Fighter Flaws Warplane Costs Soar amid Mismanagment

Defense contractor EADS appears to have cut corners in its construction of the Eurofighter jet for the German military. The government faces billions in additional costs, but it doesn't want taxpayers to find out until after federal election this fall.

AFP

It's an incident that the German military would rather have kept secret. On July 27, 2007, a Eurofighter was flying at low altitude above the Neuburg Air Base in Upper Bavaria when the pilot suddenly spotted a flock of birds in front of the plane.

His first instinct was to quickly pull his plane, with the registration number 30+39, to the side to avoid hitting the birds. But then, unexpectedly, the aircraft spontaneously rolled to the side by 90 degrees.

Personnel in the control tower panicked as the jet sped towards them. Only at the last second did the pilot manage to regain control of the jet. The investigative report by the military, or Bundeswehr, referred to the incident as a "bank angle overshoot," noting drily that "the unexpected behavior" could have resulted in the "loss of the aircraft." In other words, the jet barely escaped going down in flames.

A software error was to blame, but it wasn't the only problem that would be found in Eurofighter jets. Together with European partners, the company that eventually became defense contractor EADS took 25 years to develop and produce the aircraft. Their aim was to prove that the Americans weren't the only ones capable of building high-tech fighter jets, but what has become Europe's largest defense project was ill-fated from the start.

The mere fact that the aircraft was once known as the "Jäger 90" (Hunter 90) in Germany reveals the extent of the project's failure. After dramatic delays in development, the jet was renamed "Eurofighter," and even today, all 180 jets originally ordered by the Bundeswehr still haven't been delivered.

'Another Debacle' Looms

Now internal documents show that the aircraft's problems are much more serious than previously known. In addition, SPIEGEL calculations indicate that, by the end of this year, the Bundeswehr will already have spent €14.5 billion ($18.6 billion) of the roughly €14.7 billion that the German parliament has approved for the program. But when the money is used up, only 108 of the 143 Eurofighters ordered to date, not to mention the 180 originally planned, will have been delivered. EADS will not continue making the planes for free, though.

Even the Bundeswehr estimates the cost of the program at €16.8 billion by 2018. But that represents only 143 delivered aircraft. The last jets, part of the so-called Tranche 3 B, will cost the government billions more.

It appears that German citizens will not be informed of the true costs of the Eurofighter before the national election on Sept. 22, at least according to the Defense Ministry's plan. The case is now closed and there is "currently no reason" for further discussion of the subject, officials there say.

EADS is also unwilling to make things difficult for the government at the moment, and currently has no plans to submit a new bid. The company has no interest in making even more trouble for Defense Minister Thomas de Maizière, who is already under fire. The opposition, on the other hand, wants clarity. "After the 'Euro Hawk,' this threatens to become yet another defense debacle at the taxpayers' expense," says Rainer Arnold, a defense policy expert with the center-left Social Democratic Party (SPD), in reference to the recent cancellation of the Euro Hawk surveillance drone program, which wasted some €500 million.

One reason behind the skyrocketing costs of the Eurofighter is the apparently unprecedented sloppiness in production. SPIEGEL has obtained documents from the Bundeswehr and EADS that provide an insight into the problems. There was so much mismanagement that, on Oct. 1, 2008, the military did not extend the license to remain a Bundeswehr aviation site for an EADS plant in the Bavarian town of Manching.

Costs Get Out of Hand

What seems like a straightforward administrative procedure may have serious consequences. Even after the loss of the license, aircraft were still put into service, and the Bundeswehr, as the purchaser of the aircraft, reportedly inspected them a little more carefully, only to issue its stamp of approval, after all. This is highly controversial from a legal standpoint. If a Eurofighter were to crash over Germany, courts could reach the conclusion that the planes should never have been allowed to take off in the first place.

The Eurofighter's story is one of broken promises. When the jet's predecessor was conceived in the 1980s, shortly after Helmut Kohl came into office as chancellor, the industry guaranteed that it could build the aircraft at a cost of 65 million deutsche marks apiece. But the costs continually increased after that.

The figure had gone up to 130 million deutsche marks by the early 1990s, and when the Bundestag budget committee finally decided to order the aircraft in 1997, it set a new price ceiling: 180 aircraft were to cost no more than €11.8 billion. The price took into account the fact that the planes had been technically downgraded, an effort by then Defense Minister Volker Rühe to prevent the price from continuing to rise.

But it didn't do any good. In 2004, the price cap on the total order was increased by another €250 million. By then, Chancellor Gerhard Schröder was in office. In the current draft budget for 2013, the costs are estimated at close to €17 billion.

But this is still an estimate based on the most favorable assumptions, which will not be sufficient, as Chancellor Angela Merkel knows all too well. That's because the last 37 aircraft the Bundestag will receive are among those with the most complex technology. They are jets with "multiple banking capability," which can both engage in air strikes and intercept enemy aircraft.

This version of the Eurofighter will also be the most expensive, which means that the Bundeswehr faces a dilemma. On the one hand, its budget is almost exhausted. On the other hand, it is determined not to do without the most state-of-the-art version of the Eurofighter. The Defense Ministry is now officially saying that a decision on the purchase of the tranche hasn't been reached yet. "We are currently reviewing the next steps," the ministry writes in a statement. But it was only at the end of June that the deputy department head in charge of procurement at the ministry presented puzzled industry executives with an old, new number: 180.

Who Is to Blame?

There is a plan to sell the aircraft that were initially delivered to the German air force, which would generate several hundred million euros in revenue. But the jets are now outdated, and NATO partners are only marginally interested.

Behind the scenes, finger-pointing has already begun over who is to blame for the upcoming debacle. Officials at EADS say costs increased because the German Air Force was constantly adding new, special requests. The defense minister denies all responsibility and blames the cost increase on inflation.

But both sides are trying to conceal the fact that there could be a very simple reason for the explosion in the cost of the Eurofighter -- sloppy production, for which both EADS and the Bundeswehr were responsible. While EADS was long unable to come to grips with problems at the Manching plant, the Bundeswehr tolerated the lax production standards for too long.

The Federal Office for Arms Technology and Procurement in the western city of Koblenz is in charge of supervising EADS. The Bundeswehr's largest agency, with some 9,600 employees, it maintains field offices at the major production plants of German defense contractors, including the Manching EADS plant.

Soon after the first Eurofighters left the plant, officials there encountered problems. On Aug. 23, 2004, they noted that the plant lacked specially trained employees to supervise each individual step in the production of the highly complex aircraft. Without functioning quality management, the plant's license as a recognized aviation operation for the Bundeswehr is no longer valid. At the time, inspectors threatened to extend the license only if a long list of deficiencies were corrected.

Despite the warnings, little happened. On March 31, 2006, a Eurofighter with the registration number 98+03 took off on a flight bound for Jever Air Base in northern Germany. What the pilot didn't know was that the bolt holding the nose landing gear in its bracket was not properly secured, causing it to loosen during the flight. When the unsuspecting pilot landed, the landing gear was already hanging at an angle underneath the jet. He was lucky the landing gear didn't collapse.

According to an insider, EADS did not report the incident at first. But the Air Force's flight supervision office was notified, and the entire Eurofighter fleet was grounded immediately. The cause of the problem was quickly determined: the bolt had been improperly installed. EADS was compelled to analyze the entire production process.

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jo6pac 07/11/2013
1. Wow
I'm sorry to see that you've sunken down to Amerikas level how sad for both of us. f-35 and f-22 over budget over weigh and doesn't like to fly in bad weather or at night. Oh just get another round of tax payers money and everything will be all right.
spon-facebook-10000061525 07/12/2013
2. optional
Given the high failure rate, of high tech military projects, I would say that the Eurofighter is a succes story. Looking at American scrapped projects, the list is very long, still they continue to pump tens of billions into military innovation. Not to mention the multitrilion dollar nuclear weapon programs of the USA or their 600 billion per year military budget, Eurofighter looks like the pin in the haystack. But for the budget conscious countries of Europe the Eurofighter is indeed, expensive
dorapilot 07/16/2013
3. Eurofighter
Der Spiegel is used to offer false "scoop" like this one. Maybe such type of articles should be written by someone more focused on defense issues. First of all, Der Spiegel should know that the Eurofighter is the most safer combat aircrfat in the history of aviation! Just one fata accident for a total of over 180.000 flying hours! Just for you to know that the average for an F-16 is around one each 15.000 Flying hours! The stories used in the article are four to seven years old and reflect in no way the current status of Eurofighter program in Germany. EADS has delivered the Eurofighter, both technically and economically, in accordance with the contract to Germany and the other Eurofighter nations, as normally happen. No Air Force accept aircrfat with flaws or technical problems. The costs of the Eurofighter are within the frame agreed with the customer. Thus the Eurofighter customer nations receive the most modern combat aircraft in the world. The performance of the Eurofighter is consistently confirmed by the pilots of the customer nations and was impressively demonstrated in international operations and comparative tests. There are no quality issues with the delivered Eurofighter. Cassidian and the National Quality Assurance Office (Güteprüfstelle der Bundeswehr) test all Eurofighter as prescribed, before they are delivered to the Air Force. Eurofighter is by far the safest combat aircraft available on the market, relating to the number of flight hours without aircraft accidents. Eurofighter has proven itself in more than 186,000 flight hours to be a reliable and combat proven aircraft. The "technical problems" written in articles are things absolutely normal in any high performance combat aircrfat, with the difference that in any "normal" combat aircrfat this led to accidents, with the Eurofighter the intrinsic safety of the aircrfat allow it to go back home in total safety. Maybe the Germand should remember how many F-104 Starfighters they have lost in the '60s and '70s just to mention an aircraft, American, that had serious technical problems.
waltertchilds 12/31/2013
4. Eurofighter
Sounds like you euros don't like to hear the truth about your fighter.
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