MRL_Users_Guide.xls

Instructions

Purpose: The intent for doing the assessment for this particular sub-thread at this point in the life-cycle and the reason for doing the assessment of this particular thread at this point, i.e., what requirements/documents/procedures drive the assessment?

Sources of Information: This is where data can be collected for a particular MRL Assessment at that stage of the product life-cycle.

Questions (also called "criteria"): These are directly derived from the text of the MRL Matrix from the latest revised Version 11.5 of the MRL Questionnaire. Additional Considerations: Sometimes from past experience, services or industry have optional questions they may want to ask for specific threads or sub-threads at specific times in the life-cycle. If so, these will be included in the mega-data sheet. This part of the Users Guide may change significantly over time.

Lessons Learned: These are particular lessons derived from past experience of personnel doing risk assessments in this particular sub-thread at this specific point in the product life-cycle. These may also change as people gain more experience doing assessments of manufacturing risk and readiness.

NOTES: V11.3.13 and following fix bugs occurring when you run this application on MsExcelTM 2013. When you open the MRL Users Guide Worksheet and click on a cell, you may see only the data from that cell displayed with the MRL Matrix blanked out in the background. This mode will enable you to view the entire data sheet and its control buttons. If you wish to view the matrix in the background, uncheck the box at the top of the form that says, "View form as a tabbed page." If you do this, you may have to change your screen resolution to view the entire data sheet with its control buttons. If you wish to copy these instructions, you may find it easier to select each row of the worksheet separately and use the "copy" utility to copy it to an MsWord.doc.

Database

The development of new science and technology through investments in basic and early applied research generate the foundation of new technology that goes into future systems. While efforts are predominantly knowledge-building and early bench testing of science and technology, the technologist working on these efforts needs to apply an understanding of potential warfighter uses of the new technologies with a broad awareness of all facets of development ranging from capability improvement potential to affordability, manufacturability and even operator integration.

Concept exploration and experimentation investigates how new and even past approaches to employing operational methods and tactics can create greater capability with and without employment of technology, both new and existing. Experimentation is used to demonstrate utility success and provide inputs to new capability requirements that form Materiel Capability Decisions leading to new program initiation.

Combined, these two approaches produce the basis for acquisition program initiation. Awareness and consideration of how new technology will be matured, implemented and sustained over a program’s complete lifecycle needs a foundation from infancy to be most successful.

One of the key factors for this early exploration to eventually providing the warfighter a successful capability is to start addressing potential constraints (e.g., cost, performance, manufacturing, etc.) as part of the solution. The S&T and acquisition communities have gated processes as technology matures and moves to higher levels of funding and integration. Developing a solid understanding of these potential constraints is essential to providing the warfighter with capability needed in a timely and cost-effective manner. In order to make sound decisions at each gate, it is imperative that technology developers acquire an understanding of these constraints in parallel with the development of the technology they will deploy.

During the MSA Phase, an assessment of manufacturing readiness is conducted for each competing materiel solution being examined in the AoA with special emphasis on the proposed materiel solution to analyze feasibility from a manufacturing perspective and determine manufacturing resources needed. It is in effect a manufacturing feasibility assessment. Sources of data may include technology and mission area plans and roadmaps, market research, and early evaluations of technology maturity.

Concept development and refinement occur before Milestone A, and further technology development to flesh out the concept occurs before Milestone B. Pre-Milestone A efforts involve translating the needs of the user into clearly stated key performance parameters (KPPs) and evolving the system concept and preliminary concept of operations (CONOPS) that satisfy these needs. Only after Milestone B does a program become an enterprise with dedicated funding behind it.

About three-quarters of the total system life cycle costs are influenced by decisions made before the end of the concept refinement phase at Milestone A, while about three-quarters of life cycle funds are not actually spent until after Milestone C. This means that while engineering and development is necessary during the entire acquisition cycle, the application of high-quality system analysis, concept definition and early systems engineering to decisions made in the pre-Milestone A period is critical to avoiding (or at least minimizing) cost and schedule overruns later in the program.

Purpose of the Materiel Solution Analysis Phase The purpose of this phase is to conduct the analysis and other activities needed to choose the concept for the product that will be acquired, to begin translating validated capability gaps into system-specific requirements including the Key Performance Parameters (KPPs) and Key System Attributes (KSAs), and to conduct planning to support a decision on the acquisition strategy for the product. AoA solutions, key trades between cost and performance, affordability analysis, risk analysis, and planning for risk mitigation are key activities in this phase.

Phase Description Minimum funding required for this phase is normally that needed to analyze and select an alternative for materiel development, and to complete the activities necessary to support a decision to proceed to the next phase; technology development and concept analysis and design efforts may also be funded in this phase.

The validated ICD and the AoA Study Plan will guide the AoA and Materiel Solution Analysis Phase activity. The analysis will be conducted in accordance with the procedures in Enclosure 9 of DoDI 5000.02, and focus on identification and analysis of alternatives; measures of effectiveness; key trades between cost and capability; total life cycle cost, including sustainment; schedule; concepts of operations; and overall risk. The AoA will inform and be informed by affordability analysis, cost analysis, sustainment considerations, early systems engineering analyses, threat projections, and market research.

Prior to the completion of this phase, the DoD Component combat developer will prepare an Operational Mode Summary/Mission Profile (OMS/MP) that will include the operational tasks, events, durations, frequency, operating conditions and environment in which the recommended materiel solution is to perform each mission and each phase of a mission. The OMS/MP will be provided to the Program Manager and will inform development of the plans for the next phase including: acquisition strategy, test planning, and capability requirements trades. It will be provided to industry as an attachment for the next acquisition phase RFP.

This phase ends when a DoD Component has completed the necessary analysis and the activities necessary to support a decision to proceed to the next decision point and desired phase in the acquisition process. The next phase can be Technology Maturation and Risk Reduction (TMRR), EMD, or Production and Deployment, depending on the actions needed to mature the product being acquired. Each of these phases has associated decision points to authorize entry: Milestone A, Development RFP Release and Milestone B, or Milestone C.

Program Office Establishment and Next Phase Preparation During the Materiel Solution Analysis Phase, the CAE will select a Program Manager and establish a Program Office to complete the necessary actions associated with planning the acquisition program with emphasis on the next phase. Prior to preparation and release of a final RFP for the planned next phase, the Program Manager should complete and submit the Acquisition Strategy and obtain MDA approval. An approved Acquisition Strategy will inform development of the final RFPs for the next phase of the program.

$G$3 32 Technology Maturation and Risk Reduction (TMRR) The Milestone A decision point marks the entry into the TMRR Phase of acquisition. TMRR is a focused effort to mature, prototype, and demonstrate technologies in a relevant environment. The purpose of this phase is to reduce technology risk and to determine the appropriate set of product technologies and manufacturing capabilities to be integrated into a full system. Three major systems engineering reviews are normally conducted during this phase, the System Requirement Review (SRR), the System Functional Review (SFR), and the Preliminary Design Review (PDR).

A Technology Readiness Assessment (TRA) is completed just prior to Milestone B. When feasible, this TRA should be closely coordinated with the assessment of manufacturing readiness conducted at that time. Manufacturing subject matter experts should participate in the TRA process.

TMRR ends in a decision on the preferred system concept that provides a low risk entry into EMD. Just as it is expected that technologies will be brought to TRL 6 or better by the end of this phase, manufacturing capabilities should also be brought to at least MRL 6.

At the end of the TMRR Phase, an assessment of manufacturing readiness is conducted to baseline needed industrial capabilities and identify remaining required investments for every competing design or prototype that has conducted a PDR at the full system level. It is in effect a manufacturing capability assessment. Sources of data may include the results of SRR, SFR and incremental PDRs, ICAs, program risk management plans, and the TRA.

While it is not expected that contractors would have a complete factory and supply chain established this early in a program, key knowledge must be obtained on 3-6 critical manufacturing processes, production scale-up efforts, and potential supply chain issues. The results of the assessment of manufacturing readiness performed during the MSA Phase should be used as a baseline reference for this activity. It is possible that some technology development activities were not assessed during the MSA Phase. In that case, it is a best practice to conduct an assessment early in the TMRR Phase to establish a baseline if manufacturing risk is great enough to warrant the effort. Technology Transition Agreements should be used to manage the transition process from a manufacturability and producibility standpoint. Technologies identified to have a maturity level less than MRL 4 at the start of this phase require special attention for maturation and risk mitigation in order to bring them to MRL 6 by Milestone B.

From a manufacturing perspective, the purpose of the EMD phase is to ready the acquisition program for production by implementing manufacturing risk reduction activities that are reflected in the acquisition strategy. The basic manufacturing planning that was developed in the previous phase should be detailed in EMD and significant program emphasis should be placed on bringing all hardware to the target MRL prior to the decision point at which this phase ends—the authorization to enter LRIP or FRP for non-major systems that do not require LRIP. MRL 8 is the target for LRIP and MRL 9 is the target for FRP; these targets should be reflected in the acquisition program baseline.

During EMD, assessments of manufacturing readiness are conducted to identify remaining risks on the design and manufacturing maturity prior to a production decision. These are manufacturability assessments and should be conducted in concert with the CDR and also later in EMD just prior to the Milestone C decision. Sources of data may include technical reviews and audits, Program Support Reviews, pre-award surveys, incremental PRRs, ICAs, trade-off studies, tooling plans, make-or-buy plans, manufacturing plans, and bills of material.

The results of the assessment of manufacturing readiness performed at the end of the TD Phase will be used as a baseline reference for this activity. The assessment should focus on program-wide manufacturing risks such as fabrication, assembly, integration and test operations; the supply chain performance; the maturity of manufacturing planning; the maturity of manufacturing management systems; adequacy of funding for manufacturing risk reduction efforts and other factors defined in MRL thread descriptions. Articles manufactured on a pilot line during EMD should be made using production materials, components, tooling, facilities and personnel.

for Milestone C will decide if the program will enter LRIP or FRP. The target MRL for LRIP is 8 while the target is 9 for FRP.

If LRIP is required, to the extent practical, this production effort should be performed in a manner that uses designs, tooling, materials, components, facilities, and personnel that are representative of the FRP environment. The FRP decision requires that manufacturing risk is understood and that the manufacturing processes for the system be capable, in control, and affordable. Prior to the FRP decision, a manufacturing readiness assessment should be conducted to ensure any outstanding risks will not impact the programs ability to deliver FRP requirements.

Assessments of manufacturing readiness may be used to capture manufacturing product documentation. It is a best practice to incorporate the preservation of such manufacturing product technical data packages in the Data Management Strategy.

$L$3 37 Full-Rate Production (FRP) The FRP decision requires that manufacturing risk is understood and that the manufacturing processes for the system be capable, in control, and affordable. Prior to the FRP decision, a manufacturing readiness assessment should be conducted to ensure any outstanding risks will not impact the programs ability to deliver FRP requirements.

Assessments of manufacturing readiness may be used to capture manufacturing product documentation. It is a best practice to incorporate the preservation of such manufacturing product technical data packages in the Data Management Strategy.

This review assesses preliminary materiel solutions that were identified during the MSA phase and assesses their potential for affordability, suitability, and operational effectiveness. It also answers the question, “can this solution be developed in a timely manner at an acceptable level of risk?” Again, the manufacturing feasibility is of critical importance in this review to increase the probability of meeting the affordability and schedule constraints of each alternative concept.

Success criteria for the ASR prior to Milestone A are as follows:

· Have the preliminary manufacturing processes and risks been identified for prototypes?

· Have required investments for technology development, to mature design and manufacturing related technologies, been identified and funded?

· Have initial producibility assessments of design concepts been completed?

$G$4 44 SRR/SFR Systems Requirements Review (SRR) The SRR is a multi-disciplined technical review to ensure that the system under review can proceed into initial systems development. The review considers whether all system requirements and performance requirements derived from the Initial Capabilities Document or draft Capability Development Document are defined and testable, and are consistent with cost, schedule, risk, technology readiness, and other system constraints. The manufacturing readiness is one of more important areas to address in determining whether the program can achieve its cost and schedule constraints. Analyzing whether manufacturing processes are mature enough is an essential element in determining whether a program will achieve its required performance within budget and schedule targets. A manufacturing readiness assessment results should be used at the SRR to update the program risk assessment, the Cost Analysis Requirements Description (CARD), and the program schedule. –Link to DAG

Systems Functional Review (SFR) The SFR is a multi-disciplined technical review to ensure that the system's functional baseline is established and has a reasonable expectation of satisfying the requirements of the Initial Capabilities Document or draft Capability Development Document within the allocated budget and schedule. Again, analyzing whether manufacturing processes are mature enough is an essential element in determining whether a program will achieve its required performance within budget and schedule targets. Manufacturing readiness assessment results should also be used at the SFR to update the program risk assessment for Engineering and Manufacturing Development (EMD), the Cost Analysis Requirements Description (CARD), and the program schedule.

$H$4 45 PDR Preliminary Design Review (PDR) The PDR establishes the allocated baseline (hardware, software, human/support systems) and underlying architectures to ensure that the system under review has a reasonable expectation of satisfying the requirements within the currently allocated budget and schedule. The maturity of the manufacturing process and associated risk of attaining that maturity is an essential element in determining whether a program will achieve its required performance within budget and schedule targets. Manufacturing readiness assessment results should also be used at the PDR to update the program risk assessment for Engineering and Manufacturing Development (EMD), the Cost Analysis Requirements Description (CARD), and the program schedule.

At the PDR prior to Milestone B the following questions apply:

· Have the majority of manufacturing processes been defined and characterized?

· Are initial manufacturing approaches documented?

· Have producibility assessments of key technologies been completed?

· Has a production cost model been constructed?

· Can the industrial base support production of development articles?

· Have long-lead and key supply chain elements been identified?

$I$4 46 CDR Critical Design Review (CDR) The CDR is to ensure that the system under review can proceed into system fabrication, demonstration, and test, and can meet the stated performance requirements within cost (program budget), schedule (program schedule), risk, and other system constraints. Results of the manufacturing assessments need to be used specifically to determine whether the system under review can meet cost, schedule, and performance objectives.

Exit questions for the CDR prior to System Capability and Manufacturing Process Demonstration include:

· Have the critical manufacturing processes that affect the key characteristics been identified and their capability to meet design tolerances determined?

· Have process control plans been developed for critical manufacturing processes?

· Have manufacturing processes been demonstrated in a production representative environment?

· Are detailed trade studies and system producibility assessments underway?

· Are materials and tooling available to meet pilot line schedule?

· Has the system production cost model been updated, allocated to subsystem level, and tracked against targets?

· Are long-lead procurement plans in place and has the supply chain been assessed?

$J$4 47 PRR/SVR Production Readiness Review (PRR) The PRR examines a program to determine if the design is ready for production and if the prime and major subcontractors have accomplished adequate production planning without incurring unacceptable risks that breach thresholds of schedule, performance, cost, or other established criteria. The review examines risk; it determines if production or production preparations identify unacceptable risks that might breach thresholds of schedule, performance, cost, or other established criteria. The review evaluates the full production-configured system to determine if it correctly and completely implements all system requirements. Since the PRR looks at all system requirements, it will look at more than manufacturing issues (e.g., software, sustainment, operational testing, etc.). The review determines whether traceability of final system requirements to the final production system is maintained.

The following success criteria are associated with the PRR prior to Milestone C:

· Is the detailed design producible within the production budget?

· Are the production facilities ready and required workers trained?

· Is detail design complete and stable enough to enter low rate production?

· Is the supply chain established and stable with materials available to meet planned low rate production?

· Have manufacturing processes been demonstrated and proven in a pilot line environment?

· Have all producibility trade studies and risk assessments been completed?

· Is the production cost model based upon the stable detailed design and been validated?

System Verification Review (SVR) The SVR is a multi-disciplined product and process assessment to ensure that the system under review can proceed into Low-Rate Initial Production and Full-Rate Production within cost (program budget), schedule (program schedule), risk, and other system constraints.

Generally this review is an audit trail from the Critical Design Review. It assesses the system final product, as evidenced in its production configuration, and determines if it meets the functional requirements (derived from the Capability Development Document and draft Capability Production Document) documented in the Functional, Allocated, and Product Baselines.

The PCA is conducted around the time of the Full-Rate Production Decision. The PCA examines the actual configuration of an item being produced. It verifies that the related design documentation matches the item as specified in the contract. In addition to the standard practice of assuring product verification, the PCA confirms that the manufacturing processes, quality control system, measurement and test equipment, and training are adequately planned, tracked, and controlled. Results of the manufacturing assessments will be critical in performing this Audit.

This is the lowest level of manufacturing readiness. The focus is to address manufacturing shortfalls and opportunities needed to achieve program objectives. Basic research (i.e., funded by budget activity) begins in the form of studies.

Background:

The system is very early in the Pre Material Solution Analysis (Pre-MSA) phase before the acquisition cycle begins, and it may not even be registered as a formal program. This phase of the Research and Development is usually associated with Basic Research. Prior to MSA, manufacturing processes are limited to characterizing the state of the manufacturing risk of a potential product than assessing manufacturing aspects of the outcome of scientific discovery. Alternatively, assessing manufacturing aspects of new technologies or materials may provide insight into new manufacturing processes that need to be developed to achieve innovative new products. Activities in manufacturing design maturity are usually restricted to identifying research opportunities and making investment plans to support new approaches and technologies to support the manufacturing process.

$D$5 53 MRL 2 MRL 2: Manufacturing Concepts Identified

This level is characterized by describing the application of new manufacturing concepts. Applied research translates basic research into solutions for broadly defined military needs. Typically this level of readiness includes identification, paper studies and analysis of material and process approaches. An understanding of manufacturing feasibility and risk is emerging.

Background:

The system is early in the advanced research project, pre-Material Solution Analysis (Pre-MSA) phase before the acquisition cycle begins, and it may not even be registered as a formal program. Prior to MSA, manufacturing processes are limited to characterizing the state of the manufacturing risk of a potential product than assessing manufacturing aspects of the outcome of scientific discovery. Alternatively, assessing manufacturing aspects of new technologies or materials may provide insight into new manufacturing processes that need to be developed to achieve innovative new products. This phase of the Research and Development is usually associated with Basic Research or Applied Research in Science and Technology. Manufacturing concepts will be validated through analytical paper studies.

$E$5 54 MRL 3 MRL 3: Manufacturing Proof of Concept Developed

This level begins the validation of the manufacturing concepts through analytical or laboratory experiments. This level of readiness is typical of technologies in Applied Research and Advanced Development. Materials and/or processes have been characterized for manufacturability and availability but further evaluation and demonstration is required. Experimental hardware models have been developed in a laboratory environment that may possess limited functionality.

Background:

The system is in the Pre-MSA phase before the acquisition cycle begins, and it still may not be registered as a formal program. At this stage the program is primarily analytical, focusing on the proof of concept. Manufacturing concepts will be validated through analytical (paper studies) or early laboratory experiments. Specific materials and/or processes are not defined and are very changeable. At this stage, therefore, potential sources for a variety of materials and processes are being surveyed with no final decision made on any sources so an Analysis of Alternatives (AoA) will be conducted of potential solutions to address users’ needs. The task is to examine potential material solutions with the goal of identifying the most promising option that can best support program requirements. The main purpose of MRLs in this phase is to assess the manufacturing feasibility of various alternatives being considered to understand the risks with proceeding with the selected solution(s). The manufacturing risk(s) identified in this phase needs to be addressed in the Technology Development Phase risk mitigation efforts and reflected in all cost estimates.

$F$5 55 MRL 4 MRL 4: Capability to produce the technology in a laboratory environment

This level of readiness acts as an exit criterion for the Materiel Solution Analysis (MSA) Phase approaching a Milestone A decision. Technologies should have matured to at least TRL 4. This level indicates that the technologies are ready for the Technology Development Phase of acquisition. At this point, required investments, such as manufacturing technology development, have been identified. Processes to ensure manufacturability, producibility, and quality are in place and are sufficient to produce technology demonstrators. Manufacturing risks have been identified for building prototypes and mitigation plans are in place. Target cost objectives have been established and manufacturing cost drivers have been identified. Producibility assessments of design concepts have been completed. Key design performance parameters have been identified as well as any special tooling, facilities, material handling and skills required.

Background:

The system is now in the Material Solution Analysis (MSA) phase of the acquisition cycle. The purpose of the MSA is to assess potential materiel solutions and to satisfy the phase-specific entrance criteria for the next program milestone designated by the Milestone Decision Authority. This phase refines the initial concept by beginning to conduct an Analysis of Alternatives (AoA) of potential solutions to address user’s needs. The AoA will examine potential material solutions to identify the most promising option to best support program requirements. Components or breadboards are being validated in a laboratory environment, and specific materials and/or processes are still in a state of flux; however, systems design personnel are homing in on a few preferred design approaches. Potential sources for a materials and processes can be narrowed; however, options must be kept open until a final decision is made on the design. Special emphasis is also placed on the proposed material solution to analyze supply chain feasibility from a manufacturing perspective and determine manufacturing resources and technology needed. An Alternative Systems Review (ASR) may be performed to assess preliminary materiel solutions identified during the MSA regarding their potential for affordability, suitability, and operational effectiveness. The ASR is an attempt to ensure the system requirements align with the customer’s needs and attempts to minimize the need to change requirements in the later acquisition phases. A strategy for Technology Development should be defined and it should address quality in a general way, probably from the general requirements perspective. The main purpose of MRLs in this phase is to assess the manufacturing feasibility of various alternatives being considered in order to understand the risks with proceeding with the selected solution(s). Part of that feasibility assessment will identify workforce skills needed to produce demonstration articles in the Technology Development (TD) Phase and to forecast the needs for the production program. The manufacturing risk identified in this phase needs to be addressed in the Technology Development Phase risk mitigation efforts and reflected in all cost estimates.

$G$5 56 MRL 5 MRL 5: Capability to produce prototype components in a production relevant environment

This level of maturity is typical of the mid-point in the Technology Development Phase of acquisition, or in the case of key technologies, near the mid-point of an Advanced Technology Demonstration (ATD) project. Technologies should have matured to at least TRL 5. The industrial base has been assessed to identify potential manufacturing sources. A manufacturing strategy has been refined and integrated with the risk management plan. Identification of enabling/critical technologies and components is complete. Prototype materials, tooling and test equipment, as well as personnel skills have been demonstrated on components in a production relevant environment, but many manufacturing processes and procedures are still in development. Manufacturing technology development efforts have been initiated or are ongoing. Producibility assessments of key technologies and components are ongoing. A cost model has been constructed to assess projected manufacturing cost.

Background:

The system is now in the early stages of the Technology Development (TD) phase. The program has passed the MS A decision point. The technology applied to product and manufacturing processes is under development. The midpoint of an Advanced Technology Demonstration (ATD) may be reached if new technology is involved. Potential sources of supply have been identified. The purpose of this phase of the acquisition cycle is to assess, identify, and reduce technical risk from both a technology and manufacturing perspective, determine manufacturing capabilities to be integrated into a full system for both the prime and the supply chain, and demonstrate Critical Technologies (CTs) on prototypes. This will be done by manufacturing and testing prototype units/components in a relevant environment. Specific materials and/or processes may be in a state of flux; however, this is the stage where a formal Industrial Base Capabilities Assessment (IBCA) is done and an Analysis of Alternatives (AoA) has been performed to select the best design. At Milestone A, the Milestone Decision Authority (MDA) reviews the proposed materiel solution and the draft Technology Development Strategy (TDS) to determine if ready to proceed and has documented the decision in an Acquisition Decision Memorandum (ADM). The strategy for Technology Development should address Quality including evaluation of customer quality requirements. The TDS will undergo refinement during the TD phase. The program will have undergone a Systems Requirements Review/System Functional Review (SRR/SFR) or is preparing for a PDR in the near future. At this stage sources for a materials and processes are being fixed, but options may be kept open until the final design decision. Understanding the risk of achieving the production requirements and material maturity will be a key element of exiting this phase and assessments will be done to determine whether manufacturing technology development is required to achieve the user’s requirements.

$H$5 57 MRL 6 MRL 6: Capability to produce a prototype system or subsystem in a production relevant environment

This MRL is associated with readiness for a Milestone B decision to initiate an acquisition program by entering into the Engineering and Manufacturing Development (EMD) Phase of acquisition. Technologies should have matured to at least TRL 6. It is normally seen as the level of manufacturing readiness that denotes acceptance into a preliminary system design. An initial manufacturing approach has been developed. The majority of manufacturing processes have been defined and characterized, but there are still significant engineering and/or design changes in the system itself. However, preliminary design of critical components has been completed and producibility assessments of key technologies are complete. Prototype materials, tooling and test equipment, as well as personnel skills have been demonstrated on systems and/or subsystems in a production relevant environment. A cost analysis has been performed to assess projected manufacturing cost versus target cost objectives and the program has in place appropriate risk reduction to achieve cost requirements or establish a new baseline. This analysis should include design trades. Producibility considerations have shaped system development plans. The Industrial Capabilities Assessment (ICA) for Milestone B has been completed. Long-lead and key supply chain elements have been identified.

Background:

The system is nearing the end of the Technology Development (TD) phase and the system or subsystem model or prototype is now being demonstrated in a relevant environment. Specific materials and/or processes are quantified, and the formal Industrial Base Capabilities Assessment (IBCA) for Milestone B is complete. Industrial capability is largely in place to support development articles since sources for materials and processes are largely fixed and the program will have conducted a Preliminary Design Review (PDR). Demonstrating critical manufacturing processes in a production relevant environment is critical to assessing manufacturing risk and giving confidence that program cost, schedule and performance requirements before proceeding into EMD. This level of production realism is well beyond what is seen in a laboratory. The emphasis is on addressing higher risk areas (e.g., more advanced technologies and newer manufacturing capabilities). During this critical junction it is essential that the contractor(s) demonstrate the capability to build the product or a similar item (considering size, tolerances, quality levels, processes, and testing) in the facility that will be used during production. At the end of the TD phase an assessment of manufacturing risk and readiness is conducted to baseline needed supply chain industrial capabilities and identify remaining required investments for every competing design or prototype that has conducted a PDR. Since the program is approaching MS B, it is important to make sure the Quality Management System is developing in parallel with the system design. A Program Quality Plan should be developed and in place. Quality metrics have been identified, and improvement plans are under development. Potential sources of supply have been evaluated for quality risk, and their ability to meet customer quality requirements. Quality data on production of other similar products may provide insight into the supplier’s ability to meet our requirements. Most importantly, at this stage of development, the quality thresholds should be established with reference to past performance or anticipated design tolerances and process yields. When assessing and reducing manufacturing risk with the options being considered, it is important understand future tooling, test equipment and facilities requirements. The program should exit the Technology Demonstration (TD) Phase when the technology and manufacturing processes for that program or increment have been assessed and demonstrated in a relevant environment and manufacturing risks have been identified. The program will be approaching a Critical Design Review in the near future.

$I$5 58 MRL 7 MRL 7: Capability to produce systems, subsystems, or components in a production representative environment

This level of manufacturing readiness is typical for the mid-point of the Engineering and Manufacturing Development (EMD) Phase leading to the Post-CDR Assessment. Technologies should be on a path to achieve TRL 7. System detailed design activity is underway. Material specifications have been approved and materials are available to meet the planned pilot line build schedule. Manufacturing processes and procedures have been demonstrated in a production representative environment. Detailed producibility trade studies and risk assessments are underway. The cost model has been updated with detailed designs, rolled up to system level, and tracked against allocated targets. Unit cost reduction efforts have been prioritized and are underway. The supply chain and supplier quality assurance have been assessed and long-lead procurement plans are in place. Production tooling and test equipment design and development have been initiated.

Background:

The system is beginning Engineering and Manufacturing Development (EMD) and the system prototype is beginning demonstration in an operational environment. EMD completes the development of a system, leveraging design considerations (quality, producibility and manufacturability), completes the full system integration, develops affordable and executable manufacturing (and quality) processes, completes system fabrication, assembly, test and evaluation. Entrance into this phase depends on technology maturity, approved requirements, and full funding. Unless some other factor is overriding in its impact, the maturity of the technology determines the path to be followed. MDA approval of the Acquisition Strategy is a requirement before final RFPs for EMD can be released. Specific materials and/or processes are quantified, and the industrial base capability is being monitored. A Critical Design Review (CDR) should have been conducted or is near to being conducted, and the design is rapidly maturing. The manufacturing focus in this phase is to demonstrate that manufacturing processes will support program requirements and that manufacturing risk reduction initiatives are reflected in the acquisition strategy. It is critical that at this stage of the acquisition cycle that the contractor maintains effective supply chain management processes and procedures. Items are being designed and built in a production representative environment. Manufacturing processes are maturing, and materials are being used in the fabrication and assembly operations. The program has successfully achieved a MS B decision and the Quality Management System (QMS) is undergoing further development in parallel with the system design. A Program Quality Plan and Quality Metrics have been developed. Quality metrics have been identified, and improvement plans identified prior to milestone B are being applied. Quality targets are identified and progress on development units and other pre-production runs should show these targets are achievable. Quality data on production of other similar products may provide insight into the prime’s and supplier’s abilities to meet quality targets. Manufacturing exit criteria for this phase include a demonstration that processes are capable of producing affordable systems or components in a production representative environment and that they will be capable of producing in pilot line production. Preparations are also beginning for the manufacture of qualification test hardware.

$J$5 59 MRL 8 MRL 8: Pilot line capability demonstrated; Ready to begin Low Rate Initial Production

This level is associated with readiness for a Milestone C decision, and entry into Low Rate Initial Production (LRIP). Technologies should have matured to at least TRL 7. Detailed system design is essentially complete and sufficiently stable to enter low rate production. All materials are available to meet the planned low rate production schedule. Manufacturing and quality processes and procedures have been proven in a pilot line environment and are under control and ready for low rate production. Known producibility risks pose no significant challenges for low rate production. The engineering cost model is driven by detailed design and has been validated with actual data. The Industrial Capabilities Assessment for Milestone C has been completed and shows that the supply chain is established and stable.

Background:

The program is approaching a MS C decision and the industrial capabilities supporting the program should be defined and viable at this time. The industrial base should be capable of beginning Low Rate Initial Production (LRIP). Detailed design is complete for the majority of the system. The design should be stable so that manufacturing equipment and technologies are mature at this time.