GAO: Coast Guard should gain key knowledge before buying more ships

The United States Coast Guard urgently needs Offshore Patrol Cutters (OPC) to replace aging cutters that conduct law enforcement and search and rescue operations. The Coast Guard plans to acquire 25 OPCs in stages: stage 1 initially included OPCs 1-4, stage 2 includes OPCs 5-15, and stage 3 will include OPCs 16-25. Construction for stages 1 and 2 is underway by two different shipbuilders. But each shipbuilder’s design remains incomplete, and both have yet to deliver any ships.

The stage 1 shipbuilder made limited progress since GAO last reported on OPC. In 2023, GAO found that construction of OPCs 1-4 began without a stable design, contrary to shipbuilding leading practices. This led to rework, which delayed ship deliveries. The Coast Guard took steps in 2024 to prioritize delivery of OPC 1, such as adding payments at certain milestones, but these steps were largely unsuccessful. As of July 2025, the Coast Guard terminated construction of OPCs 3 and 4 as part of an ongoing review of the current stage 1 contract, and delivery of OPC 1 was expected more than 5 years late.

The stage 2 shipbuilder and Coast Guard incorporated some leading practices while developing the stage 2 design, such as conducting collaborative design reviews that supported timely decisions. But construction of OPC 5 began in August 2024 without a stable design. Starting construction of more stage 2 OPCs before stabilizing the design, as the Coast Guard plans to do, increases the risk that stage 2 will also encounter costly rework and schedule delays.

Read more at Government Accountability Office