14 Weapon Systems Critical Cost Growth, Army Needs Action on CROWS Software Update
Summary
GAO identified 14 Department of Defense weapon systems with critical operating and support (O&S) cost growth in fiscal years 2023 and 2024 sustainment reviews, representing at least 25 percent increases above independent cost estimates or 50 percent above original baselines. GAO's final report under the NDAA for FY 2021 statutory requirement found the Army has not completed a software update for the Common Remotely Operated Weapons Station (CROWS), a top maintenance issue affecting combat vehicles. GAO estimates completing the CROWS software update could save over $130 million over the program's remaining approximately 30 years of life.
“Doing so would yield cost savings that GAO estimates would be more than $130 million over the program's remaining approximately 30 years of life.”
Government contractors supporting Army weapon system sustainment should review their programs for identified cost-growth drivers and any remediation plans with unimplemented actions. The $130M savings opportunity from a single software update illustrates how delayed maintenance actions can compound into significant life-cycle cost overruns. Contractors should proactively flag similar delayed actions to program offices before they escalate to GAO-level findings.
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What changed
GAO's final report under the National Defense Authorization Act for FY 2021 statutory requirement evaluated DOD's weapon system sustainment reviews for fiscal years 2023 and 2024, identifying 14 systems with critical O&S cost growth representing significant increases above cost estimates. The report makes one recommendation to the Army to implement the CROWS software update identified in its own remediation plan on a timely basis.\n\nDefense contractors and program managers should note that O&S costs comprise approximately 70 percent of a system's total life-cycle cost, making sustainment a major driver of long-term defense spending. The failure to complete a relatively straightforward software update represents a missed opportunity for both operational effectiveness and cost savings of over $130 million. Program offices managing Army weapon systems should review their own remediation plans and ensure identified cost-saving actions are being executed.
Archived snapshot
Apr 23, 2026GovPing captured this document from the original source. If the source has since changed or been removed, this is the text as it existed at that time.
GAO-26-108140 Published: Apr 23, 2026. Publicly Released: Apr 23, 2026.
Fast Facts
The Department of Defense spends billions of dollars annually to operate and sustain its aircraft, ships, and combat vehicles. And sustaining these weapon systems over their lifetime is costly.
We looked at DOD's sustainment reviews and related cost estimates. While DOD has taken action to address some critical cost increases, more could be done. For example, the Army hasn't completed a software update for all units of a weapon system mounted on combat vehicles. Updating the software on all of the units could save over $130 million and ensure they operate effectively over the next 30 years.
Our recommendation addresses this issue.
The Army's Common Remotely Operated Weapons Station Needs Software Updates
A person looking into a military machine that has a gun on top and a few different sized lenses.
Highlights
What GAO Found
Operating and support (O&S) costs are comprised of costs for repair parts, maintenance activities, contract services, and personnel. The Department of Defense (DOD) identified 14 systems with critical O&S cost growth out of 36 weapon system sustainment reviews it conducted for fiscal years 2023 and 2024. This critical O&S cost growth represents at least a 25 percent increase in the cost estimate for the remainder of a system’s life cycle compared with its most recent independent cost estimate, or at least a 50 percent increase compared with the original baseline cost estimate. GAO identified common causes DOD reported for the critical O&S cost growth for the 14 systems, such as extensions to operational life.
Weapon System Sustainment Reviews with Reported Critical Operating and Support Cost Growth and Causes, Fiscal Years 2023 and 20224
Note: Weapon systems experienced critical O&S cost growth in either Category A (growth is at least 25 percent more than the estimate documented in the most recent independent cost estimate for the system) or Category B (growth is at least 50 percent more than the original baseline cost estimate for the system).
DOD has taken some actions to address critical O&S cost growth identified in fiscal year 2021 and fiscal year 2022. However, GAO found the Army has not fully completed a software update that it reported would remediate a top maintenance issue for its Common Remotely Operated Weapons Station (CROWS). Doing so would yield cost savings that GAO estimates would be more than $130 million over the program’s remaining approximately 30 years of life. Without ensuring that its units implement the software update identified in the CROWS remediation plan on a timely basis, the Army is missing an opportunity to address a top maintenance issue affecting this weapon system and to achieve a cost savings of more than $130 million over the remaining life of the program.
DOD identified challenges in conducting sustainment reviews and determining O&S cost growth. GAO found that DOD has taken steps to address challenges, such as revising guidance to correct cost estimating data deficiencies.
Why GAO Did This Study
DOD spends tens of billions of dollars to sustain its weapon systems. O&S costs are about 70 percent of a system’s total life-cycle cost. In response to a statutory provision, DOD has been required to annually submit sustainment reviews that include O&S cost estimates and the reasons for any critical cost growth, although the National Defense Authorization Act for Fiscal Year 2026 eliminated the requirement for DOD to include the O&S cost growth information in its sustainment reports.
The National Defense Authorization Act for Fiscal Year 2021 included a provision for GAO to review DOD’s annual sustainment reviews and O&S cost estimates through 2025. This report, the final one to be submitted under this statutory requirement, evaluates the extent to which DOD (1) identified critical O&S cost growth in its fiscal years 2023 and 2024 weapon system sustainment reviews and the causes of that growth, (2) has taken actions to address the critical O&S cost growth identified in the fiscal years 2021 and 2022 sustainment reviews, and (3) has taken steps to identify challenges and improve the sustainment review process.
GAO analyzed DOD guidance and weapon system sustainment reviews DOD conducted in fiscal years 2023 and 2024 and cost savings initiatives identified in the fiscal years 2021 and 2022 reviews and interviewed DOD officials who conducted the reviews.
Recommendations
GAO is making one recommendation to the Army to ensure that its units implement the software update identified in the Common Remotely Operated Weapons Station remediation plan on a timely basis. DOD agreed with the recommendation.
Recommendations for Executive Action
| Agency Affected | Recommendation | Status |
|---|---|---|
| Department of the Army | The Secretary of the Army, in coordination with the Chief of Staff of the Army, should ensure that the Army's units implement the software update identified in the CROWS remediation plan on a timely basis. (Recommendation 1) | Open When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information. |
Full Report
GAO Contacts
Diana Maurer Director Defense Capabilities and Management maurerd@gao.gov
Media Inquiries
Sarah Kaczmarek Managing Director Office of Public Affairs media@gao.gov
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Topics
National Defense Military forces Weapon systems Cost estimates Operating and support costs Software Military departments Cost savings Systems acquisition Remediation Military readiness
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Completing Software Update on CROWS Could Save Taxpayers $130 Million
Thursday, April 23, 2026
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