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June 12, 2025


DOD Cost Overruns and The Nunn-McCurdy Act


Since the U.S. Department of Defense's (DOD)
establishment, Congress has expressed interest in ensuring
that DOD procures major weapons systems efficiently,
including that a program maintain the same projected costs
throughout its lifecycle. DOD requested a total of $168
billion for defense-wide procurement for fiscal year (FY)
2025. Controlling DOD procurement costs has typically
challenged DOD, which periodically has cost overruns,
or instances when a program surpasses its initial cost
estimate.

Congressional efforts to maintain DOD program costs have
included defining programs in statute and creating reporting
requirements, including Selected Acquisition Reports
(SARs), in statute. SARs require DOD to notify Congress
about changes to baseline cost estimates of major defense
acquisition programs (MDAPs) and potential risk factors
and requirements originally outlined in the 1982 Nunn-
McCurdy  Act. The Nunn-McCurdy   Act (10 U.S.C. §§4371-
4377) requires DOD to report to Congress if an MDAP
experiences a cost overrun that exceeds certain thresholds.
Depending  on the size of the program and extent of the cost
overrun, DOD  is legally required to take certain actions and
report its findings to Congress.

DOD Acquisition Categories
The level of management and congressional oversight of an
acquisition program generally corresponds with the cost
and technical complexity of the program. All DOD
acquisition programs are designated by an acquisition
category (ACAT). The category is primarily based on the
program's total cost.

ACAT   I refers to the largest acquisition programs in terms
of dollar amounts, and are also known as MDAPs. An
MDAP   is defined in statute as any program that is (1) not a
highly sensitive classified program, and (2) so designated
by the Secretary of Defense, or (3) has an eventual total
expenditure for procurement of more than $1.8 billion or,
for research and development (R&D), of more than $300
million (both in FY1990 constant dollars). According to
DOD   estimates, these dollar amounts are adjusted to $3.065
billion for procurement and $525 million for R&D in
FY2020  constant dollars. ACAT I programs are also further
divided into sub-categories depending on their level of
decision authority, or which DOD office is designated to
determine whether or not the program should advance
throughout DOD's  acquisition process milestones.

ACAT   I programs have three major milestones,
(Milestones, A, B, and C) requiring milestone decision
authority (MDA) approval. For the highest cost or most
technically complex ACAT  I programs, the Undersecretary
of Defense for Acquisition and Sustainment (USD(A&S))
is typically the MDA, the DOD entity responsible for


certifying and approving a program's procession through
the different formal stages of acquisition.

Although there are three other acquisition program
categories, only ACAT I/MDAP  programs are subject to
the statutory reporting and oversight requirements of Nunn-
McCurdy,  including reporting requirements concerning the
program's cost, and procedures DOD must follow should
an MDAP's  eventual cost exceed by a certain percentage its
original estimated cost.

Selected Acquisition Reports (SARs)
Selected Acquisition Reports (SARs) consist of information
detailing an MDAP's cost, schedule, and performance. Per
Title 10, SARS must be provided to Congress either
annually (within 30 days after the President's budget is
transmitted to Congress) or quarterly (within 45 days after
the end of the fiscal year quarter). Quarterly SARs are
required if DOD finds that the program had a 15% or more
cost increase and/or a six-month or more delay of one of the
major program milestones in the last quarter.

Title 10 also requires that DOD establish a program's
baseline description, including a program's baseline
estimate, or a description of the program that must be
prepared early in the program's acquisition lifecycle.
Should the program experience a cost overrun, the baseline
description is to be used as a point of reference concerning
DOD's  original intentions for the program. Baseline
descriptions may be revised or adjusted, including in the
event of a cost breach, but DOD is to report such an update
in the program's next SAR.

The   Nunn-McCurdy Act
The Nunn-McCurdy   Act requires that DOD report to
Congress if an MDAP  experiences a cost overrun that
exceeds certain tiers of percentages. Depending on the
threshold, DOD must take certain actions and report its
findings to Congress.

Two  major types of cost growth threshold breaches (also
called a Nunn-McCurdy breach or a Nunn-McCurdy,
after the sponsors of the original legislation, in the DOD
acquisition community) exist:

    1)  Significant breach. A significant breach occurs
        when  a program's cost increases either 15% from
        its current baseline estimate, or 30% from its
        original baseline estimate; and

    2)  Critical breach. A critical breach occurs when a
        program's cost increases either 25% from its
        current baseline estimate or 50% from its original
        baseline estimate.


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