PDF DoD Manufacturing Readiness Levels (MRLs)
MRL Matrix Version 7.1 May 2009
Technology & Industrial Base
Version 7.1
May 2009
Acq Phase
Thread
Sub-Thread
Pre MSA MRL 1
Technology Maturity
Technology Transition to Production
Should be assessed at TRL 1.
Pre MSA MRL 2
Pre MSA MRL 3
DoD Manufacturing Readiness Levels (MRLs)
MSA - MS A
TD
TD MS B
MRL 4
MRL 5
MRL 6
EMD MRL 7
EMD MS C MRL 8
LRIP - FRP MRL 9
FRP MRL 10
Should be assessed at TRL 2. Should be assessed at TRL 3. Should be assessed at TRL 4. Should be assessed at TRL 5. Should be assessed at TRL 6. Should be assessed at TRL 7 Should be assessed at TRL 7. Should be assessed at TRL 8. Should be assessed at TRL 9.
Potential sources identified for technology needs. (Understand state of the art).
Industrial Base capabilities and Industrial Base assessed to
gaps/risks identified for key
identify potential manufacturing
technologies, components, and/or sources.
key processes.
Industrial Capability Assessment (ICA) for MS B has been completed. Industrial capability in place to support mfg of development articles. Plans to minimize sole/foreign sources complete. Need for sole/foreign sources justified. Potential alternative sources identified.
Industrial capability to support Industrial Capability Assessment Industrial capability is in place to
production has been analyzed. (ICA) for MS C has been
support start of FRP.
Sole/foreign sources stability is completed. Industrial capability is
assessed/monitored. Developing in place to support LRIP.
potential alternate sources as Sources are available, multi-
necessary.
sourcing where cost-effective or
necessary to mitigate risk.
Industrial capability supports FRP. Industrial capability assessed to support mods, upgrades, surge and other potential manufacturing requirements.
Manufacturing Technology Development
Producibility Program
New manufacturing concepts and Manufacturing technology
potential solutions identified.
concepts identified through
experiments / models.
Relevant materials/processes evaluated for manufacturability using experimental results.
Mfg science & advanced mfg technology requirements identified.
Producibility & Manufacturability assessment of design concepts completed. Results guide selection of design concepts and key components/technologies for Technology Development Strategy. Required Test Evaluation Strategy (TES) includes Design for Test during production.
Required manufacturing
Manufacturing technology efforts
technology development efforts continuing. Required
initiated.
manufacturing technology
development solutions
demonstrated in a production
relevant environment.
Producibility & Manufacturability Producibility assessments of key
assessments of key technologies technologies/components and
and components initiated.
producibility trade studies
Systems Engineering Plan (SEP) (performance vs. producibility)
requires validation of design
completed. Results used to
choices against manufacturing shape System Development
process and industrial base
Strategy and plans for SDD or
capability constraints.
technology insertion programs
Manufacturing processes
phase.
assessed for capability to test and
verify in production, and influence
on Operations & Support (O&S).
Manufacturing technology efforts Manufacturing technology efforts Manufacturing technology efforts Manufacturing technology efforts
continuing. Required
continuing. Required
continuing. Manufacturing
continuing. Manufacturing
manufacturing technology
manufacturing technology
technology process improvement technology continuous process
development solutions
solutions validated on a pilot line. efforts initiated for FRP.
improvements ongoing.
demonstrated in a production
representative environment.
Detailed producibility trade
Producibility improvements
Prior producibility improvements On-going producibility
studies using knowledge of key implemented on system. Known analyzed for effectiveness during improvements analyzed for
design characteristics and related producibility issues have been LRIP. Producibility issues/risks effectiveness. Producibility
manufacturing process capability resolved and pose no significant discovered in LRIP have been refinements continue. All mods,
completed. Producibility
risk for LRIP.
mitigated and pose no significant upgrades, Diminishing Mfg
enhancement efforts (e.g. Design
risk for FRP.
Sources & Material Shortages
For Mfg Assembly) initiated.
(DMSMS) and other changes
assessed for producibility.
Design
Design Maturity
Manufacturing opportunities identified.
Applications defined. Broad
Top level performance
Initial Systems Engineering Plan Identification of enabling/critical
performance goals identified that requirements defined. Trade-offs and Test and Evaluation Strategy technologies and components is
may drive manufacturing options. in design options assessed based recognize the need for the
complete and includes the
on experiments. Product lifecycle establishment/validation of
product lifecycle. Evaluation of
and technical requirements
manufacturing capability and
design Key Characteristics (KC)
evaluated.
management of manufacturing initiated.
risk for the product lifecycle.
Initial Key Performance
Parameters (KPPs) identified.
Basic system design requirements defined. All enabling/critical technologies/components have been tested and validated. Product data required for prototype manufacturing released. A preliminary performance as well as focused logistics specification is in place. Key Characteristics and tolerances have been established.
Product requirements and
Detailed design of product
features are well enough defined features and interfaces is
to support detailed systems
complete. All product data
design. All product data essential essential for system
for manufacturing of component manufacturing released. Major
design demonstration released. product design features are
Potential KC risk issues have sufficiently stable such that key
been identified and mitigation LRIP manufacturing processes
plan is in place. Design change will be representative of those
traffic may be significant.
used in FRP. Design change
traffic does not significantly
impact LRIP. Key characteristics
are stable and have been
demonstrated in SDD or
technology insertion program.
Major product design features are Product design is stable. Design stable and LRIP produced items changes are few and generally are proven in product testing. limited to those required for Design change traffic is limited to continuous improvement or in minor configuration changes. All reaction to obsolescence. All KCs are controlled in production KCs are controlled to 6-sigma or to 3-sigma or other appropriate other appropriate quality levels. quality levels.
MRL Matrix Version 7.1 May 2009
Version 7.1
May 2009
Acq Phase
Thread
Sub-Thread
Production Cost Knowledge (Cost modeling)
Pre MSA MRL 1
Pre MSA MRL 2
Cost model approach defined.
DoD Manufacturing Readiness Levels (MRLs)
Pre MSA
MSA - MS A
TD
TD MS B
EMD
MRL 3
MRL 4
Technology cost models
Detailed process chart cost
developed for new process steps models driven by key
and materials based on
characteristics and process
experiments.
variables. Manufacturing,
material and specialized reqt.
cost drivers identified.
MRL 5
MRL 6
MRL 7
Detailed end-to-end value stream Cost model inputs include design Cost models updated with
map cost model for major system requirements, material
detailed designs and features,
components includes materials, specifications, tolerances,
collected quality data, plant
labor, equipment, tooling/STE, integrated master schedule,
layouts and designs, and
setup, yield/scrap/rework, Work results of system/subsystem
obsolescence solutions.
In Progress (WIP), and
simulations and production
capability/capacity constraints. relevant demonstrations.
Component simulations drive cost
models.
EMD MS C
LRIP - FRP
FRP
MRL 8
MRL 9
Engineering cost model driven by Actual cost model developed for detailed design and validated with FRP environment. Variability data from relevant environment. experiments conducted to show
FRP impact and potential for continuous improvement.
MRL 10
Cost model validated against actual FRP cost.
Cost & Funding
Cost Analysis
Manufacturing Investment Budget
Maturity Availability
Any manufacturing cost implications identified.
Potential investments identified.
Material properties identified for exploration.
Cost elements identified.
Program/ projects have budget estimates for reaching MRL 3 through experiment.
Material properties and characteristics predicted.
Material availability assessed
Sensitivity analysis conducted to Material, manufacturing, and
Current state analysis of cost of Cost analysis of mfg future
Costs rolled up to system level Cost analysis of proposed
LRIP cost goals met and learning FRP cost goals met. Cost
define cost drivers and production specialized reqt. costs identified design choices, make/buy,
states, design trades, supply
and tracked against targets.
changes to requirements or
curve validated.
reduction initiatives ongoing.
development strategy (i.e. lab to for design concepts. Producibility capacity, process capability,
chain/yield/rate/SDD/technology Detailed trade studies and
configuration.
pilot to factory).
cost risks assessed.
sources, quality, key
insertion plans. Allocate cost engineering change requests
characteristics, yield/rate, and targets. Cost reduction and
supported by cost estimates.
variability.
avoidance contract incentives Cost reduction efforts underway
identified.
and incentives in place.
Program/ projects have budget Manufacturing technology
Program has budget estimate for Program has budget estimate for Program has budget estimate for Program has budget estimate for Program has budget estimate for Production budgets sufficient for
estimates for reaching MRL 4. initiatives identified to reduce reaching MRL 6 by MS B.
reaching MRL 7 by Critical Design reaching MRL 8 by MS C.
reaching MRL 9 by the FRP
lean implementation during FRP. production at required rates and
costs. Program has budget
Estimate includes capital
Review (CDR). All Risk Mitigation Estimate includes investment for decision point. Estimate includes All Risk Mitigation Plans required schedule.
estimate for reaching MRL 5. All investment for production-
Plans required to raise deficient Low Rate Initial Production. All investment for Full Rate
to improve deficient subsystems
Risk Mitigation Plans required to representative equipment. All elements to MRL 6 are fully
Risk Mitigation Plans required to Production. All Risk Mitigation to MRL 9 during FRP are fully
raise deficient elements to MRL 4 Risk Mitigation Plans required to funded.
raise deficient sub systems to Plans required to raise deficient funded.
are fully funded.
raise deficient elements to MRL 5
MRL 7 are fully funded.
sub systems to MRL 8 are fully
are fully funded.
funded.
Material properties validated and Survey completed to determine if Materials have been
Material maturity verified through Materials maturity sufficient for Materials proven and validated on Material is proven and controlled Material is proven and controlled
assessed for basic
materials have been used before manufactured or produced in a technology demonstration
pilot line build. Material
System Demonstration and
to specification in LRIP.
to specification in FRP.
manufacturability using
in a manufacturing environment. prototype environment. Maturity articles. Preliminary material specifications approved.
Development (SDD) production
experiments.
Preliminary plans in place to
efforts in place to address new specifications in place.
as adequate to support LRIP.
address producibility risks of new material production risks for
Material specification stable.
material.
technology demonstration.
Material scale-up issues identified.
Lead times have been identified for all materials. All exotic (difficult to obtain, process, or hazardous) materials identified.
Availability issues addressed for Availability issues addressed to Availability issues addressed to
prototype build. Significant
meet technology demonstration meet SDD builds. Long lead
material risks identified for all articles. SDD long lead time items procurement identified/planned
materials. Planning has begun to identified. Obsolescence issues for Low Rate Initial Production.
address scale-up issues.
identified.
Obsolescence plan in place.
Long lead procurement initiated Long lead procurement initiated
for LRIP. Availability issues pose for Full Rate Production (FRP).
no significant risk for LRIP.
Availability issues pose no
significant risk for FRP.
Program is in FRP with no material availability issues.
Supply Chain Management
Special Handling (i.e. shelf life, security, hazardous materials, storage environment, etc.)
Initial evaluation of potential regulatory requirements and special handling concerns.
Initial assessment of potential supply chain capability.
Special Handling procedures applied in the lab. Special handling concerns assessed. Material Safety Data Sheets (MSDS) prepared.
Survey completed for potential supply chain sources.
Supply chain sources identified. Supply chain plans in place (e.g., Effective supply chain
Supply chain stable and
Supply chain is stable and
Sole/single/foreign source
teaming agreements, etc.)
management process in place. adequate to support LRIP.
adequate to support FRP. Long
vendors have been identified and leading to an SDD contract
Completed assessment of supply Completed assessment of supply term agreements in place where
planning has begun to minimize award.
chain first tier.
chain second tier.
practical.
risks.
Supply chain proven and supporting FRP requirements.
Special handling procedures applied. Special handling requirements identified. Material Safety Data Sheets (MSDS) reviewed and updated.
Special handling procedures
Special handling procedures
Special handling procedures
applied. Special handling
applied. Plans to address special applied. Special handling
requirement gaps identified. New handling requirement gaps
procedures developed.
special handling processes
complete.
demonstrated in lab environment.
Special handling procedures applied. Special handling procedures demonstrated on SDD or technology insertion programs production. Special handling issues pose no significant risk for LRIP.
Special handling procedures applied. Special handling procedures demonstrated in LRIP. Special handling issues pose no significant risk for FRP.
Special handling procedures effectively implemented in FRP.
Materials (Raw Materials, Components, Sub-assemblies and Sub-systems)
MRL Matrix Version 7.1 May 2009
Version 7.1
May 2009
Acq Phase
Thread
Sub-Thread
Modeling & Simulation (Product & Process)
Process Capability & Control
Manufacturing Process Maturity
Process Yields and Rates
Quality Management including Supplier Quality.
Quality Management
Mfg Personnel
Facilities
Mfg Management
Mfg Planning & Scheduling
Materials Planning
Tooling / Special Test and Inspection Equipment (STE/SIE)
Pre MSA MRL 1
Pre MSA
MRL 2 Initial models developed, if applicable.
DoD Manufacturing Readiness Levels (MRLs)
Pre MSA
MSA - MS A
TD
TD MS B
MRL 3
MRL 4
MRL 5
MRL 6
Identification of proposed
Production modeling & simulation Initial simulation models (product Initial simulation models
manufacturing concepts or
approaches for process or
or process) developed at the
developed and validated at the
producibility needs based on high- product are identified.
component level and validated. technology, sub-system or
level process flow chart models.
system level.
EMD
EMD MS C
LRIP - FRP
FRP
MRL 7
MRL 8
MRL 9
MRL 10
Simulation models used to
Simulation models verified by Simulation model verified by LRIP Simulation model verified by FRP
determine system constraints and SDD article build. Results used to build and assists in management build. Production simulation
identify improvement
improve process and determine of LRIP. Determine that FRP
models used as tool to assist in
opportunities.
that LRIP requirements can be requirements can be met.
management FRP.
met.
Identification of material and/or process approaches.
Document high level
Complete a survey to determine
manufacturing processes. Critical the current state of critical
manufacturing processes
processes.
identified through
experimentation.
Maturity has been assessed on similar processes in production. Process capability requirements have been identified.
Manufacturing processes demonstrated in production relevant environment.
Manufacturing processes demonstrated in a production representative environment.
Initial estimates of yields and rates based on experiments or state of the art.
Yield and rates assessment on Target yield and rates established Yield and rates evaluated in
Yield and rates estimated in
proposed processes complete for production. Yield and rate production relevant environment. production representative
and applied within the Analysis of issues identified. Improvement Improvement plans on-going and environment.
Alternatives (AoA).
plans developed/initiated.
updated.
Manufacturing processes verified Manufacturing processes &
for LRIP on a pilot line. Process procedures are established and
capability data being collected or controlled in production to 3-
estimated.
sigma or other appropriate
quality level.
Manufacturing processes & procedures are established and controlled in production to 6sigma or other appropriate quality level.
Yield and rates required to begin Yield and rate targets achieved. Yield and rate targets achieved. LRIP verified using SDD articles. Yield improvements on-going. Yield improvements on-going.
Quality strategy identified as part Quality strategy refined in the Initial Quality Plan and Quality
of the Technology Development System Engineering Plan and Management System are in
Strategy.
Key Characteristics are identified place. Quality risks and metrics
during technology
have been identified.
demonstrations.
Quality targets established.
Quality targets demonstrated on
Demonstrate ability to collect and pilot line.
analyze quality data (process and
system) in the production
representative environment.
Quality targets verified on production line. Continuous quality improvement begins.
Quality targets verified on production line. Continuous quality improvement on-going.
New manufacturing skills identified.
Specialized facility requirements/needs identified.
Mfg skill sets identified to overcome production barriers
Skill sets identified to meet prototype production runs. Special skills certification and training requirements quantified
Mfg workforce skills available for production in a relevant environment. Training resources identified for production workforce.
Mfg workforce resource
Mfg workforce resource
LRIP personnel requirements
requirements identified for pilot requirements identified for LRIP. met. FRP personnel
line. Training resources identified Ability of mfg workforce to
requirements identified..
for special skills deficiencies and produce repeatable products and
LEAN 6-sigma training
measure workforce quality.
Training initiated for certification
on special skills
FRP personnel requirements met. Production workforce skill sets maintained due to attrition of workforce.
General industrial base (IB) capability identified for key technologies.
IB capabilities and gaps to
Mfg facility and facility
support SDD and LRIP identified. development plans adequate to
Plan in place to fill gaps.
support SDD or technology
insertion programs.
Facility capabilities for LRIP and Mfg facilities exist and are
Mfg facilities in place and
FRP identified. Plan in place to adequate to begin LRIP. Plans in demonstrated in LRIP. Capacity
fill gaps. Plant layout and design place to support transition to
plans adequate to support FRP
initiated.
FRP.
decision.
Production facilities in place and capacity demonstrated to meet maximum FRP requirements. Executable facilities surge plan available.
Mfg strategy developed and
Mfg strategy refined. Prototype
integrated with acq strategy.
schedule risk mitigation efforts
Prototype schedule risk mitigation initiated.
efforts incorporated into
Technology Development
Strategy (TDS).
Initial mfg approach developed. All system design related mfg events included in Integrated Master Plan/Schedule. Mfg risk mitigation approach for SDD or technology insertion programs defined.
Initial mfg plan developed. Mfg risks integrated into Risk Mitigation Plan.
Mfg plan completed. All key manufacturing risks have been validated & mitigated using SDD or technology insertion program work products.
Mfg plan updated and validated for FRP. All manufacturing risks have been validated and mitigated using LRIP articles.
All manufacturing risks have been validated and mitigated using FRP articles.
Parts list in development with Parts list maturing and make/buy Most material decisions made Analyses for make/buy decisions Make/buy decisions & BOM
associated lead time calculations. evaluations ongoing. Lead times, (make/buy), material risk
& BOM complete. Material
complete to support LRIP.
quality, cost and other risks
identified and plans made to
planning systems in place for pilot Material planning systems
identified.
mitigate. Bill Of Materials (BOM) line build.
validated on pilot line build.
initiated.
Make/buy decisions & BOM complete to support FRP. Material planning systems validated on LRIP build.
Program is in FRP with only process improvement/obsolescence make/buy or BOM changes allowed. Material planning systems validated on FRP build.
Tooling / Special Test Equipment Identify tooling /STE/SIE reqts &
(STE) / Special Inspection
provide supporting rationale and
Equipment (SIE) requirements schedule.
are considered.
Prototype tooling concepts demonstrated in relevant mfg environment.
Production tooling and STE/SIE design and development efforts initiated.
All tooling, test and inspection All tooling, test and inspection Proven tooling, test and
equipment proven on pilot line. equipment proven on LRIP.
inspection equipment in place to
Multiple tooling reqts identified for Multiple tooling reqts identified for support maximum FRP.
LRIP.
FRP.
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