Spare Parts Shortages Adversely Affect Mission Performance, Economy and Efficiency of Operations, and Retention of Military Personnel

The shortages of spare parts for the three aircraft systems we reviewed have not only affected readiness but also have created inefficiencies in maintenance processes and procedures and may adversely affect the retention of military personnel. The number of usable spare F-100-220 engines that the Air Force had on hand fell short of its goal by as few as 6 and as many as 104 engines during the same period. Spare Parts Shortages Contributed to Three Systems’ Failure to Meet Mission Performance Goals

The Air Force did not achieve its mission-capable goals during fiscal years 1996-2000 for any of the three Air Force aircraft systems we reviewed, in part, due to spare parts shortages. The majority of factors were associated with work circumstances such as the lack of parts and materials needed to successfully complete daily job requirements. Contracting Issues

Both the Air Force and the Defense Logistics Agency have encountered a variety of problems in contracting for spare parts needed for repairs. We did not review these plans or the specific initiatives.
What GAO Found

Spare parts shortages on the three Air Force systems GAO reviewed have undermined the performance of assigned missions and the economy and efficiency of maintenance activities. Specifically, the Air Force did not meet its mission-capable goals for the E-3 or C-5 aircrafts during fiscal years 1996-2000, nor did it have enough F-100-220 engines to meet peacetime and wartime goals during that period. These shortages may also affect personnel retention. GAO recently reported that the lack of parts and materials to successfully complete daily job requirements was one of six major factors causing job dissatisfaction among military personnel. Item managers at the maintenance facilities often indicated that spare parts shortages were caused by the inventory management system underestimating the need for spare parts and by delays in the Air Force's repair process as a result of the consolidation of repair facilities. Other reasons included difficulties with producing or repairing parts, reliability of spare parts, and contracting issues. The Air Force and the Defense Logistics Agency have planned or begun many initiatives to alleviate shortages of the spare parts for the three systems GAO reviewed.