene an FCS configuration steering board.
We recommended that if an incremental approach is selected for FCS, the
first increments should be justifiable on their own as worthwhile
military capabilities that are not dependent on future capabilities for
their value. We further recommended that spin out items are fully
tested in production representative form before they are approved for
initial production. Finally, we recommended that the Secretary reassess
the role of the lead system integrator, particularly with respect to
any future role in production efforts.
Mr. Chairman, this concludes my prepared statement. I would be happy to
answer any questions you or members of the subcommittee may have.
Contacts and Staff Acknowledgements:
For future questions about this statement, please contact me on (202)
512-4841 or francisp@gao.gov. Individuals making key contributions to
this statement include William R. Graveline, Assistant Director;
William C. Allbritton; Noah B. Bleicher; Tana M. Davis; Marcus C.
Ferguson; Carrie W. Rogers; and Robert S. Swierczek.
[End of section]
Footnotes:
[1] Pub. L. No. 109-163, §211.
[2] GAO, Defense Acquisitions: Decisions Needed to Shape Army's Combat
Systems for the Future, [hyperlink,
http://www.gao.gov/products/GAO-09-288] (Washington, D.C.: March 12,
2009).
[3] John Warner National Defense Authorization Act for Fiscal Year
2007, Pub. L. No. 109-364, § 214 (2006).
[4] These costs do not include the costs of the FCS spin out
initiative, currently estimated at about $21 billion.
[5] The funds requested in fiscal year 2009 and 2010, and a portion of
that in 2011 are for Non-Line-of-Sight-Cannon production.
[6] Heavy brigades are equipped with armor, such as the Bradley
Fighting Vehicle. Light brigades are equipped with motorized infantry,
such as the High Mobility Multi-purpose Wheeled Vehicle.
[End of section]
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