I\'m strongly considering adding unit testing to an existing project that is in production. It was started 18 months ago before I could really see any benefit of TDD
I suggest reading a brilliant article by a TopTal Engineer, that explains where to start adding tests: it contains a lot of maths, but the basic idea is:
1) Measure your code's Afferent Coupling (CA) (how much a class is used by other classes, meaning breaking it would cause widespread damage)
2) Measure your code's Cyclomatic Complexity (CC) (higher complexity = higher change of breaking)
You need to identify classes with high CA and CC, i.e. have a function f(CA,CC) and the classes with the smallest differences between the two metrics should be given the highest priority for test coverage.
Why? Because a high CA but very low CC classes are very important but unlikely to break. On the other hand, low CA but high CC are likely to break, but will cause less damage. So you want to balance.
It's absolutely worth it. Our app has complex cross-validation rules, and we recently had to make significant changes to the business rules. We ended up with conflicts that prevented the user from saving. I realized it would take forever to sort it out in the applcation (it takes several minutes just to get to the point where the problems were). I'd wanted to introduce automated unit tests and had the framework installed, but I hadn't done anything beyond a couple of dummy tests to make sure things were working. With the new business rules in hand, I started writing tests. The tests quickly identified the conditions that caused the conflicts, and we were able to get the rules clarified.
If you write tests that cover the functionality you're adding or modifying, you'll get an immediate benefit. If you wait for a re-write, you may never have automated tests.
You shouldn't spend a lot of time writing tests for existing things that already work. Most of the time, you don't have a specification for the existing code, so the main thing you're testing is your reverse-engineering ability. On the other hand, if you're going to modify something, you need to cover that functionality with tests so you'll know you made the changes correctly. And of course, for new functionality, write tests that fail, then implement the missing functionality.
Whether it's worth adding unit tests to an app that's in production depends on the cost of maintaining the app. If the app has few bugs and enhancement requests, then maybe it's not worth the effort. OTOH, if the app is buggy or frequently modified then unit tests will be hugely beneficial.
At this point, remember that I'm talking about adding unit tests selectively, not trying to generate a suite of tests similar to those that would exist if you had practiced TDD from the start. Therefore, in response to the second half of your second question: make a point of using TDD on your next project, whether it's a new project or a re-write (apologies, but here is a link to another book that you really should read: Growing Object Oriented Software Guided by Tests)
My answer to your third question is the same as the first: it depends on the context of your project.
Embedded within you post is a further question about ensuring that any retro-fitted testing is done properly. The important thing to ensure is that unit tests really are unit tests, and this (more often than not) means that retrofitting tests requires refactoring existing code to allow decoupling of your layers/components (cf. dependency injection; inversion of control; stubbing; mocking). If you fail to enforce this then your tests become integration tests, which are useful, but less targeted and more brittle than true unit tests.
Update
6 years after the original answer, I have a slightly different take.
I think it makes sense to add unit tests to all new code you write - and then refactor places where you make changes to make them testable.
Writing tests in one go for all your existing code will not help - but not writing tests for new code you write (or areas you modify) also doesn't make sense. Adding tests as you refactor/add things is probably the best way to add tests and make the code more maintainable in an existing project with no tests.
Earlier answer
Im going to raise a few eyebrows here :)
First of all what is your project - if it is a compiler or a language or a framework or anything else that is not going to change functionally for a long time, then I think its absolutely fantastic to add unit tests.
However, if you are working on an application that is probably going to require changes in functionality (because of changing requirements) then there is no point in taking that extra effort.
Why?
Unit tests only cover code tests - whether the code does what it is designed to - it is not a replacement for manual testing which anyways has to be done (to uncover functional bugs, usability issues and all other kinds of issues)
Unit tests cost time! Now where I come from, that's a precious commodity - and business generally picks better functionality over a complete test suite.
If your application is even remotely useful to users, they are going to request changes - so you will have versions that will do things better, faster and probably do new things - there may also be a lot of refactoring as your code grows. Maintaining a full grown unit test suite in a dynamic environment is a headache.
Unit tests are not going to affect the perceived quality of your product - the quality that the user sees. Sure, your methods might work exactly as they did on day 1, the interface between presentation layer and business layer might be pristine - but guess what? The user does not care! Get some real testers to test your application. And more often than not, those methods and interfaces have to change anyways, sooner or later.
What will be more benefical; spending a few weeks adding tests or a few weeks adding functionality? - There are hell lot of things that you can do better than writing tests - Write new functionality, improve performance, improve usability, write better help manuals, resolve pending bugs, etc etc.
Now dont get me wrong - If you are absolutely positive that things are not going to change for next 100 years, go ahead, knock yourself out and write those tests. Automated Tests are a great idea for APIs as well, where you absolutely do not want to break third party code. Everywhere else, its just something that makes me ship later!
If I were in your place, I would probably take an outside-in approach, starting with functional tests that exercise the whole system. I would try to re-document the system's requirements using a BDD specification language like RSpec, and then write tests to verify those requirements by automating the user interface.
Then I would do defect driven development for newly discovered bugs, writing unit tests to reproduce the problems, and work on the bugs until the tests pass.
For new features, I would stick with the outside-in approach: Start with features documented in RSpec and verified by automating the user interface (which will of course fail initially), then add more finely-grained unit tests as the implementation moves along.
I'm no expert on the process, but from what little experience I have I can tell you that BDD via automated UI testing is not easy, but I think it's worth the effort, and probably would yield the most benefit in your case.