Frank Kendall, the Pentagon’s top weapons-buyer, convened the so-called “Quick Look Review” panel in October. Its report — 55 pages of dense technical jargon and intricate charts — was leaked this weekend. Kendall and company found a laundry list of flaws with the F-35, including a poorly placed tail hook, lagging sensors, a buggy electrical system and structural cracks.
Some of the problems — the electrical bugs, for instance — were becoming clear before the Quick Look Review; others are brand-new. The panelists describe them all in detail and, for the first time, connect them to the program’s underlying management problems. Most ominously, the report mentions — but does not describe — a “classified” deficiency. “Dollars to doughnuts it has something to do with stealth,” aviation guru Bill Sweetman wrote. In other words, the F-35 might not be as invisible to radar as prime contractor Lockheed Martin said it would be.
The JSF’s problems are exacerbated by a production plan that Vice Adm. David Venlet, the government program manager, admitted two weeks ago represents “a miscalculation.” Known as “concurrency,” the plan allows Lockheed to mass-produce jets — potentially hundreds of them — while testing is still underway. It’s a way of ensuring the military gets combat-ready jets as soon as possible, while also helping Lockheed to maximize its profits. That’s the theory, at least.
“Concurrency is present to some degree in virtually all DoD programs, though not to the extent that it is on the F-35,” the Quick Look panelists wrote. The Pentagon assumed it could get away with a high degree of concurrency owing to new computer simulations meant to take the guesswork out of testing. “The Department had a reasonable basis to be optimistic,” the panelists wrote.
But that optimism proved unfounded. “This assessment shows that the F-35 program has discovered and is continuing to discover issues at a rate more typical of early design experience on previous aircraft development programs,” the panelists explained. Testing uncovered problems the computers did not predict, resulting in 725 design changes while new jets were rolling off the factory floor in Fort Worth, Texas.
And every change takes time and costs money. To pay for the fixes, this year the Pentagon cut its F-35 order from 42 to 30. Next year’s order dropped from 35 to 30. “It’s basically sucked the wind out of our lungs with the burden, the financial burden,” Venlet said.