TABLE 4.1 Summary of Reusable Booster System Cost Estimating Approaches

Cost Category

Cost Model/Method

DDT&E

RBD (Except NK-33 Engine)

NAFCOM

RBS

NAFCOM

AJ-26 Engine Development

Contractor estimate + OGC

LES

NAFCOM

RS-25E Engine Development

N/A—NASA developed

Castor 30 (Mods for Side Mounting)

NAFCOMa

Star 63D (Mods for Side Mounting)

NAFCOMa

ΔDDDT&E (After Flight Test Program)

NAFCOM

Production

RBS

NAFCOM

AJ-26 Engines

Contractor estimate + OGC

LES

NAFCOM

RS-25E Engines

Contractor estimate + OGC

Castor 30

NAFCOM

Star 63D

NAFCOM

Facilities

SLC-2W for RBD (VAFB)

VAFB estimate + OGC

SLC-3E (VAFB)

Facilities modelb

SLC-41 (CCAFS)

Facilities modelb

New Facility (CCAFS)

Facilities modelb

Operations and Sustainment

RBD Flight Test Program

ODMb

RBS Flight Test Program

ODMb

RBS Launch Operations

ODMb

RBS Mission Integration

Based on EELV data

RBS Transportation

Based on EELV data

Range Costs

Based on EELV data

Sustainment

Based on EELV data

a Used first unit production cost as mod estimate

b Aerospace model

NOTE: CCAFS, Cape Canaveral Air Force Station; DDT&E, design, development, test and engineering; EELV, Evolved Expendable Launch Vehicle; NAFCOM, NASA/Air Force Cost Model; ODM, Operations Design Model; OGC, Other Government Costs; VAFB, Vandenberg Air Force Base.

SOURCE: Air Force Space and Missile Systems Center, SMC Developmental Planning, “Reusable Booster System Costing,” presentation to the committee, February 15, 2012. Approved for Public Release.

Other key assumptions in the cost assessment include these:

• A production learning rate of 95 percent for the RBS and large expendable stage (LES) and 98 percent for the solid motors,

• A 10-flight interval between depot maintenance (with engine replacement after every 20 flights), and

• A 5-year overlap of RBS operations with EELVs.

4.2 ASSESSMENT OF BASELINE COST MODELING

To assess the approach used for cost modeling, RBS costs have been divided into four areas: vehicle, engine, facilities, and operations. The cost estimates for each are based on different approaches, as described below. While there is a strong interrelationship among these elements, the linkages are captured only to the degree that



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