Air Force Foresaw Fatal F-22 Problems; Rejected $100,000 Fix As Too Expensive
McGruber writes "The Associated Press is reporting that years before F-22 stealth fighter pilots began getting dizzy in the cockpit, before one struggled to breathe as he tried to pull out of a fatal crash, before two more went on the '60 Minutes' television program to say the plane was so unsafe they refused to fly it, a small working group of U.S. Air Force experts knew something was wrong with the prized stealth fighter jet. This working group, called RAW-G, was created in 2002 at the suggestion of Daniel Wyman, then a flight surgeon at Florida's Tyndall Air Force Base, where the first F-22 squadron was being deployed. Wyman is now a brigadier general and the Air Combat Command surgeon general. RAW-G proposed a range of solutions by 2005, including adjustments to the flow of oxygen into pilot's masks. But that key recommendation was rejected by military officials reluctant to add costs to a program that was already well over budget. Kevin Divers, a former Air Force physiologist who led RAW-G until he left the service in 2007, believes the cost of adjusting the oxygen flow would have added about $100,000 to the cost of each $190 million aircraft."
Anyway the days of manned fighters is coming to an end.
But would that 100K 1 time cost, have led to a much more expensive battery of tests to re-validate the entire aircraft?
Its like a 2 line code change that causes 100hrs of test cases.
1 plane crash because of the issue would cause a cost equivalent to 1900 planes being fixed (assuming a 0 cost of life and training)
Assuming that not a single plane would crash because of this would be wrong
Probably some other reason that hasnt been dislosed behind the lack of a fix?
The solution was to add a DoD toilet to each aircraft?
"RAW-G recommended more tests and that the F-22’s oxygen delivery system be adjusted through a digital controller and a software upgrade."
So the $100kis average-per-plane of cost of testing side effects of more oxygen on pilots?
4wdloop
No denying that shaving off so little and leaving the program and the warfighters at such known risk was a tragic mistake. But I don't know the genesis of the $100,000 cost for software mods. TBH, the Engineering Change Proposal process required to convey the modified requirements in order to change the software as directed may have required more than that much cost just in terms of specification and process costs. Add to that the uptick in formal requirements verification costs, and program schedule delays by adding yet another function point to the development schedule of an already-late program.
No matter what it cost, it would have been worth it, but keep an open mind as to whether a mere $.1 million upper over the program costs is credible.
Remember, this is a DoD development program regulated by the Federal Acquisition Regulations and DoD Systems Architecture and Engineering processes. There is no such thing as a cheap change to program baseline.
Welcome to the Panopticon. Used to be a prison, now it's your home.
Air Force physiologist who led RAW-G until he left the service in 2007, believes the cost of adjusting the oxygen flow would have added about $100,000 to the cost of each $190 million aircraft
The air force doesn't do anything for $100,000
Who take seriously the estimates a physiologist would give to an engineering problem.
If you read past page 1, what RAW-G warned about isn't even quite what had been happening recently:
"The link between oxygen saturation at lower altitudes and the recent spate of hypoxia-like incidents at high altitudes remains a matter of debate, and it is likely that there are other contributing factors."
But don't let that get in the way of headlines.
Well, at $100k per plane, it's far cheaper to not make that fix and simply loose a few $190M aircraft.
Um...wait..
Oh, nevermind, this is government accounting. Everything adds up.
On one hand you can say that arguing this now is ridiculous now that we know it is actually a problem, there are probably 100's of other things that were budget slashed and worked out fine. On the other hand the entire reason the plane costs 190 million is because every single transistor and bolt in the aircraft is backed by millions of hours of testing and fail-over systems and with such a high priority placed on safety and reliability it seems ludicrous that they would skimp on safety to the pilot. You have to draw the line somewhere though, turns out someone was wrong and is now a higher up, and in true CYA fashion the problem is buried rather than fixed.
DO YOUR BEST WORK OUR YOUNG MENS LIVES RIDE ON IT:2010 -> http://developers.slashdot.org/comments.pl?sid=1898806&cid=34472826
* I wrote about it here a couple years ago, & it made me sick (but aware of HOW the "real world" actually does work) - what if it was YOUR (insert relative/loved one here) WAS RIDING ON IT?
At the time, it was one of mine doing so (surviving 2 wars now, he's part of that SAME "military industrial complex" now, & is a Bronze-Star decorated field-grade officer (Major))...
Folks?
It's "ALL ABOUT THE BENJAMINS" & keeping them out of YOUR POCKET as "normal folks" ( & enriching the "investment class 1%'ers" all the more...)
APK
P.S.=> That's what you GET when GREED, rules!
It's what you GET, when wealth distribution is SO "F'd UP" that MOST PEOPLE lives lives of "quiet desperation" alright:
Folks taking shit and listening to "managers" (who most have very little hands-on product knowledge in whatever it is they're making + selling) & their "plans" (merely more crookery coming from "boards of directors" & marketers)
Those "schemes" shit their companies up even MORE, meaning job cuts occur even more (while they offshore labor & import more, stopping the U.S. Citizen from having a job & spending their disposable income INSIDE our borders on product made here) - why?
Well - product quality in materials + payrolls? EASIEST "cost centers" to control is why...
... apk
ADM = Additional Dealer Markup
DPC = Deal promotional charges
sed -e 's/Chuck Norris/Rajnikant/g' joke > fact
"We have a choice to either squander $xy billion in state-of-the-art F-22s to the aircraft graveyards, or increase their costs by 0.0005%."
"Meh, junk em'."
This is, by the way, how a $90M aircraft quickly grows to be a $190M aircraft. It's not one thing that sends a project over budget, it's a series of cascading events each with a minor impact on the design which causes over-runs. It may very well be that this was a good idea overlooked, but there are literally thousands of these good ideas in a product cycle like a modern aircraft.
Is it just my observation, or are there way too many stupid people in the world?
Dogfight? Dogfights are passe. A drone knocks out the other guy 100 miles out and if it doesn't, who gives a shit. Drones are relatively cheap - especially compared to the F-22.
Close combat with a drone? It's already here.
Let's face it, drones are a cheaper and safer alternative and they're getting better every day.
And planes like the F-22 have a serious defect: they are worthless against wave after after wave after wave of cheap planes. The F-22 would run out of bullets and missiles and while it's running away to get more, it'll get it's ass shot off or it's base blown to smithereens - LOTS of dead people.
And don't get me started on the disappointment of the F-35. Our current line up of planes are fine for current needs and we just need to replace our Air Force with all drones.
Our air force is not ready for future conflicts - we are still in this Cold War mentality. And if there is another big conflict, I'm afraid we will have a very rude awakening.
the cost of adjusting the oxygen flow would have added about $100,000 to the cost of each $190 million aircraft.
That's pretty cheap for an aircraft that cost $412 million a piece. And that's just development and production costs, not even touching TCO.
Lockheed-Martin is full of people who didn't want to be the one guy who tacked an extra $100,000 onto the already astronomical cost of the F-22 and then had to justify it. The buck got passed until it was fumbled, and now here we are with a fighter that has killed more of its own pilots than any enemy.
For an increased cost of roughly .05%, the pilot gets to breathe. Seems like money well spent.
Oliver's law of assumed responsibility: If you're seen fixing it, you will be blamed for breaking it.
Lee Iaccoca must be advising the Air Force...
“He’s not deformed, he’s just drunk!”
The problem was not the aircraft and was not the oxygen flow. The solution was found to be overinflation of the pilots upper G-suit ("Combat Edge") that had been occuring for years and in aircraft such as the F-16 and F-15 but no on noticed it then.
Here is a link to the USAF describing the problem and fix:
http://www.bloomberg.com/news/2012-07-24/oxygen-problem-with-f-22-now-solved-pentagon-s-little-says.html
As a secondary precaution the F-22 is also having a particle filter removed from the air supply (the topic of this Slashdot article) but this is not the primary fix.
The "Raptor cough" which (nugget?) pilots got spooked about is actually common for pilots flying all high-performance jets after performing high-G manuevers. It just happens that the performance of the F-22 is good enough that a lot of these maneuvers can be performed before energy bleeds off enough you can pull them (that is, the Raptor can use them to end nearly all Within Visual Range training encounters - although lesser aircraft occasionally beat less experienced Raptor pilots from time-to-time, which opponents of the Raptor love to crow about). The medical name of this acceleration-induced coughing is.
acceleration atelectasis
Please refer to: http://www.flightglobal.com/news/articles/combat-edge-anti-g-ensemble-might-be-causing-raptors-oxygen-woes-372642/
So please could everyone stop with the media-included scaremongering and stop blaming the F-22 or invoke spooky and mysterious illnessed that pilots of that aircraft are afflicted with (ignoring that fact that the G-suit issue and acceleration atelectatis occurs on other aircraft, just less often because the F-15 and F-16 are relatively lower performance [lol, never thought I'd say that] compared to the F-22).
Now you whippersnappers get off my flight deck!
One of those questions: why in the hell do we need to spend $190M on a plane to fight a war that we'd never get in if we didn't have jackasses running our country that only get in these fights because they have the biggest stick.
I think I answered my own question.
See my journal for slashdot ID's by year. Mine created in 2005. http://slashdot.org/journal/289875/slashdot-ids-by-year
It's time to get the government out of our military.
You are welcome on my lawn.
That.
Also, the F-22 /already has/ a backup oxygen supply, contrary to the assertion made by this article. The fixes proposed in the $100K/per retrofit were over-priced ($200 worth of parts and 2 hours of labor at $100K?), and would have created unnecessary redundancies. Contrary to popular belief, the Pentagon does, occasionally, know what the frack it's talking about.
I am glad they stopped production at the ~187. I would have preferred stopping at 100, but the Feds are incompetent. Now, those expensive fighters can get some real world trials, and bug fixes can be made before large scale production resumes.
I see the US military complex is making good use of the SCC strategy: introduce lots of little flaws, so that nobody realizes they don't need the product anyway.
PlusFive Slashdot reader for Android. Can post comments.
"Oh, and I just LOVE getting anally violated by large women.
APK" - by Anonymous Coward A SCUMBAG TROLL TRYING TO "IMPERSONATE ME" & TO WEAKLY "DISCREDIT ME" on Friday September 28, @04:22PM (#41493225)
See subject-line above & this, troll: GROW UP!
* You truly have "issues"...
( & you FAIL also, of course, since I "caught you in the act", red-handed!)
APK
P.S.=> However, your particular brand of idiocy here, in *trying* to "impersonate" me? Not a first, & not even ORIGINAL...
... apk
Wish I had the mod points ... so hopefully this message will prompt others to mod you up, rather than the grandparent who likely posted w/out fully reading the article (or summary).
Build it, and they will come^Hplain.
The article says the fix would've added 100k$ (yeah, that's kilobucks) to the cost of a 190M$ aircraft. Let's assume more pessimistic numbers, i.e., that one aircraft actually costs only 180M$ and the fix cost 200k$ (double!). That still results in a fix that amounts to well under 1% of the total cost of the aircraft. It's almost rounding error.
Look at it another way. There's fewer than 200 F-22s out there. If the fix really cost only 100k$, that comes out to about 20M$ in total. That's a fraction of the amount that some bank execs get for annual bonuses. Is it really too much money to spend on pilot safety?
How can it cost 100K to tweak the oxygen flow to a mask?
In near future, there will probably be drones which are meant for dogfighting. And drones can have at least one advantage over traditional fighters: tolerating g-forces better than what human is ever able to do -- even with g-suit on.
On the other hand, traditional fighters have other advantages. Drones may be more vulnerable to all kinds of jamming -- and you are allowed to use laser to blind the cameras and other sensors of drones, but you are not allowed to use laser which are meant to (permanently) damage the eyes of a fighter pilot.
190 million dollars for each fighter plane, think about that for a moment...
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Do we know that the pilots were performing high-g maneuvers before choking? That could be a cause, but likely not the only one.
Why the fuck do you care? Get the fuck away from me!
I know I'm old, but why is it the first thing I thought of when I read this was the $5 gas tank fix for the Ford Pinto that Ford ignored..
Why not buy a fully tested and reliable system from the Russians? they're selling one piece for a pound of herring.
Yes, in my youth I read that story too. It came to an abrupt end when wreckage from one of those high speed passes got sucked into the engine intake and the resulting FOD downed the supersonic fighter for good. The pilot safely ejected, but was stranded in the past.