19
DOCUIENT RSSUM! 02154 - [A1532531] (Cost Bstimates of the B-1 Aircraft Progras]. PSAD-77-116, 117-121; D-163058. say 25, 1977. 3 pp. Report to Sen. John C. Stennis, Chairman, Senate Committee on treed Services; Sen. Edmund S. Huskie, Chairsam, Senate Committee on Budget; Rep. George B. Hahon, Chairman, House Committee on appropriations; Rep. Helvin Price, Chairman, House Committee on Armed Services; Rep. Robert I. Giaimo, ChairRan, HRouse Committee on Budget; Sen. John L. McClellan, Chairman, Senate Committee on Appropriations: Defense Subcommittee; by Elmer B. Staats, CoRptroller General. Issue Area: Federal Procurement of Goods and Services: Notifying the Congress of Status of Important Procurement Programs (1905). Contact: Procurement a:.d Systems Acquisition Dive Budget Function: National Defense (050); Nbtional Defense: weapon Systens (057). Organizaticn Concerned: Department of Defense; Department of the Air Force. Con;ressional Relevance: House Committee on Appropriations; House Committee on Armed Services; Senate Committee on Arise Services; Senate Committee on Budget; House Committee on Budget; Senate Committee on Appropriations: Defense Subcommittee. Two independent cost analyses of the B-1 aircraft program prepared by the Air Force resulted in estimates that showed an appreciable difference from the Systems Program Office (SPO) estimate of S22.8 billion for 244 aircraft. Finlings/Conclusions: One of the analyses used current and projected cost data from the F-15, F-16, and A-10 prcgrams, while the second was based ¢or historical data from about 20 different aircraft programs. In both cases, the actual B-1 cost data available as of June 30, 1976, were included. The estimate based on historical data was 4% higher than the SPO estimate, while the estimate based on current data was 20% higher. The major reasons for the differences between the independent estimates and the StO estimate were: (1) different learning curves (improvements in production costs) that are anticipated to be achieved during the production of 240 aircraft; (2) the amount of production experience that can be retained from the four research and development aircraft; and (3) a diffe. nce of two percentage points in the amount of fee that contractors ere expected to earn. A cost review team from the Office of the Secretary of Defense was of the opinion that the independent hir Force estimate based on current data was the most reasonable, and even that estimate appeared somewhat low. Recoamendations: The Department of Defense should present and discuss the various estimates with the Congress because of the significant differences in the estimates and the conaressional interest in 79M k P' ()t

PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

  • Upload
    ngodiep

  • View
    213

  • Download
    1

Embed Size (px)

Citation preview

Page 1: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

DOCUIENT RSSUM!

02154 - [A1532531]

(Cost Bstimates of the B-1 Aircraft Progras]. PSAD-77-116,117-121; D-163058. say 25, 1977. 3 pp.

Report to Sen. John C. Stennis, Chairman, Senate Committee ontreed Services; Sen. Edmund S. Huskie, Chairsam, SenateCommittee on Budget; Rep. George B. Hahon, Chairman, HouseCommittee on appropriations; Rep. Helvin Price, Chairman, HouseCommittee on Armed Services; Rep. Robert I. Giaimo, ChairRan,HRouse Committee on Budget; Sen. John L. McClellan, Chairman,Senate Committee on Appropriations: Defense Subcommittee; byElmer B. Staats, CoRptroller General.

Issue Area: Federal Procurement of Goods and Services: Notifyingthe Congress of Status of Important Procurement Programs(1905).

Contact: Procurement a:.d Systems Acquisition DiveBudget Function: National Defense (050); Nbtional Defense:

weapon Systens (057).Organizaticn Concerned: Department of Defense; Department of the

Air Force.Con;ressional Relevance: House Committee on Appropriations;

House Committee on Armed Services; Senate Committee on AriseServices; Senate Committee on Budget; House Committee onBudget; Senate Committee on Appropriations: DefenseSubcommittee.

Two independent cost analyses of the B-1 aircraftprogram prepared by the Air Force resulted in estimates thatshowed an appreciable difference from the Systems Program Office(SPO) estimate of S22.8 billion for 244 aircraft.Finlings/Conclusions: One of the analyses used current andprojected cost data from the F-15, F-16, and A-10 prcgrams,while the second was based ¢or historical data from about 20different aircraft programs. In both cases, the actual B-1 costdata available as of June 30, 1976, were included. The estimatebased on historical data was 4% higher than the SPO estimate,while the estimate based on current data was 20% higher. Themajor reasons for the differences between the independentestimates and the StO estimate were: (1) different learningcurves (improvements in production costs) that are anticipatedto be achieved during the production of 240 aircraft; (2) theamount of production experience that can be retained from thefour research and development aircraft; and (3) a diffe. nce oftwo percentage points in the amount of fee that contractors ereexpected to earn. A cost review team from the Office of theSecretary of Defense was of the opinion that the independent hirForce estimate based on current data was the most reasonable,and even that estimate appeared somewhat low. Recoamendations:The Department of Defense should present and discuss the variousestimates with the Congress because of the significantdifferences in the estimates and the conaressional interest in

79M k P' ()t

Page 2: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

:COMPTOLLER GENERAL OA TMH UNITID IrTAIy

WAHINlSTON. ¢C. AM

B-163058

0The Honorable John C. StennisChairman, Committee on MAY 5 1977

Armed ServicesUnited States Senate

Dear Mr. Chairman:

In our report titled "Status of the B-1 Aircraft Program,"(PSAD-77-35, dated F bruary 16, 1977) we stated that inde-pendent cost estimates were prepared for the B-1 program in1976 but were not available to GAO because the Department ofDefense considered the estimates internal documents being usedat that time for decisionmaking purposes. The estimates,recently made available for our review, are discussed below.

In preparation for the Defense Systems AcquisitionReview Council (DSARC) III in December 1976 and as a check onreasonableness of the Systems Program Office (SPO) estimate,two independent cost analyses were made by the Air Force. Theywere first completed in September 1976 and revised in January1977. In the first case, the analysis used current and pro-jected cost data from the F-15, F-16, and A-10 programs. Inthe second case, the analysis was based on historical datafrom about 20 different aircraft programs. In both cases, theactual B-1 cost data available as of June 30, 1976, was included.The resulting estimates showed an appreciable difference fromthe SPO estimate of $22.8 billion for 244 aircraft. The esti-mate based on historical data was 4 percent higher and theestimate based on the current data was 20 percent higher. TheAir Force team that prepared the independent cost analysesconcluded that the SPO estimate for production is optimistic.

The major reasons for the differences between theindependent estimates and the SPO estimate were:

1. Different learning curves (improvements inproduction costs) that are anticipated to beachieved during the production of 240 aircraft.

2. The amount of production experience that canbe retained from the four research and develop-ment aircraft.

PSAD-77-116

Page 3: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

3. A difference of two percentage points in theamount of fee that the contractors are expectedto earn.

As has been the practice for the past several years, theAir Force independent estimates were reviewed by a cost reviewteam from the Office of the Secretary of Defense (OSD) inpreparation for the DSARC III. Accordingly, in making the deci-sion on December 2, 1976, authorizing the Air Force to proceedwith production of the B-1 aircraft, the Secretary of Defensehad a number of opinions on the probable cost of the program.These included (1) the SPO estimate which was the officialAir Force estimate, (2) the Air Force independent estimates,and (3) results of the evaluation of the Air Force independentestimates by the OSD cost review team.

The OSD team was of the opinion that the independentAir Force estimate based on current data was the most reason-aole. Further, the review team did not agree with a credittaken in the independent estimate of about $1 billion (then-year dollars) which was based on the assumption that saviAgsin production costs could be achieved through better engineer-ing effort. The review team also noted two other items thatcould have a future impact on costs: (1) defensive avionicswas not well defined and costs were uncertain, and (2) theweight given to experience on the research and developmentaircraft and the use of this data in establishing a startingpoint: for a learning curve. Thus, to the review team, thehighest estimate presented appeared somewhat low.

The Department of Defense Instructions recognize thatestimates prepared by different groups will most likely differ.The instructions leave it up to the Secretary of Defense todecide which is the most reasonable estimate and use it forofficial purposes. In this case, after consideration of factsand opinions which were provided, the Secretary of Defenseaccepted the SPO estimate of $22.8 billion as the December 1976approved acquisition funding plan for the B-1 program. Thisestimate may be somewhat optimistic in view of the independentestimates and the conclusions reached by the OSD cost reviewtear. However, GAO recognizes that at this point in a lifecycle it is difficult to determine a correct esti!ate. Inthe past, GAO has recommended that a range of estimates onmajor programs be presented to the Congress. We believe itwould be appropriate in this case to present and discuss thevarious estimates because of the significant differences inestimates and the congressional interest in the 3-1 program.

2

Page 4: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

We are also sending this report to the Chairman of theHouse Armed Services Committee, the Chairman of the House Appro-priations Committee, the Chairman of the Senate AppropriationsSubcommittee on Defense, and the Chairmen of the House andSenate Budcget Committees. Copies are being sent to the Secretaryof Defense and the Secretary of the Air Force.

Sincerely yours,

Comptroller Genera.of the United States

3

Page 5: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

COMPTROLLER GENERAL OF THE UNITED STATESWASHINGTON. D.C. 1W

B-163058 MAY 25 1977

The Honorable Edmund S. MuskieChairman, Committee on BudgetUnited States Senate

Dear Mr. chairman:

In our report titled "Status of the B-1 Aircraft Program,"(PSAD-77-35, dated February 16, 1977) we stated that inde-pendent cost estimates were prepared for the B-1 program in1976 but were not available to GAO because the Department ofDefense conisidered the estimates internal documents being usedat that time for decisionmaking purposes. The estimates,recently made available fur our review, are discussed below.

In preparation for the Defense Systems AcquisitionReview Council (DSARC) III in December 1976 and as a check onreasonableness of the Systems Program Office (SPO) estimate,two independent cost analyses were made by the Air Force. Theywere first completed in September 1976 and revised in January1977. In the first case, the analysis used current and pro-jected cost data from the F-15, F-16, and A-10 programs. Inthe second case, the analysis was based on historical datafrom about 20 different aircraft programs. In both cases, theactual B-1 cost data available as of June 30, 1976, was included.The resulting estimates showed an appreciable difference fromthe SPO estimate of $22.8 billion for 244 aircraft. The esti-mate based on historical data was 4 percent higher and theestimate based on the current data was 20 perce.t higher. TheAir Force team that prepared the independent cost analysesconcluded that the SPO estimate for production is optimistic.

The major reasons for the differences between theindependent estimates and the SPO estimate were:

1. Different learning curves (improvements inproduction costs) that are anticipated to beachieved during the production of 240 aircraft.

The amount of Production experience that canbe retained from the four research and develop-ment air; aft.

PSAD-77-120

Page 6: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

_. A difference of twc percentage points in theamount of fee that the contractors are expectedto earn.

As has been the practice foi the past several years, theAir Force independent estimates were reviewed by a cost reviewsteam from the Office of the Secretary of Defense (OSD) inpreparation for the OSARC III. Accordingly, in making the deci-sion on December 2, 1976, authorizing the Air Force to proceedwith production of the B-1 aircraft, the Secretary of Defenseida a number of opinions on the probable cost of the program.lheae included (1) the SPO estimate which waF the officialAir Force estimate, (2) the Air Force independent estimates,and (3) results of the evaluation of the Air Force independentestimates by the OSD cost review team.

The OSD team was of the opinion that the independentAir Force estimate based on c;urent data was the most reason-able. Further, the review team did not agree with a credittaken in the independent estimate of about $1 billion (then-year dollars' which was based on the assumption that savingsin production costs could be achieved through better engineer-ing effort. fhe review team also noted two other items thatcould have a future impact on costs: (1) defensive avionicswas not well defined and costs were uncertain, and (2) theweight given to experience on the research and developmentaircraft and the use of this data in establishing a startingpoint for a learning curve. Thus, to the review team, thehighest estimate presented appeared somewhat low.

The Department of Defense Instructions recognize thatestimates prepared by different groups will most likely differ.The instructions leave it up to the Secretary of Defense todecide which is the most reasonable estimate and use it forofficial purposes. In this case, after consideration of factsand opinions which were provided, the Secretary of Defenseaccepted the SPO estimate of $22.8 billion as the December 1976approved acquisition funding plan for the B-1 program. Thisestimate may be somewhat optimistic in view of the independentestimates and the conclusions reached by the OSD cost reviewteam. Powever, GAO recognizes that at this point in a lifecycle it is difficult to determine a correct estimate. Inthe past, GAO has recommended that a range of estimates onmajor programs be presented to the Congress. We believe itwould be appropriate in this case to present and discuss thevarious estimates because of the significant differences inestimates and the congressional interest in the B-1 program.

2

Page 7: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

We are also sending this report to the Chairman of theHouse Budget Committee, the Chairmen of the House and SenateArmed Services Committees, the Chairman of the House Appro-priations Committee, and the Chairman of the Sendte Appro-priations Subcommittee on Defense. Copies are being sentto the Secretary of Defense and the Secretary of the AirForce.

Sinc yours,

Comptroller Generalof the United States

3

Page 8: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

COMPTROiERR GENERAL OF THE UITIOD STATIa

WAHINGTON. O.C. ms

B-163058

AY 2 5 1977

The Honorable George H. Mahon

Chairman, Committee onAppropriations

House of Representatives

Dear Mr. Chairman:

In our report titled "Status of the B-1 Aircraft Program,"

(PSAD-77-35, dated February 16, 1977) we stated that inde-

oendent cost estimates weri prepared for the B-1 program in

1976 but were not available to GAO because the Department of

Defense considered the estimates internal documents being used

at that time for decisionmaking purposes. The estimates,

recently made available for our review, are discussed below.

In preparation cor the Defense Systems Acquisition

Review Council (DSARC) III in December i976 and as a check on

reasonableness of the Systems Program Office (SPO) estimate,

two independent cost analyses were made by the Air Force. They

were first completed in September 1976 and revised in January

1977. In the first case, the analysis used current and Dro-

jected cost data from the F-15, F-16, and A-13 programs. In

the second case, the analysis was based on historical data

from about 20 different aircraft programs. In both cases, the

actual B-1 cost data available as of June 30, 1Y76, was included.

The resulting estimates showed an appreciable difference from

the SPO estimate of $22.8 billion for 244 aircraft. The esti-

mate based on historical data was 4 percent higher and the

estimate based on the current data was 20 percent higher. The

Air Force team that prepared the independent cost analyses

concluded that the SPO estimate for production is optimistic.

The major reasons for the differences between the

independent estimates and the SPO estimate were:

1. Different learning curves (improvements in

production costs) that are anticipated to be

achieved during the production of 240 aircraft.

2. The amount of production experience that can

be retained from the four research and develop-

ment aircraft.

PSAD-77-117

Page 9: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

3. A difference of two percentage points in theamount of fee that the contractors are expectedto earn.

As has been the practice for the past several years, theAir Force independent estimates were reviewed by a cost reviewteam from the Office of the Secretary of Defense (OSD) in

preparation for the DSARC III. Accordingly, in making the deili-

sion on December 2, 1976, authorizing the Air Force to proceed

with production of the B-1 aircraft! the Secretary of Defensehad a number of opinions on the probable cost of the program.

These included (1) the SPO estimate which was the officialAir Force estimate, (2) the Air Force independent estimates,and (3) results of the evaluation of the Air Force independentestimates by the OSD cost review team.

The OSD team was of the opinion that the independent

Air Force estimate based on current data was the most reason-able. Further, the review team did not agree with a credittaken in the independent estimate of about $1 billion (then-

year dollars) which was based on the assumption that savingsin production costs could be achieved through better engineer-

inc effort. The review team also notea two other items thatcould have a future impact on costs: (1) defensive avionics

was not well defined and costs were uncertain, and (2) theweight given to experience on the research and developmentaircraft and the use of this data in establishing a startingpoint for a learning curve. Thus, to the review team, thehighest estimate presented appeared somewhat low.

The Department of Defense Instructions recognize thatestimates prepared by different groups will mobt likely differ.

The instructions leave it up to the Secretary of Defense to

decide which is the most reasonable estimate and use it forofficial purposes. In this case, after consideration of facts

and opinions which were provided, the Secretary of Defenseaccepted the SPO estimate of $22.8 billion as the December 197C

approved accusition funding plan for the B-1 program. Thisestimate mat be somewhat optimistic in view of the independentestimates and the conclusions reached by the OSD cost reviewteam. However, GAO recognizes that at this point in a life

cycle it is difficult to determine a correct estimate. Inthe past, GAO has recommended that a range of estimates on

major programs be presented to the Congress. We believe itwould be appropriate in this case to present and discuss thevarious estimates because of the significant differences inestimates and the congressional interest in the B-1 program.

2

Page 10: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

We are also sending this report to Lthe Chairman of theSenate Appropriations Subcommittee on Defense, the Chairmenof the Hoube and Senate Armed Services Committees, and theChairmen of the House and Senate Budget Committees. Copiesare being sent to the Secretary of Defense and the Secretaryof the Air Force.

$;; 2rely yo

Comptroller Generalof the United States

3

Page 11: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

OMdOLLAR GRMNIRAL OF TK UNITEDO ATIB

WASINGTON. D.C. SOe

B-163058 MAY 2 t7

The Honorable Melvin PriceChairman, Committee on

Armed ServicesHouse of Representatives

Dear Mr. Chairman:

In our report titled "Status of the B-1 Aircraft Program,"(PSAD-77-35, dated February 16, 1977) we stated that inde-oendent cost estimates were prepared for the B-1 program in1976 but were not available to GAO because the Department ofDefense considered the estimates internal documents being usedat that time for decisionmaking purposes. The estimates,recently made available for our review, are discussed below.

In preparation for the Defense Systems AcquisitionReview Council (DSARC) III in December 1976 and as a check onreasonableness of the Systems Progra:( Office (SPO) estimate,two independent cost analyses were made by the Air Force. Theywere first completed in September 1976 and revised in January1977. In the first case, the analysis used current and pro-jected cost data from the F-15, F-16, and A-10 programs. Inthe second case, the analysis was based on historical datafrom about 20 different aircraft programs. In both cases, theactual B-1 cost data available as of June 30, 1976, was included.The resulting estimates showed an appreciable difference fromthe SPO estimate of $22.8 billion for 244 aircraft. The esti-mate based on historical data was 4 percent higher and theestimate based on the current data was 20 percent higher. TheAir Force team that prepared Lhe independent cost analysesconcluded that the SPO estimate for production is optimistic.

The major reasons for the differences between theindependent estimates and the SPO estimate were:

1. Different learning curves (improvements inproduction costs) that are anticipated to beachieved during the production of 240 aircraft.

2. The amount of production experience that canbe retained from the four research and develop-ment aircraft.

PSAD-77-119

Page 12: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

3. A difference of two percentage points in theamount of fee that the contractors are expectedto earn.

As has been the practice for the past several years, theAir Force independent estimates were reviewed by a cost reviewteam from the Office of the Secretary cf Defense (OSD) inpreparation for the DSARC III. Accordingly, in making the deci-sion on December 2, 1976, authorizing the Air Force to proceedwith production of the B-1 aircraft, the Secretary of Defensehad a number of opinions on the probable cost of the program.These included (1) the SPO estimate which was the officialAir Force estimate, (2) the Air Force independent estimates,and (3) results of the evaluation of the Air Force independentestimates by the OSD cost review team.

The OSD team was of the opinion that the independentAir Force estimate based on current data was the fost reason-able. Further, the review team cid not agree wita a credittaken in the independent estimate of about $1 billion (then-year dollars) which was based on the assumption that savingsin production costs could be achieved through better engineer-ing effort. The review team also noted two other items thatcould have a future impact on costs: (1) defensive avionicswas not well defined and costs were uncertain, and (2) theweight given to experience on the research and developmentaircraft and the use of this data in establishing a startingpoint for a learning curve. Thus, to the review team, thehighest estimate presented appeared somewhat low.

The Department of Defense Instructions recognize thatestimates prepared by different groups will most likely differ.The instructions leave it up to the Secretary of Defense todecide which is the most reasonable estimate and use it forofficial purposes. In this case, after consideration ot factsand opinions which were provided, the Secretary of Defenseaccepted the SPO estimate of $22.8 billion as the December 1976approved acquisition funding plan for the B-1 program. Thisestimate may be somewhat optimistic in view of the independentestimates and the conclusions reached by the OSD cost reviewtear,. However, GAO recognizes that at this point in a lifecycle it is difficult to determinie a correct estimate. Inthe past, GAO has recommended that a range of estimates onmajor proarams be presented to the Congress. We believe itwould be ;appropriate in this case to present and discuss thevarious e:stimates because of the significant differences inestimate, and the congressional interest in the B-1 program.

2

Page 13: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

We are also sending this report to the Chairman of theSenate Armed Services Committee, the Chairmawn of the HouseAppropriations Committee, the Chairman of the SenateAppropriations Subcommittee on Defense, and the Chairmenof the House and Senate Budget Committees. Copies arebeing sent to the Secretary of Defense and the Secretary c2the Air Force.

Since y yours,

Comptroller Generalof the United States

3

Page 14: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

COMPTROLLIN GENERAL OP THE UNITED STATESWAIHINSTNM D.C. ZiMM

B-163058

The Honorable Robert N. Giaimo AA 191 77Chairman, Committee on BudgetHouse of Representatives

Dear Mr. Chairman:

In our report titled "Status of the B-1 Aircraft Program,"(PSAD-77-35, dated February 16, 1977) we stated that inde-pendent cost estimates were prepared for the B-1 program in1976 but were not available to GAO because the Department ofDefense considered the estimates internal documents being usedat that time for decisionmaking purposes. The estimates,recently made available for our review, are discussed below.

In preparation for the Defense Systems AcquisitionReview Council (DSARC) III in December 1976 and as a check onreasonableness of the Systems Program Office (SPO) estimate,two independent cost analyses were made by the Air Force. Theywere first completed in September 1976 and revised in January1977. In the first case, the analysis used current and pro-jected cost data from the F-15, F-16, and A-10 programs. Inthe second case, the analysis was based on historical datafrom about 20 different aircraft programs. In both cases, theactual B-1 cost data available as of June 30, 1976, was included.The resulting estimates showed an appreciable difference fromthe SPO estimate of $22.8 billion for 244 aircraft. The esti-mate based on historical data was 4 percent higher and theestimate based on the current data was 20 percent higher. TheAir Force team that prepared the independent cost analysesconcluded that the SPO estimate for production is optimistic.

The major reasons for the differences between theindependent estimates and the SPO estimate were:

1. Different .7arning curves (improvements inproduction costs) that are anticipated to beachieved during the production of 240 aircraft.

2. The amount of production experience that canbe retained from the four research and develop-ment aircraft.

PSAD-77-121

Page 15: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

3. A difference of two percentage points in theamount of fee that the contractors are expected

to earn.

As has been the practice for the past several years, the

Air Force independent estimates were reviewed by a cost review

team from the Office of the Secretary of Defense (OSD) in

preparation for the DSARC III. Accordingly, in making the deci-

sion on December 2, 1976, authorizing the Air Force to proceed

with production of the B-1 aircraft, the Secretary of Defense

had a number of opinions on the probable cost of the program.

These included (1) the SPO estimate which was the officialAir Force estimate, (2) the Air Force independent estimates,

and (3) results of the evaluation of the Air Force independent

estimates by the OSD cost review team.

The OSD team was of the opinion that the independent

Air Force estimate based on current date was the most reason-

able. Further, the review team did not agree with a credit

taken in the independent estimate of about $1 billion (then-

year dollars) which was based on the assumption that savings

in production costs could be achieved through better engineer-

ing effort. The review team also noted two other items that

could have a future impact on costs: (1) defensive avionics

was not well defir.ed and costs were uncertain, and (2) the

weight given to experience on the research and development

aircraft and the use of this data in establishing a starting

point for a learning curve. Thus, to the review team, the

highest estimate presented appeared somewhat low.

The Department of Defense Instructions recognize that

estimates prepared by different groups will most likely differ.

The instructions leave it up to the Secretary of Defense to

decide which is the most reasonable estimate and use it for

official purposes. In this case, after consideration of facts

and opinions which were provided, the Secretary of Defense

accepted the SPO estimate of $22.8 billion as the December 1976

approved acquisition funding plan fur the B-1 program. This

estimate may be somewhat optimistic il view of the independent

estimates and the conclusions reached by the OSD cost review

team. However, GAO recognizes that at this point in a life

cycle it is difficult to determine a correct estimate. In

the past, GAO has recommended that a range of estimates on

major programs be presented to the Congress. We believe it

would be appropriate in this case to present and discuss the

various estimates because of the significant differences in

estimates and the congressional interest in the B-1 program.

2

Page 16: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

We are also sending this report to the Chairman of theSenate Budget Committee, the Chairmen of the House and SenateArmed Services Committees, the Chairman of the House Appro-priations Committee, and the Chairman of the Senate Appro-priations Subcommittee on Defense. Copies are being sentto the Secretary of Defense and the Secretary of the AirForce.

Sin ey yours

Comptroller Generalof the United States

3

Page 17: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

COMPTROLLER GENERAL OF THE UNITED STATe

WASHINGTON. D.C. US11

B-163058

MAY 5 177

The Honorable John L. McClellanChairman, Subcommittee on DefenseCommittee on AppropriationsUnited States Senate

Dear Mr. Chairman:

In our report titled "Status of the B-1 Aircraft Program,"(PSAD-77-35, dated February 16, 1977) we stated that inde-Pendent cost estimates were prepared for the B-1 program in1976 but were not available to GAO because the Department ofDefense considered the estimates internal documents being usedat that time for decisionmaking purposes. The estimates,recently made available for our review, are discussed below.

In preparation for the Defense Systems AcquisitionReview Council (DSARC) III in December 1976 and as a check onreasonableness of the Systems Program Office (SPO) estimate,two independent cost analyses were made by the Air Force. Theywere first completed in September 1976 and revised in January1977. In the first case, the analysis used current and pro-jected cost data from the F-15, F-16, and A-10 programs. inthe second case, the analysis was based on historical datafrom about 20 different aircraft programs. In both cases, theactual B-1 cost data available as of June 30, 1976, was included.The resulting estimates showed an appreciable difference Lromthe SPO estimate of $22.8 billion for 244 aircraft. The esti-mate based on historical data was 4 percent higher and theestimate based on the current data was 20 percent higher. TheAir Force team that prepared the independent cost analysesconcluded that the SPO estimate for production is optimistic.

The major reasons for the differences between theindependent estimates and the SPO estimate were:

1. Different learning curves (improvements inproduction costs) that are anticipated to beachieved during the production of 240 aircraft.

2. The amount of production experience that canbe retained from the four research and develop-ment aircraft.

PSAD-77-118

Page 18: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

3. A difference of two percentage points in theamount of fee that the contractors are expectedto earn.

As has been the practice for the past several years, theAir Force independent estimates were reviewed by a cost reviewteam from the Office of the Secretary of Defense (OSD) inpreparation for the DSARC III. Accordingly, in making the deci-sion on December 2, 1976, authorizing the Air Force to proceedwith production of the B-1 aircraft, the Secretary of Defensehad a number of opinions on the probable cost of the program.These included (1) the SPO estimate which was the officialAir Force estimate, (2) the Air Force independent estimates,and (3) results of the evaluation of the Air Force independentestimates by the OSD cost review team.

The OSD team was of the opinion that the independentAir Force estimate based on current data was the most reason-able. Further, the review team did not agree with a credittaken in the independent estimate of about $1 billion (then-year dollars) which was based on the assumption that savingsin production costs could be achieved through better engineer-ing effort. The review team also noted two other items thatcould have a future impact on costs: (1) defensive avionicsw.s not well defined and costs were uncertain, and (2) theweight given to experience on the research and developmentaircraft and the use of this data in establishing a startingpoint for a learning curve. thus, to the review team, thehighest estimate presented appeared somewhat low.

The Department of Defense Instructions recognize thatestimates prepared by different groups will most likely differ.The instructions leave it up to the Secretary of Defense todecide which is the most reasonable estimate and use it forofficial purposes. In this case, after consideration of factsand opinions which were provided, the Secretary of Defenseaccepted the SPO estimate of $22.e billion as the December 1976approved acquisition funding plan for the B-1 program. Thisestimate may be somewhat optimistic in view of the independentestimates and the conclusions reached by the OSD cost reviewteam. However, GAO recognizes that at this point in a lifecycle it is difficult to determine a correct estimate. Inthe past, GAO has recommended that a range of estimates onmajor programs be presented to the Congress. We believe itwould be appropriate in this case to present and discuss thevarious estimates because of the significant differences inestimates and the congressional interest in the B-1 program.

2

Page 19: PSAD-77-116-121 Cost Estimates of the B-1 Aircraft Program · PDF file(SPO) estimate of S22 ... Secretary of Defense was of the opinion that the independent hir ... PSAD-77-116-121

We are also sending this report to the Chairman of theHouse Appropriations Committee, the Chairmen of the Houseand Senate Armed Services Committees, and the Chairmenof the House and Senate Budget Committees. Copies arebeing sent to the Secretary of Defense and the Secretaryof the Air Force.

Sin ly your

Comptroller Generalof the United States

3