PDF Manufacturing Readiness Assessments

Manufacturing Readiness Assessments

-- 15 March 2017 --

Dave Riel

Defense Acquisition University/Midwest Region david.riel@dau.mil (937) 781-1060

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GAO-10-439: DoD Can Achieve Better Outcomes by Standardizing the Way Manufacturing Risks Are Managed

-- April 22, 2010 --

"DOD faces problems in manufacturing weapon systems -- systems cost far more and take much longer to build than estimated. Billions of dollars in cost growth occur as programs transition from development to production, and unit-cost increases are common after production begins. Several factors contribute to these problems including inattention to manufacturing during planning and design, poor supplier management, and a deficit in manufacturing knowledge among the acquisition workforce. Essentially, programs did not identify and resolve manufacturing risks early in development, but carried risks into production where they emerged as significant problems."

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Ike Skelton National Defense Authorization Act for Fiscal Year 2011

SEC. 812. MANAGEMENT OF MANUFACTURING RISK IN MAJOR DEFENSE ACQUISITION PROGRAMS.

(a) GUIDANCE REQUIRED.--Not later than 180 days after the date of the enactment of this Act, the Secretary of Defense shall issue comprehensive guidance on the management of manufacturing risk in major defense acquisition programs.

(b) ELEMENTS.--The guidance issued under subsection (a) shall, at a minimum--

(1) require the use of manufacturing readiness levels as a basis for measuring, assessing, reporting, and communicating manufacturing readiness and risk on major defense acquisition programs throughout the Department of Defense;

(2) provide guidance on the definition of manufacturing readiness levels and how manufacturing readiness levels should be used to assess manufacturing risk and readiness in major defense acquisition programs;

(3) specify manufacturing readiness levels that should be achieved at key milestones and decision points for major defense acquisition programs;

(4) identify tools and models that may be used to assess, manage, and reduce risks that are identified in the course of manufacturing readiness assessments for major defense acquisition programs; and

(5) require appropriate consideration of the manufacturing readiness and manufacturing readiness processes of potential contractors and subcontractors as a part of the source selection."

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Definitions and Policy

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Manufacturability

? The characteristics considered in the design cycle that focus on process capabilities, machine or facility flexibility, and the overall ability to consistently produce at the required level of cost and quality. Associated activities may include some or all of the following:

? Design for commonality and standardization--uses fewer parts ? Design for environmental and safety compliance ? Design for multi-use and dual-use applications ? Design for modularity and plug compatible interface/integration ? Design for flexibility/adaptability or use "robust design" ? Utilize reliable processes and materials ? Utilize monolithic and determinant assembly ? Design for manufacturing and assembly ? Achieve production yield

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Producibility

? The relative ease of producing an item that meets engineering, quality and affordability requirements. Associated activities may include some of the following:

? Design for specific process capability and control parameters ? Perform material characterization analysis ? Perform variable reduction analysis, e.g., Taguchi and design of

experiments ? Develop critical materials and processes before selecting product

design ? Utilize modeling and simulation for product and process design

tradeoffs ? Design and development of closed-loop process control on critical items

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