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Year in Review
2004
RISING TO THE CHALLENGE
by Robert Elrod
F-35 JSF PROGRAM MANAGER
LM AERO EXECUTIVE VICE PRESIDENT
fewer parts will be needed in inventory and far fewer deliver the capabilities
F-35 JSF PROGRAM
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F-35 JSF PROGRAM
Production The Precision Milling Machine, also accurate to 50
microns, is built with an equipment enclosure that is
Operations temperature-controlled to plus/minus 1 degree Fahrenheit.
Such consistency helps assure a much higher degree of
precision in the manufacturing process.
The sheer size of both of these machines – whose cost
Ed Linhart represents a large portion of the capital investment –
VICE PRESIDENT, F-35 JSF posed significant challenges, since scaling up existing
PRODUCTION OPERATIONS models had the effect of enlarging specific problems.
Software issues required the arrival of a special team
Production facilities for the world’s from the manufacturer in Germany. Parts shortages also
challenged engineers as they worked through adjustments
most revolutionary fighter program were for tolerances on both the machines.
completed at Lockheed Martin in Production start-up was achieved on time, despite
these obstacles. Components for A-1, the first F-35, have
Fort Worth, Texas; Northrop Grumman been completed on schedule, including structures for
in Palmdale, Calif.; and BAE SYSTEMS the forward fuselage and the wing. Parts had the lowest
rejection rate of any program in the company’s history,
in Samlesbury, England. Major and required fabrication hours have been cut in half.
subassemblies from those centers will No tolerance issues have emerged on what everyone
recognizes as the first fully digital fighter ever developed.
be mated during F-35 final assembly at Much of the credit for this success goes to a team
Fort Worth. The machines at the three organized specifically to resolve production problems.
The Tiger Team includes engineers, tooling specialists and
principal production sites will be used procurement personnel, as well as other technical specialists.
for the most highly automated assembly The team has attacked problems as they emerge, and all
members are given a voice in proposing solutions.
ever developed for a fighter aircraft.
Looking ahead, Production Operations is focused on
upcoming final engineering release dates. The F-35 mate
Precision Milling Machine.
station is near completion with the first mate planned
for the spring of 2005. The team is also addressing
supply chain issues that are anticipated during high-rate
production in 2014.
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F-35 JSF PROGRAM
International Maintaining confidence in the team’s progress on a
range of technical issues – many of which were gaining
Programs attention in the worldwide press – meant assuring all
partners that the issues were being successfully addressed
early in the program. This, in turn, mandated continuous
communication as the technical members of the team
Mike Cosentino developed solutions to the most prominent issue:
platform weight.
DIRECTOR, F-35 JSF
INTERNATIONAL PROGRAM OFFICE Singapore and Israel joined the team in 2004 as
Security Cooperation Participants. This, too, helped
A fighter program with such secure confidence that challenges were being successfully
resolved. Engineers in Denmark, Italy and Turkey
international scope represents a were integrated deeper into the program, and industrial
challenge unto itself, as nations around cooperation programs were more fully developed, with
partners getting ready to participate in production. Export
the world have signed on at various licensing data was secured. Support relationships gained
momentum, as parts-supply plans and global-sustainment
levels of partnership. The task of systems continue to be refined.
managing these relationships grew in Looking ahead to 2005, International Programs will be
complexity and size throughout 2004 – heavily engaged in addressing the closeout of industrial
program participation and will focus on weapons systems
and will continue to do so in 2005. and additional supply-chain management issues. The team
will continue to nurture a culture that seeks to expand
collaboration with partners.
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F-35 JSF PROGRAM INTEGRATION
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F-35 JSF PROGRAM INTEGRATION
Business operationally and technically. Fortunately, the program
secured full funding for 2005 and is currently on track to
Development be fully funded in 2006.
Domestically, weight issues and the subsequent schedule
replan required constant interaction with all members
of the customer base. BD focused on the services, the
Jim Grant Office of the Secretary of Defense, and Congress to keep
DIRECTOR, F-35 JSF them informed and supportive of the program. Using all
BUSINESS DEVELOPMENT available venues – including plant visits, trade shows, base
visits and media briefings – the BD team advocated the
Business Development (BD) has a benefits of the F-35. Likewise, recognizing the need to
expand stakeholder interest in the program, BD developed
vital and challenging role on JSF: Keep a series of briefings to explain the benefits of the F-35 as a
the program sold! Budget pressures, close air support asset. These briefings were presented at
the very highest levels of the U.S. Army and are helping
technical challenges and changes in shape joint/coalition warfare.
key leadership all provided challenges Internationally, BD enhanced the commitment of the eight
partners and two participant nations by advocating how the
in 2004, but in the end, the program is JSF program and the F-35 aircraft will meet each country’s
funded and tracking to meet warfighter national objectives. The partner nations are beginning to
formalize their purchase plans, and BD, working in lock
requirements. Through a nonstop series step with the Joint Strike Fighter Program Office and our
of meetings, briefings, visits, trade shows, International Program Office, is solidly focused on strategies
that ensure international users remain a prominent and
demonstrations and liaison activities, BD continuing part of the JSF program. Beyond the partner
interacted with all levels of our customer nations, international interest in the F-35 remains high as
public awareness on the program increases and emphasis on
community to maintain confidence in, coalition warfare gains momentum.
and funding for, the JSF program. As we shift focus to a new year – budget pressures from
the war, deficit-reduction initiatives, and other competing
Winning the System Development and Demonstration service and national priorities will bring new challenges to
down-select in 2001 was not the end of the JSF the BD team. The team will remain focused on making sure
competition; it only shifted the focus to a different arena. our customers’ needs are fully understood and the program
Each year we must prove ourselves worthy of continued receives the full funding necessary to execute on schedule.
customer confidence, support and funding. It is a BD
responsibility to lead the implementation of strategies
that reinforce the “value” of the F-35 in meeting both
U.S. and international needs – politically, economically,
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F-35 JSF PROGRAM INTEGRATION
Strategy to understand specific Air System needs and execute
related special studies. These studies cover a broad
Integration spectrum – from operations in severe environments, such
as icy runways, to the stressful heat/humidity conditions
of the Persian Gulf; unique vehicle or mission-system
requirements; carriage/employment of new or unique
Paul Leamer country weapons; or peculiar support-system needs.
Approximately 20 studies were initiated in 2004, while
DIRECTOR,
F-35 JSF STRATEGY INTEGRATION 40 to 50 are anticipated in 2005. Every study is important
to the sponsoring customer and, therefore, to the entire
JSF program team because of shared interests.
Every nation that operates the
The Strategy Integration team is also supporting the
F-35 will enjoy the economic Joint Strike Fighter Program Office with long-range
rewards of commonality in a very planning for major capability upgrades such as Block 4
and beyond. While Block 4 is targeted for possible
high performance aircraft. Yet, every authorization in the 2009–2010 period, these plans
typically look into the future 10 to 20 years. This is
nation also has individual needs and driven by the long acquisition process associated with
requirements. These are being addressed the planning, budgeting, contracting, development and
production/retrofit incorporation of a given upgrade.
by the Strategy Integration team. Lockheed Martin and its partners Northrop Grumman
and BAE SYSTEMS are also assessing F-35 derivative
In addition to its responsibility for integration of concepts such as a two-seat variant and an electronic-
strategy elements, this team is working on the future of the attack variant. This long-term planning is focused on
program. It works with various domestic and international making certain the F-35 is always the system of choice
customers through the Joint Strike Fighter Program Office to satisfy our customers’ changing needs.
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F-35 JSF PROGRAM INTEGRATION
Northrop Fort Worth, Texas. Initial tests of the F-35’s first-flight
CNI system were flawless. This demonstrates Northrop
Grumman Grumman’s spiral development approach that allows
hardware and software integration years earlier than
in previous programs and ensures system stability
and robustness.
Janis Pamiljans Northrop Grumman also delivered and tested
VICE PRESIDENT AND F-35 PROGRAM a fully instrumented, full-scale inlet model that
MANAGER, NORTHROP GRUMMAN will determine engine propulsion system
characteristics; performed radar cross-section
Northrop Grumman has marked a year tests on a full-scale inlet model used to verify
propulsion system performance; delivered a
of significant progress for the F-35 Joint vertical-tip antenna designed to verify
Strike Fighter Team, the highlight of which communications requirements; and
initiated qualification testing on the
was the start of production. With assembly fire-protection system and
of the center fuselage under way, Northrop weapons-bay door drive to
ensure system functionality
Grumman ushered in a new era for this requirements are met.
already dynamic program and forged Also in 2004, the company
continued laying critical
the way for the team to meet its goal of groundwork for the
building the most advanced tactical fighter aircraft’s operational
effectiveness by
aircraft in history on the most advanced conducting a weapons-
production line ever built. loading demonstration
with military ordnance crews from the
Our delivery of one of the aircraft’s key mission systems United Kingdom. The demonstration –
test stations further exemplifies Northrop Grumman’s similar to a weapons-loading exercise with
critical role on this team. The stations will enable users to U.S. ordnance crews in December 2003 – involved
test software on the same hardware platform that will personnel from the Royal Air Force and Royal Navy
host the software on the aircraft – significantly reducing loading mock-ups of several weapons into a full-scale
risk prior to domain and system integration. mock-up of the F-35’s internal weapons bay. The
participants later provided evaluations of the process to the
After completing a successful comprehensive review F-35 design team. Involving operational users early in
in February 2004, Northrop Grumman made the first the design of key aircraft components is unprecedented
significant delivery for the F-35 mission systems segment. in military aircraft programs.
The communications navigation and identification (CNI)
radios for the F-35’s first flight were delivered to the
Lockheed Martin Mission Systems Integration Lab in
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PARTNERS
Center fuselage.
In May, Northrop Grumman began rooftop integration Canada, Denmark, Norway and Turkey. Companies around
range-testing of the F-35’s fire control radar. The radar, the world are delivering parts to support the first CTOL
which the company has developed under contract with build. Northrop Grumman also selected the first Small
Lockheed Martin, features an active electronically Business Innovative Research Program participant on the
scanned array that enables multiple radar functions program. The company will provide a component for high-
almost simultaneously. fidelity power testing of the communications avionics.
Northrop Grumman continued to aggressively pursue Many more milestones await Northrop Grumman in 2005,
international participation by identifying production and we look forward to building upon the success of this
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PARTNERS
Bill Gostic
DIRECTOR, F135 ENGINE PROGRAMS
FX643 in afterburner.
Both the CTOL/CV and STOVL systems showed marked specification levels of thrust in excess of 39,000 pounds.
improvement in weight reduction. Current estimates show This unprecedented level of testing has validated
the CTOL/CV and STOVL configurations are below predictions, as well as identified maturation issues to be
specification weight. The F135 program has plans in place resolved prior to initial flight release (IFR) qualification.
to realize further reductions in 2005 and beyond. To assist the JSF program in achieving a viable STOVL
P&W celebrated a record year of software accomplishments. configuration, improvements required to achieve higher
Software versions critical to the operation of the F135 thrust have been incorporated into the F135 propulsion
STOVL propulsion system, including the operation of the system and program. These improvements, currently in
clutch and the thrust split, were developed and implemented the design phase, include an optimized STOVL nozzle
into the F135 engine-validation program. and the addition of “roll post modulation.” Thrust
The F135 SDD test program continued to make increases will be achieved in both vertical-powered lift
tremendous progress on the road to qualification for mode as well as the short-takeoff mode.
first flight. The team delivered the program’s first STOVL Pratt & Whitney has also implemented a plan to
propulsion system, FX641, to test, as well as maximize F135 industrial activity within the JSF partner
STOVL propulsion systems FX640, countries. This multifaceted plan has the support of
FX642 and FX643. The CTOL/CV- P&W leadership and involves many organizations across
configured FX632 was delivered to the the enterprise. A cornerstone of the plan is the direct
Arnold Engineering Development Center engagement with international companies to match
in Tullahoma, Tenn., for altitude testing, for capabilities with potential opportunities. Pratt & Whitney’s
a total of seven assets in the test program. efforts have led to contracts with more than 40 suppliers in
Over the course of the year, all eight of the JSF partner nations. The team will continue
the F135 test program to complement this success with additional international
accumulated almost 1,700 industrial contract awards in 2005.
total hours. At the same time, As we move into 2005, the F135 program will look to
Rolls-Royce made tremendous build upon the sound foundation of 2004 accomplishments
progress in testing of the lift fan, to accumulate the test hours required for CTOL IFR.
accumulating more than 1,000 Furthermore, P&W will deliver the first CTOL flight test
test hours. Both the CTOL/CV- engine in the fourth quarter of 2005. The production-
and STOVL-configuration readiness process is in full gear to support engines for flight
engines have demonstrated testing, recognizing that single-engine safety is paramount
to the success of the program. The F135 program is focused
on providing the most technically advanced,
reliable and safest propulsion system for
the F-35’s first flights in 2006.
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PARTNERS
GE Rolls-Royce
Fighter Engine Team
Bob Griswold
PRESIDENT,
GE ROLLS-ROYCE FIGHTER ENGINE TEAM
Tom Hartmann
SENIOR VICE PRESIDENT,
GE ROLLS-ROYCE FIGHTER ENGINE TEAM
2004 was the year that both the conventional takeoff and landing (CTOL) configuration,
demonstrated two soft light-offs and smooth transition to
GE Rolls-Royce Fighter Engine Team idle for a total of 1 hour and 17 minutes of testing. During
follow-on testing, engine 625-002 demonstrated smooth
(FET) and the F136 engine left the starts, throttle transients, low vibration levels and stall-free
drawing board and became a reality. operation. In mid-August, 625-002 achieved 105 percent
maximum design speed. An additional 300 to 400 hours of
The FET demonstrated an unprecedented level endurance testing is planned for 2005.
of cooperation, unwavering commitment and unyielding In keeping with the hectic pace of the overall JSF program,
determination to produce and successfully test its first the second F136 engine was assembled and delivered
revolutionary F136 propulsion system for the F-35 Joint soon afterwards. This is our first short takeoff/vertical
Strike Fighter. Within months of this milestone, the joint landing (STOVL) engine (625-003); it will be tested in
venture received official recognition for the first time with early 2005 at the GEAE Peebles, Ohio, facility. Testing of
the placing of the Transition Award Contract with the FET. this engine will close out our highly successful Phase III,
Building on the successes of 2003, the FET took the pre-SDD contract and propel the team forward toward our
F136 interchangeable engine from vision to reality. On anticipated Phase IV SDD award contract in 2005.
July 22, 2004 – the 1,000th day of the JSF program – FET In our quest to reach SDD Phase IV, the FET achieved
successfully performed its first ground test at the GE yet another first on November 1, when our Transition
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Aircraft Engines Evendale, Ohio, facility, achieving the Award Contract began. This event is significant to the
PARTNERS
high-water mark of our Phase III, pre-System Development F136 program because it is the first contract officially
and Demonstration (SDD) contract. Engine 625-002, in the awarded to the GE Rolls-Royce Fighter Engine Team.
F136 STOVL variant during LiftFan™ assembly.
This contract is designed to fund the F136 program internship program to support the F136 program. In this
incrementally until our SDD contract award is authorized ongoing program, the dual goals of knowledge-sharing
in the third quarter of 2005. with partner nations and helping young engineers as they
On the global front, the FET has worked hard to start their careers are realized.
incorporate key technologies from the eight partner nations The year 2004 was excellent, but 2005 is looking
(United Kingdom, Italy, Netherlands, Turkey, Canada, sensational! Testing is ongoing with our two engines,
Denmark, Norway and Australia) participating in the JSF hours of steady-state data are being recorded, and all key
program. Eight summits were held in 2004 with the goal of performance parameters are being met. Our objectives are
identifying key companies. Industrial participation by all clear and our team resolute. We will continue to play our
nations is anticipated for the SDD phase. part in manufacturing a first-class, affordable propulsion
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As a further commitment to international partners, system that will power F-35s all over the world well into
PARTNERS
Program
Priorities
• Complete Replan
• Track to First Flights
• Track to Air System Critical JSF Guiding
Design Reviews Principles
• Track to Low-Rate Initial Production Inspire Excellence
We recognize and reward excellence in both our
Contract Awards teammates and the product. Our actions and attitudes
• Finalize Global Sustainment provide positive and motivating examples to our
teammates. We continually strive to achieve our vision,
Concept of Operations program objectives and priorities.
Northrop Grumman
BAE SYSTEMS
Lockheed Martin
Aeronautics Company
P.O. Box 748
Fort Worth, TX 76101
Visit our Web site at
www.lockheedmartin.com
A04-13718A001