Description
Organization: NAVAIR, NAWC Aircraft Division, PMA-265
Team Name: F/A-18 E/F Program Integrated Test Team
Related Acquisition Topic(s): Acquisition Practices Streamlining, Cycle Time Reduction (CTR), Integrated Product Teams (IPT), Integrated Product and Process Development (IPPD), Partnering
Description:
Traditionally, three teams (Industry, Government Developmental Testing (DT), and Government Operational Testing (OT)) operated serially, with considerable duplication of effort to validate performance data reported by the "other" teams. The ITT concept permitted integrated planning, reducing overall requirements and duplication of effort. Joint execution of the test plan permitted data sharing, while further reducing the need for duplicitous test, dramatically reducing cost, schedule and assets required. The F/A-18E/F test phase is being supported by 3 ground and 7 flying test articles, 4 fewer flying test articles than the F/A-18A/B program.
The Naval Air Warfare Center Aircraft Division (NAWCAD), Patuxent River, Maryland is designated the principal site for Development, Test and Evaluation (DT&E) of the F/A-18E/F aircraft. In accordance with the detailed specification, the F/A-18E/F flight test program is being conducted under the ITT, an integrated Contractor and Government team concept. The ITT conducts all contractually required functional, system, and air vehicle flight tests. The Contractor led ITT is responsible for the conduct of the development flight test program. Contractor members of the ITT, as well as contractor Product Definition Team (PDT) members in St. Louis, support the Contractor Flight Test Director (CFTD) in preparing and approving Test Work Descriptions (TWDs) and assuring planned testing is conducted safely and efficiently. The contractor ITT members are responsible for coordinating with PDT members at the contractor's facility to ensure that flight test data satisfies the demonstration requirements. The contractor remains accountable for all contractual efforts. The Government Flight Test Director (GFTD) is the primary interface between the contractor and the government at Patuxent River. The government members of the ITT are primarily responsible for identifying and incorporating government unique requirements into the Master Test Plan and TWDs. Government members of the ITT and E/F IPT support the GFTD in preparing and approving TWDs and assuring planned testing is conducted safely and efficiently. Government members of the ITT review generated data for adequacy, evaluate and analyze data to support flight test, assess mission effectiveness, and ensure that government management is informed on program status and issues. Members of the ITT witness formal demonstration tests as required. Government and Contractor pilots participate in all phases of the E&MD flight test program.
The F/A-18F/F flight test program is an extremely aggressive one. Its accelerated schedule has be made possible by the concurrent and integrated testing by the ITT. In less than one year since the F/A-18E/F Super Hornet arrived at Patuxent River, the ITT has logged more than 618 flight hours (24 January 1997) during 383 test sorties. Initial Sea Trials (IST) were completed aboard USS John C. Stennis (CVN 74) on 23 January 1997 less than one year after commencing tests at Patuxent. The savings in time and cost avoidance in dollars resulting from concurrent and integrated, single site testing of the Super Hornet is dramatic.
The success of the F/A-18E/F ITT in dealing with the recent E/F F414 Engine High Cycle Fatigue (HCF) test incident typifies the gains realized by this Acquisition Reform initiative. The E/F ITT's timely and decisive problem solving actions are an excellent example of partnering and teaming at their best. On 16 November 1996 F/A-18E1 experienced in-flight compressor stalls. Post-flight investigation revealed cracks in the trailing edge of stage 3 stator vanes. Further checks indicated the cracks were not isolated to aircraft E1. The E/F flight test program was temporarily suspended. The issues were communicated quickly, and a "wide net was cast" by the ITT to bring the best minds together to solve this serious problem. In addition to government ITT personnel who worked the problem, experts in metallurgy, structures, aeromechanics, and HCF were brought in from around the country to assist. The Navy/Industry team ultimately isolated the problem to a "minor configuration change" to the compressor stator assembly which had been intended to enhance manufacturing and improve performance. The Navy/Industry technical team concluded that the design change resulted in resonance and flutter of the stator vane, which led to high cycle fatigue. On 15 December 1996 F/A 18F1 launched in support of IST after the compressor stator vane assembly's configuration had been returned to its previous design. The E/F aircraft have resumed flight tests. The Navy/Industry partnering and teaming demonstrated by the F/A18E/F F414 Engine HCF problem solving is indicative of the new culture brought on by Acquisition Reform initiatives. The timely resolution of this test incident allowed the E/F flight test schedule to remain on track enabling Initial Sea Trials to be completed on schedule in mid-January and the program to make its Defense Acquisition Board Review in March of 1997.
Two of the Navy Acquisition Reform Office's Ten Guiding Principles of Acquisition Reform are epitomized by the F/A-18E/F ITT. They are "Operate in Integrated Product Teams" and "Test and Inspect in the least obtrusive manner to add value to the process or product."
