13 February 2008

Major General Charles R. Davis, USAF

Program Executive Officer, F-35 Lightning II Program

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 BF-1 At Roll-Out

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 Critical Design Review
June 18, 2007
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 CF-1 Progressing
Forward Fuselage Wing

Center Fuselage

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 Master Schedule
FY 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
CY 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Initial Operational Capability
Critical Design Reviews
USAF / USMC USN CDR
USMC USAF USN
Major First Flights
Program USAF Test Completions
Events USMC Developmental
AA-1 (15 Dec)
USN Operational

Production and Sustainment

LRIP 1 (2)
CATB (23 Jan) LRIP 2 (12)
Low-Rate LRIP 3 (19)
Initial LRIP 4 (32)
Production LRIP 5 (47)
(LRIP) Planned U.S. Production and Sustainment LRIP 6 (118)
• Air Force 1,763 A/C LRIP 7 (132)
• Dept of Navy 680 A/C
Multiyear 1 EOQ MYP Î
Planned International Production > 500
EOQ = Economic Order Quantity MYP = Multi-Year Procurement
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 Program Schedule
FY 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
CY 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
Initial Operational Capabilities

USMC USAF USN UK

Low-Rate
Initial
Production
(LRIP)
LRIP 1 (2)
LRIP 2 (12) Production
LRIP 3 (19)
LRIP 4
LRIP 5
LRIP 6
LRIP 7
Multi-Year 1 EOQ MYP

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6
 2007 Milestones
Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec
LRIP #2 LL 1st STOVL Engine and Lift
Proposal CV CDR Delivery LRIP #2 FF
Submittal ALIS Proposal
Ft Worth Submittal

STOVL Engine
Pilot STOVL and Lift Fan
CATB 1st Flight Training
LRIP #1 Power On Installation
CDR
Award

Partner MoU BF1 Wing CATB 1st BF-1 Rollout

Signatures Complete Completion Mission
Systems
Flight

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7
 2008 Milestones
Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec
BF-1 Deploy
LRIP #2 CTOL LRIP #3 FF Sustainment to PAX River
FF Approved Proposal Readiness
Submitted Review-PAX
BF-1 FRR

BF-1 AF-1 Rollout Maintenance

Structural BF-1: Hover AF-1 Training CDR
Coupling Pit Testing Power On
Tests Start

BF-1 1st Flight

BF-4 Rollout Alis 1.0.2
AA-1 Launch BF-3 Rollout Delivery
BG-1 transfer to EAFB
to Test Lab

LRIP #2
BF-2 Rollout CATB 1st AG-1 Static
STOVL FF CF-1 Start Test Start
Sustainment Federated
LRIP #3 LL Approved Major Mate
Readiness Flt
Approved
Review-EAFB

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 Flight Test Underway

Objectives Objectives
• Mission Systems Risk • Risk Reduction/Confirmation
Reduction/Confirmation • Basic Envelope Expansion
• Missions Systems Integration • Systems Integration
Status Status
• 29 Flights To Date; 85.5 Flt Hrs • 25 Flights To Date; 28 Flt Hrs
• Basic Airworthiness Proven • 38,000 Feet, 0.8 Mach, 20 Degrees AoA
• Initial Mission Systems Installed • Vehicle Systems Being Validated
• First Mission Systems Flight on Dec 7, 2007 • Reliability/Maintainability Evaluation

CATB STOVL CTOL CV

23 Jan ‘07 May ‘08 2009 2009

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DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

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 First Flights Status

CATB
CTOL AA-1 23 Jan ‘07

15 Dec ‘06

STOVL (BF-1) CTOL (AF-1) CV (CF-1)

Jun ‘08 2009 2009

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 What We Have Learned From AA-1
That Reduces Program Risk
Handling Qualities Development
• Excellent Handling qualities verify design goals. F-135 Engine
• Initial Autopilot testing • Engine Transients to AB
• Mode – Speed Brake/ Air Refuel/ APC • Engine Response
• ‘Control to Thrust Concept’

IPP
• Cross wind Start
Electrical System
• IPP screen • ICC Operation EHA
• ECS Temperature • Emergency Fill in • Integration with electrical system –
• ECS Deicing • 270 V Power to produced gear box changes / REGEN
Flight controls resistor .
• EPU operation
• Hydraulic Reservoir Temperatures
• Temperature Control • High altitude Electronics Unit Changes
• Defog pattern to improve component design.
• IPP operation • IBIT Mechanization
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 F135 Turbine Blade Failure Summary

Failure Summary – October 2007

• Engine #FX634 surge / failure in STOVL mode at MIL power
• Root Cause: High cycle fatigue failure of a 3rd Stage LPT blade
• Testing curtailed while corrective actions and path ahead approved
Return to Test Strategy – December 2007
• Finished NDI of all turbine blades – No issues
• Finished “Proof test” of test cell engine to confirm LPT durability – No issues found
• All test assets will be proof tested with periodic Eddy Current Inspection—CTOL flying
and STOVL engines returned to test
• Potential design changes identified; verification test plan built
Failure Summary – February 2008
• Failure almost identical to FX634 in August
• Root Cause: High cycle fatigue failure of a 3rd Stage LPT blade
• Confirmed to be STOVL powered lift issue
Way Forward
• Fly STOVL about 30 days late on a CTOL clearance
• Validate stresses and confirm root cause fix—May-Jun
• Re-clear BF-1 for STOVL ops Dec-Jan
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 Validating Mission Systems in Flight
QF-4 F-16

EO DAS
Systems Lab
Flight Hrs
in Test Hrs
15 Hrs
HMD 950
(AA-1) DAS, EW CM
125 Hrs
Sabreliner Radar 6500 F-35 AA-1
(BAC- 111)
EOTS 83 Hrs
EO DAS (F-16, BAC-111, 4700
QF-4)
10 Hrs
EOTS (Sabreliner) 3650
BAC-111 (CATB – Fall ’08)
20+ Hrs INS: AA-1 HMD MFD
10 Hrs INS/GPS:
Integrated
BAC-111 4400 CATB
CNI
35 Hrs RALT
(CATB Fall 07)
EW/CM 70+ Hrs 11,255

Radar, EO DAS, INS, GPS

Fully Integrated MS
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 Key Performance Parameter Status
3 Jan 08
240-4.7 CTOL 240-4.4; STOVL 240-4.3; CV 240-4.5
Combat Radius Mission Reliability
CTOL CTOL
CV CV
(HHH Profile)
STOVL
STOVL USMC
UK Profile (HMMH): 468 nm
STOVL UK
CV Recovery 240-4.7
CTOL 240-4.4; STOVL 240-4.3; CV 240-4.5
Vpamin
Sortie Generation Rate
CTOL
240-4.7
STOVL Performance CV
STO Distance STOVL USMC
Flat Deck
(HHH Fuel) STOVL UK
Ski Jump 240-4.4; 240-4.5
(HMMH Fuel) Logistics Footprint—C-17 Loads
VLBB CTOL
STOVL USMC
240-4
Interoperability 240-4.4; 240-4.3; 240-4.5
Logistics Footprint—Volume
Net Ready Criteria
CV
240-4.7
RF Signature STOVL USMC
STOVL UK
• CTOL 240-4.4; STOVL 240-4.3; Threshold Requirement 240-4.4; 240-4.3; 240-4.5
CV 240-4.5 unless noted
• Contract Engine Deck
CE Performance Logistics Footprint—Weight
Exceeds ORD Objective
• Projected IOC Weight Empty Meets Rqmt/ExceedsTripwire
based on WSR 209 CE CV
• Data as of 1-3-08
Meets Rqmt/In Tripwire Band
Does Not Meet Requirement STOVL USMC
DISTRIBUTION STATEMENT A.
STOVL UK
Approved for public release; distribution is unlimited.
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 The F-35 Design Requirement
Go Deep Into a Double Digit SAM Environment . . .
Surface-to-Air Missiles

SA-10 SA-12 SA-15 2S6M/SA-19

. . . Locate, Identify and Destroy Mobile/Moving Targets Through the

Weather . . . While Outnumbered by Fourth Generation Fighters

Fighter
Aircraft
Su-
Su-27
Su-27 MIG-
MIG-35
MIG-35 Su-
Su-30
Su-30 Su-
Su-35
Su-35 Su-
Su-37
Su-37

Air-to-Air
Missiles
AA-10 ALAMO AA-11 ARCHER PYTHON AA-12 ADDER MICA

From Any Base At Significantly Lower Cost Than Legacy Systems

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 F-35 Program Enablers

• Stealth
– Surprise
– Maintainability
• Complex Packaging
– Highly Integrated Vehicle Systems
– More Electric Architecture
– Single Engine
• Fully Integrated Avionics
– Real Time Situational Awareness
– Information Sharing
• Within/Outside the Anti-Access Bubble
• With foot soldier

Unprecedented Integration Challenge

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 Stealth

• Air to Ground Design

Challenging
– Excellent Air to Air Fallout
• Design Drives Majority of
Effectiveness
– Aligned Edges
– Imbedded Antennas
– Internal Weapons
• Single Engine Packaging
Challenge
• Coatings Application
– Signature Performance vs
Sustainability vs Durability
• F-35 Advances State of the Art

Enables Tactical Advantage of Surprise

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 Complex Packaging
Federated Emergency & Auxiliary
Integrated
Subsystems Power Units Subsystems Electro
Hydrostatic
Hydraulic Actuators Actuators
Powered by Central
Hydraulics

Switched Reluctance
Air Cycle Starter /Generators
Environmental on Engine
Control System
Vapor Cycle Integrated Power
Environmental Airframe Mounted Package (IPP)
Control System Accessory Drive
Fan Duct
Heat Exchanger

Drives More Electric Architecture

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 Fully Integrated Avionics

Exceptional Situational Awareness

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Cooperative Avionics Test Bed - 737

First Full Fusion Flying Laboratory

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 Integrated Ground Test Labs In Place
Manned Tactical Simulators Mission Systems Integration Lab Prognostic Health
Management Lab

Hydraulic System
Integration

Vehicle
JSF Interoperability Lab Systems
Integration
Facility Flight
Control
System
Integration
Air
System
Integration Electrical Power
Facility System Integration
Vehicle Systems Processor /
Flight Control Systems Autonomic
Integration Facility Logistics Lab Utilities and Subsystems Integration Facility

Fuel System Simulator

Lab Integration – Unprecedented Collocation, Coordination and

Capacity
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Harnessing Computational Power and World-
Wide Supply Chains and the Challenges This
Presents to Lean Manufacturing

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 Digital Thread Throughout Life-Cycle

Development
Virtual M&S

Design Build

Program
Management
Support,
Maintain Test
and Train

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

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 Production “Kill Chain”

Procurement

% Parts Accepted
Mismatches
Engineering P.O. Backlog
Release MR’s Late to Need
% Parts Delivered On Time
BTP Release Planning
CR Activity FAB
BOM %
Accuracy Reqmt’s Received Parts Status
Planning Late To Need
Development Starts/Completes To
By Program
PIOS Schedule Assembly
By Aircraft
Behind Schedule Hours
By Commodity
Indenture 2 Shortages SPI / CPI
By Supplier
Projected Load Line By Program
By SWBS
By Component
Hours Planned vs.
Hours Earned
Starts / Completes
% Out Of Station
By Component
Our ability make a very complex digital design has By Aircraft

really challenged the entire production “kill chain”

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 Current Production Status

Forward Fuselages (LM)

• 8 in Assembly
• 4 Delivered

Center Fuselages (NGC)

• 12 in Assembly
• 4 Delivered

Major Assembly (LM)

Aft Fuselages (BAE) • 3 in Major Mate
• 7 in Assembly • 2 in Flight Ops
• 4 Delivered

Wing (LM) All SDD and LRIP 1 Aircraft

• 7 in Assembly in Production
• 4 Delivered
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 Advanced Manufacturing Technologies
Required to Meet New Challenges . . .

Precision Fabrication Flexible/Automated Solutions

Computer Simulations

Robotic Spray

Automated Part
Marking
Laser Control
High Quality /
Affordable Solutions

Laser Projection

Lean Practices Digital Assembly

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 What’s Working (and Not) ?

• Successes
– Center Fuselage Ahead of Schedule Delivery w/min. travelled work
• Some redesigns required for proceeding at risk without final loads
– Forward Fuselage On-Time Delivery
– Aft Fuselage On-Time Delivery with reduced traveled work
– Empennage On-Time Delivery
– 11 shipsets of Wing Bulkheads Delivered (with QARs)

• Challenges
– Lack of Brackets for Wing Pre-Assembly
– Inner Wing Assembly (Bulkhead Droop/Warpage, Shortages)
– CTOL Outer Wing leading/trailing edge tolerances
– Wing Traveled Work to Mate (Out of Station)
– Harness Rework
– Instrumentation Integration

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 Assembly Defects per 1K act Hrs
Combined BAE, NGC, and LM Aero

50.0
45.0
41.3
40.0
Defects per 1K act hrs

F22 2007 YTD Avg

35.0
30.0
26.0 F16 2007 YTD Avg
25.0 21.7 22.0
20.0 17.6 16.3
14.1
15.0
10.0
5.0
0.0
2AA1* 2BF1 2BF2 2BG1 2BF3 2BF4 2AF1

Exceptional Quality Results Compared to Legacy

* 2AA1 Does not include Flight Line As of : 12-17-07
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 Must Ensure Production Efficiency Improves
Across The F-35 Global Supply Team
The Netherlands Norway Canada
Dutch Space
PHM Consortium Howmet Ben Marine
Aeronamic Kitron
Fokker - Elmo ASCO DY4 Mindready
DAP Applica
TNO NLR SP Aerospace FTG Dishon Cyclone
Metronor Megellan-Bristol
Sun Electric Techni Honeywell Eng Sys
Brookx Hexagon
Dutch Aero Corena DRS Technologies
Axxiflex Kongsberg Herou Devtek
Flextronics
Eurocast Fokker - Aerostructures Avcorp
DNV EPM Technology CMC Electronics
Thales Cryogenics Thales Nederlands
Magellan-Chicopee

Denmark United Kingdom

Systematic Software Engineering BAE SYSTEMS
Smiths
Terma Aerospace Goodrich
GPV
Maersk Logistics Microfiltrex Hamble Structures
IFAD
Corena
HiQ Wise GKN
Helmut
Danish Aerotech Integrated Sys.
Bruel & Kjaer Martin Baker
Beaufort

Samputensilli
Italy Australia
Aermacchi
Cusinetti
Alenia Broens
Mecear Levett
York Datamat Micro LTD Aerostaff
Turkey Cablex
Galileo Marconi Sirio Panel
Piaggio Kalekalip Varley Metaltech Ferra Engr.
Aerea
Umbra Milsoft Ayesas Adecel Lovitt
Moog - SBC BAE Australia
UoP GKN Marand
Oto Meleraia Havelsan TAI Aselsan
Logic GPC
Marconi Selenia Hawker de Havilland
Magnaghi Mikes ALP Aviation Goodrich Services
Segundo Mona Production Parts
Vestel Gate Elektronik
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
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 F-35 Global Delivery System
Operational Locations: 52 Bases, 9 Ships, 156 Squadrons
Aircraft

USAF 1763
DoN 680
BAE Partners 682
Total 3125

NGC
LM

Prime Contractors
OEMs
FET
Pratt & Whitney
BAE
Northrop Grumman
Lockheed Martin
Depots / FRCs
F-16 Locations
F/A-18 Locations
AV-8B Locations

F-35 Requires Global Supply Chain Solution

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 F-35 Strategic Initiatives
SDD Program Schedule SDD Production Firing Order MCRR

• Leverage JSF
Global Distribution System Investments
Lightning Strike • Replenish MR

• LRIP Affordability
• Partner Keep Sold Lead Turning the Next Set of Challenges
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 F-35 Take Away Messages

• F-35 Is Meeting Operational Requirements

• F-35B STOVL Tracking to First Flight in Jun

• Coalition Partnership Remains Strong

• F-35 Program Enablers Very Challenging and Complex

• Manufacturing and Production Must Never be Underestimated

• 2007 Was a Challenging Year-2008 Will Be Tougher and More

Rewarding

• F-35 Strategic Initiatives Critical to program Success

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

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Lockheed Martin Aeronautics Company
 QUESTIONS

Lockheed Martin Aeronautics Company

DISTRIBUTION
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A. Approved for
forpublic release;
public release; distribution
distribution is unlimited.
is unlimited. 33