PDF DoD Manufacturing Readiness Levels (MRLs)

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´╗┐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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