Where Have Our "Kelly Johnsons" Gone?

The disappearance of the aerospace vehicle design engineer has long been used as an indictment against the engineers of today. When people ask, where is the Werner Von Braun or Kelly Johnson of this generation of engineers it is typically cited as proof that engineers of today are not as competent as those of previous generations of Americans. That perception is wrong and the disappearance of the aerospace design engineer actually points to a plot that is much more sinister. It is a plot by our military-industrial complex to spend more of your money while providing the US taxpayer in return with much less "bang for the buck".

What's that, another baseless conspiracy theory, you say? Ok, try this, send your resume to NASA, Lockheed Martin, Boeing, or Northrop-Grumman, make it look as good as you want, and tell them you want to apply for a job designing rockets or airplanes. The position no longer exists! When NASA shut down the Apollo program it retired not only the Chief Designer of the Apollo rocket program, Werner Von Braun, but his position as well. The design of NASA's rockets is no longer conducted by highly qualified people with years of experience and demonstrated results designing rockets.

From the shuttle program forward, NASA's rockets have all been designed by committees, often involving non-technical people, rather than by engineers. Who designed the shuttle? Have you ever wondered? I remember Von Braun, the Saturn V’s designer, appearing on TV. Walt Disney often interviewed Von Braun to promote his ideas for space exploration. Von Braun put a man on the Moon in a decade, a feat few thought possible. A few nuts even today question whether or not it actually happened given the fact that we have not been able to repeat this activity in over 40 years.

Look around you; clearly we have much more technology at our disposal today than we did in 1969! The computer you are viewing this blog on is likely more powerful than the fastest computer available to NASA in 1969. Your cell phone has many times the computing power of the computer that navigated the Apollo capsule to the Moon. Yet today we cannot land a man on the Moon. So it seems obvious that when rockets were designed by scientists and engineers clearly those vehicles were more capable than what we have now. None the less, it is over 40 years after man first put a footstep on the Moon and NASA still will not take a resume for Von Braun’s position. The position did not transfer to NASA’s contractors. Lockheed Martin does not have a Chief of Rocket Design position. Boeing, the builder of the Saturn V, doesn’t have that position. No one does. It fell off the face of the Earth even though it clearly worked quite well once.

Outside of aerospace we still see famous engineers. Burt Rutan is famous for building innovative general aviation aircraft and for winning the X-prize with his suborbital Space Ship 1. Steve Jobs at Apple Computers is plenty famous, and their stock prices rise and fall with rumors of his health, but in the aerospace industry where they hire thousands upon thousands of engineers not one is famous. Engineers used to commonly rise to the top of these companies. Now we see many new aerospace CEOs coming from the financial ranks, and at the same time the number of programs that are on schedule, on budget, and developing vehicles meeting the technical goals of the program has dwindled to nothing. Yet still, we never hear any proposals from contractors, NASA, or even the US Air Force to bring back the position of the Chief of Rocket or Airplane Design.

What happened to that position that made engineering stars of the past famous? We are told that aerospace vehicles of today are so complicated that no single person could possibly design them. Is that true? Kelly Johnson designed the SR-71 in 1968, but the F-22 is so much more complicate that even with all our computing power it could not be designed by one person today? The F-22 doesn’t look that complicated to me, and I spent a year designing various parts of that airplane. So where did the aerospace vehicle designer go? I submit for your consideration this: the Chief of Vehicle Design position had to be eliminated in order for the current “profit on development” procurement system to be put into place. None of the highly visible Chief of Aircraft or Rocket Designers could be counted on to go along with the dragging out of these critical aerospace vehicle programs into the 2 and 3 decade long cycles they now routinely use and thus their positions had to be eliminated first before this type of procurement system was implemented.

In fact, if you look at the origin of the “profit on development” approach to procurement you will see that it started with NASA. Because of NASA’s status as a research and development agency of the federal government, NASA has always paid a profit on research and design. They buy very few quantities of vehicles (unlike the military, historically which typically bought by the thousands) so in order for a contractor to make a profit on vehicles developed for NASA contractors typically get the same approximately 10% fee (contract language for profit) on both the design and manufacture of the vehicle. If all of the profit on the Apollo program had come from delivery of the Saturn V first stage boosters themselves by Boeing, then the profit margin would have been in the 100% - 200% range. This was thought to be excessive and politically unattractive to the US taxpayer.

Rockwell developed the space shuttle. That single vehicle took much longer to develop than the entire series of vehicles that went into the Apollo program. Rockwell had found the secret to making a lot of money from the low profit margin in the development of the shuttle. They dragged out the development phase of the program where the risks were low. The risk in designing a vehicle is much less than the risk of building one. Typically an aerospace vehicle must fly in some fashion and vehicles of that type require that many high performance parts fit and work together. In the design phase of a program, if anyone asks, you tell them all is going well. Your only risk is that somehow it might get out that things are not going well.

The shuttle program became the model that many defense contractors sought to fashion the military procurement system after. When the defense contractors realized the profits possible under NASA’s “profit on development” approach and saw how “profit on development” reduced their development risks to nothing, they all rallied around the implementation of that system in the Department of Defense (DoD). Their gain was obvious. Sure, the company doing the development work did not have to front the money for the design, but that was only part of it. Because such a huge government bureaucracy would be built around buying the product being developed, the contractor was assured of having a customer for what they produced, no matter how poorly that product performed. The necessary development bureaucracy would resist any attempts to terminate the program and thus terminate the bureaucracy. The first rule of bureaucracies is that they exist to exist.

So it was that together the defense contractors began eliminating the position of the vehicle designer in preparation for their lobbying assault on Washington DC to institute NASA style “profit on development” procurement in the DoD. With the Chief of Vehicle Design positions gone it is a simple thing for these contractors to keep this farce in place. There is no credible source to take the complaint public.

The government loves this system of procurement because it ensures a maximum number of bureaucrats are required on their side to watch the greedy contractors. Our military is made up of a mere 15% of combat soldiers. It is one of the most inefficient militaries in the world. A large part of the other 85% get cushy assignments in procurement where they can rest assured they will never be shot at or have to work in a building without air conditioning. The contractors love this system because no one can stop really them from “robbing us blind” when it comes to development, at least not until thought police have been perfected. There is no apparent difference between someone who is sabotaging a development program by purposely trying to drag it out and stupidity. In fact, contractors hire and promote a significant number of stupid people to provide the necessary cover for those who are actively engaged in this kind of intellectual sabotage.

No high profile engineer would stand for this. They would be lobbying congress right now to put an end to paying profit on development. A development program that lasts 25 years as F-22’s did would last an entire career of an airplane designer. It would leave them with nothing to do next, nothing to do with what they had learned. By getting these high profile people out of the way, the industry cleared the way for the current “profit on development” procurement scheme to continue. A scheme that is causing our military superiority to become a thing of the past and raising the cost of weapons development to record heights while also raising the contractors’ profits to record levels.

So the next time someone asks you where our Kelly Johnson’s have gone, tell them what happened. Tell them that our engineers fell victim to a scheme to maximize corporate profits while minimizing risks. Tell them this generation of engineers is ready, willing, and able to do the job their predecessors once did. We are ready to go back to the Moon and beyond. We are ready to develop weapons to keep this country free. We need only the opportunity.

Comments

good observation

It's true. It used to be the engineers were the ones acknowledged, interviewed and the techies managed the engineering projects, rightly so, because they knew what's going on.

Now techies have been marginalized, where you get the "CEO" as "speaker" as if just anyone can design this stuff.

It's no wonder the United States technology edge is declining and somehow I don't think "social networking" is up there with the invention of the transistor or getting a rocket to the moon.

 

Remarkable Coincidence?

At first when I drew this connection I said to myself, "no, surely there wasn't that much advanced thought put into this." Then I realized that they gave Von Braun the bum's rush to get him out of the way in NASA's contracting, which was remarkably easy probably due to his background in Germany during WW2. What has always amazed me about the shuttle program is how such a huge failure could be spun into a success. The shuttle met none of its performance goals and kept us from going beyond low Earth orbit for 30+ years. The one proposed version of the shuttle that would have fixed that, shuttle-c, was never accepted by NASA who had fully invested themselves into the story that we've been to the Moon and there's nothing of value there (how convenient). On the down side, the Chinese no longer believe that crap, but we still have no lauch system that will get us back to the Moon.

In the DoD world contractors had been getting reimbursed for their development costs since the C-5 program in the late '60s and it became common place throughout the '70s and '80s. It was not until late 1993 or early 1994 that DoD contracts paid profit on development, which coincided with Ben Rich's retirement from the Skunk Works in December of 1990.

 

Big Pharma

A similar thing happened in drug research. It used to be coming out of universities and then they privatized it. Now we have "research" for the drugs with the most profit potential instead of the most societal benefit. Notice that? We get things like Viagra and "toenail fungus" now, instead of vaccines for the worst diseases.

 

Speaking of "Big Pharma"...

 I stumbled upon this site, "CoreAdvisor", which is related to this site "Corrystone Global Partners" - for which both sites appear to be run by an indian organization. "CoreAdvisor" appears to have a lot of re-print/re-posts of articles, from other sources (i.e. economictimes) dealing with indian offshoring deals.... For which I found the following 2 Pharma articles....

1) Indian pharma and the race for global offshoring

2) Big Pharma Moving More Work Offshore

 

 Oh hey, while I was on the "CoreAdvisor" site, I found articles about Walmart, Target, and BJ Wholesale Club's involvement with offhsoring and/ or engaging indian consulting companies. They also have a lot of other articles about india's ambitions and how well they are doing (head count and earnings numbers) while U.S. corporations continue to fund their campaign by sending our jobs overseas to india.

 

nice finds

Yeah, and right now Obama is proclaiming offshore outsourcing doesn't hurt U.S. workers or the economy.

I believe in 2006 was the mass exodus on drug companies, manufacturing and advanced R&D. Be nice to find all of those displaced PhDs and chemical engineers to join in the fight for U.S. jobs.

 

Very interesting take on

Very interesting take on this. I have not heard of this before.

 

Not Illegal, Undesirable

It is unfortunate that so many organizations dedicated to stopping waste, fraud, and abuse remain convinced what is wrong with the defense industry involves illegal activity. While they waste their time looking for the illegal fraud that does exist to some limited extent, they miss the vast majority of the waste by not looking at how the legal procurement system works and has been manipulated through legal means by lobbyists and campaign donations. This is a case where there is no smoking gun held by a nefarious character who has done this to us. Instead it has been a group of people working to further their own self interests that have caused such damage to how our weapons are developed and procured. Generally I think these people have done this while convinced they were also doing what was best for their country, though their morals have been very short sighted.

 

Where Have All Our Aerospace Jobs Gone?

"Every generation has its own milestone," Zhang Yanzhong, the aircraft's chief engineer, told state media last year. "We've already accomplished [nuclear weapons and satellites], the Three Gorges Dam and manned space exploration. Now the big-jet project is the next milestone."

The aircraft's builders are so confident, the first "9" in the jetliner's name was picked because it sounds like "forever" in Chinese.

China is already a major assembler and parts supplier for some of the world's best-known aircraft. Airbus' A320s reach their final assembly in the northern port city of Tianjin. Half of Boeing's fleet of 12,000 airplanes includes components made in China. About 600,000 Chinese workers are employed in aerospace, about as many as in the United States. -- LA Times

Our government spends twice as much on defense as the rest of the world combined, has hiked the amout the DoD spends on contractors by a factor of 2 in the last decade, meanwhile hiring of Americans in the defense sector is at an all time low. Clearly many of our defense sector dollars and jobs are finding their way to China. If Americans are so stupid they think we can remain a free nation while outsourcing our most stratigically critical jobs to Communist China, then perhaps they are too stupid to be saved from themselves.

 

The Case For Reform

This letter released as a blog post from CounterPunch.org makes an excellect case for the need for defense reform:

[O]ver the last decade, the Navy budget received $293 billion more than the baseline of spending in 2000 anticipated (adjusted for inflation). Seen another way, the 2011 Navy's "base" budget, which does not include spending for the wars in Iraq and Afghanistan, is 44 percent higher than it was in 2000. Yet the size of the Navy's combat fleet went down in this period, from 318 ships and submarines to 287 - a decline of 10 percent. This is not a smaller, newer fleet; it is a smaller, older fleet - about four years older, on average, according to the Congressional Budget Office (CBO). It is also less ready to fight: for the past year the press has repeatedly reported on severe maintenance problems throughout the fleet, and Navy combat pilot training in the air has remained at historic lows.

The situation in the Air Force is worse. It received $320 billion more than the base budget levels anticipated in 2000 and increased by 2011 by 43 percent. During the same 2000-2011 period, the number of active and reserve fighter and bomber squadrons went from 146 to 72, a decline of 51 percent. According to CBO, our combat air fleet is now about nine years older than in 2000 - an historic high average age of about 23 years. Fighter pilot in-air training hours today are one-half to one-third of what they were in the 1970s, an era not noted for high readiness.

The Army received a $297 billion budget plus-up, a 53 percent increase. In this case, the combat forces did increase; the number of brigade combat teams grew from 44 to 46, an increase of 5 percent. A 53 percent budget increase bought a 5 percent increase in combat forces. But CBO tells us that major Army equipment inventories are mostly older, and in 2006, the House Armed Services Committee held hearings and leaked a memo documenting historic lows in the readiness of active Army units. The analysis has not been publicly updated, but we should worry that it has gotten worse.

There is no mystery why the increased spending has led to shrinking, aging hardware inventories. New weapons systems cost three to ten times more to buy and operate than the weapons they are replacing. Even if their budgets could grow steadily at five percent per year (over and above inflation), the cost explosion in new weapons dooms the military services to being unable to buy as many weapons as they had - hence the shrinking hardware inventories. Because they can buy so few new planes, tanks or ships, they extend the life of the old ones - hence the aging.

At $707 billion, the defense budget is today higher in than it has ever been since the end of World War II, even when the effects of 65 years of inflation are removed. This spending level is unrelated to the military threat. During the Cold War, from 1948 to 1990, when we faced the sizeable forces of the Soviet Union and the Warsaw Pact, annual Pentagon spending averaged $440 billion in inflation-adjusted dollars, (and that includes the effects of the Korean and Vietnam wars). Today, big spending advocates point to China, with a defense budget variously estimated at from $80 to $180 billion per year, as the future threat we must prepare against. But, if we add the highest available defense budget estimates for China, Russia, Iran, North Korea, and Cuba and then double that sum, the Pentagon still spends more. As to the threat of terrorism, we almost certainly spend more in one day than al Qaeda, the Taliban and all their affiliates spend in an entire year.

Despite Secretary of Defense Robert Gates' efforts to cancel or redo several weapon programs that were over cost and under-performing, the number of major defense acquisition programs has changed from 91 programs costing $1.6 trillion to 87 programs costing $1.6 trillion. As you know, Secretary Gates has also imposed a plan on the DOD bureaucracy to transfer internally $102 billion dollars over 5 years, but there is no net savings to help the deficit.

Instead, Secretary Gates wants the DOD budget to grow one percent per year plus inflation for the next 10 years. That would increase the base DOD budget from $554 in 2010 to $735 billion in 2020 - a 33 percent increase, not including any spending for the wars against terrorism. While the Co-Chairs' Proposal seeks a number of terminations, reductions, and efficiencies beyond the Gates' plan (many of them welcome and overdue, but some that we believe require major modification), both the Co-Chairs Proposal and the Gates' plan project into the future a defense program that is essentially the same as that we have today, simply at different spending levels. Under either plan, the size and modernity of our forces will continue to shrink and age, even if all remaining programs are implemented without any cost increases or schedule delays.

We believe there is a path that meets the goals of deficit reduction and strengthens real national defense. That path needs to start with the acknowledgement of a need for fundamental reform. -- Counter Punch

Unfortunately their recommendations regarding what to do to reform defense fall flat. The authors of this letter seem to believe that an application of tighter accounting standards would pencil whip our problems away. While I have no doubt that better accounting standards would be helpful, they won't fix the root of our current problems, which is the payment of profit on the design and development of weapons. That is both the cause of why programs drag on and typically go up in cost to the tune of single or double digit multiples of their quoted development costs. Many times the increase in development costs are masked by a huge reduction in weapons bought. Which do you think will keep you safer, a paper design or an actual weapon?

On the up side, though, this letter also supports some of what I was saying regarding the power wielded even by some of our retired weapons designers. You'll notice this name in the signature block:

Pierre M. Sprey
a key designer of the F-16 & A-10
defense career started: 1956
pierre[at]mapleshaderecords[dot]com

Imagine if Kelly Johnson or Werner Von Braun were to weigh in on the fiasco we call our defense procurement system today? Congress would have no choice but to do something. The problem has been, every time they've done "something" in the past, they've only made things worse, not better. It is clearly time to undo some of what they've done, before it is too late.

 
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