Attachment 03 - MPF Production Readiness Review Checklist.xlsx
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Attachment 03 - MPF Production Readiness Review Checklist
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PRR Checklist
| Attachment 03 | 7-Sep-17 | |
| MPF Production Readiness Review Checklist | ||
| 1 | 1. Engineering and Product Design Technical Documentation, Systems Integration, and Coordination | |
| 2 | 1a. Technical Documentation, Systems Integration, and Coordination | |
| 3 | Are the contractor’s engineering drawings and documents complete for describing the equipment and the applicable software to be delivered under this program? Explain. | |
| 4 | Are there provisions to assure that obsolete drawings are removed and discarded? Explain. | |
| 5 | Are there procedures to assure that all engineering drawings are consistently prepared and that all revisions and Class I engineering changes are incorporated into the drawings? Explain. | |
| 6 | Are the engineering drawings and specifications complete and descriptive for production purposes? Explain. | |
| 7 | Is there an effective system for managing standards such as drawings, engineering changes, and specifications? Explain. | |
| 8 | Who is responsible for design control? How are changes approved? | |
| 9 | Are incorporated changes identified on the contractor’s inspection records? (In regards to FIR inspection for vehicle sale) Explain. | |
| 10 | Are copies of drawings provided to the appropriate inventory control point? Inventory control point is defined as ECARDS, flat file, BOM, Team Center, Windchill, etc? Explain. Can other entities access the drawings as required. | |
| 11 | Can other entities access the drawings as required? Is training or access needed for other entities to understand the system and access drawings? Explain. | |
| 12 | Is the software documentation complete and have the appropriate data rights been secured? Explain. | |
| 13 | Does the Depot/Arsenal have full access to all technical data including engineering change proposals? Explain. | |
| 14 | Are there any proprietary drawings associated with this effort? Explain. | |
| 15 | Are critical characteristics identified for all critical safety items? Explain. | |
| 16 | 1b. Status of System Integration | |
| 17 | Are the functional responsibilities of all disciplines adequately documented in contracts, Memoranda of Agreements (MOA), and Interface Control Documents (ICD)? List entities and the agreement method. | |
| 18 | Have the interface responsibilities of the contractor and the government been described for all Government Furnished Equipment (GFE)? Explain. (GFE is equipment/tools provided by MPF, a depot, or another govt entity.) | |
| 19 | Are procedures in place to assure that the complete system, including all parts and assemblies, conform to all required design specifications such as performance, reliability, cost, and life-cycle? Explain. | |
| 20 | 1c. Engineering and Product Design | |
| 21 | Has a test plan/final inspection record (FIR) been developed and approved? When? By whom? Is it proprietary? | |
| 22 | How are changes to the FIR proposed and approved? | |
| 23 | Has the vehicle configuration for this effort been defined at a production level? Explain. | |
| 24 | Is there a difference between the production vehicle and the tdp (paper) configuration of the vehicle? (explain for your component if you are a GFM supplier) | |
| 25 | Is STS support required for this program during production? If yes, is that support currently in place? Explain. | |
| 26 | Are there problem reporting and corrective action system is in place that documents all failures and identifies that effective corrective actions have been implemented a timely manner? Explain. | |
| 27 | Does the manufacturing screening program use Environmental Stress Screening (ESS) e.g., thermal cycling and random vibration at all levels i.e., Module, Shop Replaceable Assembly (SRA), Weapon Replacement Assembly (WRA), and System to eliminate latent defects and workmanship problems from the components during the manufacturing process prior to final acceptance by the Government? Explain. | |
| 28 | Where required, have provisions for Unique Identification (UID) of parts been incorporated? Explain. | |
| 29 | 2. Materials and Purchased Parts | |
| 30 | What is the contractor's inventory control system for tracking assets to meet schedule? Explain. | |
| 31 | Is there a segregation of Government owned material from contractor owned material? Explain. | |
| 32 | What procedure is used for segregating material dedicated to this program from identical material intended for other programs? Explain for CFM and GFM. | |
| 33 | How does the contractor assure the safeguarding of Government property (GFM)? Explain. | |
| 34 | Does the contractor provide for the preservation and inspection of property in storage (after DD250 or due to vendor supplying all assets in a bulk delivery) to assure protection and maintain critical environments? Explain. | |
| 35 | What assures physical inventories are conducted in accordance with contractual requirements? | |
| 36 | What is the system to assure that material handling for planned production correlates with planned workflow and schedules? How is it assured that GFM and CFM issued from storage do not exceed work-in-process requirements? Explain. | |
| 37 | What method identifies shortages and deficiencies and initiates prompt corrective action to explain/correct those actions? How are those shortages/deficiencies made up? | |
| 38 | Does the contractor maintain accurate scrap and salvage records? How? Explain. | |
| 39 | Is the contractor able to account for the return of reusable containers? Explain. |
| 40 | What is the procedure for the transfer or disposal of property? (includes DRMO/demil, DD250, ll49s, etc) Who provides approval for this transfer/disposal and where is it documented? |
| 41 | Does the contractor maintain absolute control, including identification, handling, storage, and shipping (if necessary) of flammable or hazardous materials? |
| 42 | What procedure is used for controlling sensitive or classified material? |
| 43 | What system identifies handling and transportation deficiencies and formulates corrective actions for GFM and CFM? |
| 44 | Does the contractor have a system that authorizes advance procurement of long lead-time materials? Explain. |
| 45 | What documentation is in place to ensure each entity (PM, contractors, etc) know what parts they are purchasing and providing? |
| 46 | Where are these parts being purchased from? Explain (include how you qualify your suppliers). |
| 47 | Will you be using the FSS? If yes, what forecasting and requirements provisioning has been completed? |
| 48 | Have dof factors been assigned to all reclaimed parts? Have these dof factors been agreed to by MPF before the contract is signed? |
| 49 | Have any high risk components or suppliers been identified for this program? What mitigation steps are in place in case these components or suppliers are not ready at the beginning of the program? |
| 50 | Have all components been identified to be used at a specific workstation? Explain. |
| 51 | 3. Industrial Resources |
| 52 | 3a. Policies and Procedures for Facilities and Equipment Selection |
| 53 | What analyses have been conducted to determine facilities and equipment requirements for this program? Explain. |
| 54 | Were security and classification considerations (i.e., storage and handling of classified material and equipment) part of the facilities and equipment selection? |
| 55 | How does the facilities management system respond to the needs and priorities of this program? |
| 56 | Is the facilities management tied into the production contracts with overhead rates or responsibilities? Explain. |
| 57 | Does a redesign/construction of a current facility or new facility need to be created for this program? Explain. |
| 58 | What entity is in charge of the construction effort and is it on contract and funded? |
| 59 | How long will construction take? |
| 60 | What is the workaround plan if construction is not complete when the program begins? |
| 61 | 3b. Facilities and Equipment Utilization Planning |
| 62 | What are the provisions for scheduled and unscheduled maintenance on facilities and equipment? |
| 63 | How are major considerations of planned workloads, production rates, and workflow addressed in the facilities and equipment utilization plans? |
| 64 | What are the alternative uses of the existing facilities and equipment, when they are not experiencing maximum usage? |
| 65 | What considerations exist in the utilization plan for fire protection, waste disposal, fuel, and other facilities? |
| 66 | 3c. Facilities and Equipment Allocation |
| 67 | Have all facilities and equipment that need to be used for the production of this program been identified? Is there currently a program being worked in this area? Can the area handle both workloads? Explain. |
| 68 | How have the facilities and equipment required for this program been factored into the program schedule if movement/purchasing and install is required? Explain. |
| 69 | How will the facilities support transportation, storage, and handling of planned inventories? |
| 70 | What contractor / Government-owned resources including facilities, tooling, and equipment that are available, planned, and dedicated for use on this program? |
| 71 | 3d. Plant Layout Design |
| 72 | Where is the physical arrangement diagram that identifies and depicts dimensions of all functional areas to be used? |
| 73 | Where is the plant layout, which shows the component and product flow including material receiving and storage? |
| 74 | What is the contingency plan for adaptation to the plant layout for revised production rates? |
| 75 | What rates are you currently planning for in FY16-FY25? Include all workload utilizing these areas/machines. |
| 76 | What is your surge capacity? Define and explain. |
| 77 | 3e. Test Equipment and Tooling Policy and Procedure |
| 78 | What are the procedures for maintaining test equipment and tool designs as engineering and manufacturing methods change? |
| 79 | What procedures govern the storage, maintenance, repair and overhaul of test equipment and tooling? |
| 80 | What procedure governs how test equipment and tooling are assigned to the work centers, and how is accountability maintained? |
| 81 | How do the procedures for test equipment and tooling design provide for coordination with all other disciplines such as methods / processes, quality assurance, production, plant layout, etc.? |
| 82 | What are the requirements for the calibration, inspection, and test of test equipment and tooling according to specifications? |
| 83 | Have all special tools, molds, machinery (etc) been ordered for the program? What are the projected delivery dates and alternate plans if not ready when production begins? Explain. |
| 84 | 3f. Contractor Manpower and Personnel Organization |
| 85 | How does the organization provides for lines of communication among the various functional organizations? |
| 86 | What is the system that provides for training and updating the skills of the work force? |
| 87 | Does the contractor conduct periodic analysis of manpower requirements based on changes to programs and / or budgeting? Explain. |
| 88 | Is there a hiring action required to fully staff up for this program? When will this action complete? Explain. |
| 89 | On average, how long does it take to train a worker to a proficient level of workmanship? Will this impact the start of the program? |
| 90 | 3g. Contractor Manpower and Personnel Policy and Procedure Documentation |
| 91 | What is the methodology that establishes the priority of work force assignments relative to the various production programs? |
| 92 | What procedures describe the level and mix of labor classifications that are required for this program? |
| 93 | What procedures are in place for analyzing data such as turnover rates, complaints, grievances and absenteeism, and the implementation of methods to improve the work force efficiency? |
| 94 | What are the policies and procedures relative to the evaluation of employee performance, and are they well documented and utilized? |
| 95 | What metric provides for management review of productivity and performance for each work center? Is this information provided to the customer? Explain. |
| 96 | 4. Quality Assurance |
| 97 | 4a. Quality Assurance Policy and Procedure Documentation |
| 98 | What is the process for performing internal audits and initiating corrective actions? |
| 99 | What plans and milestones identify additional quality assurance staffing requirements? |
| 100 | How does the Quality Program Plan address the role of quality in the inspection and acceptance of product and software? |
| 101 | Does the Quality Program Plan provide for the reporting of software discrepancies and implementation of corrective action? |
| 102 | What is the quality organization's role in the preparation, classification, and distribution of waivers, deviations, and engineering changes? |
| 103 | Is the quality program clearly defined as the objective and policy of top management? |
| 104 | What is the quality organization's procedure for assuring that documented procedures and changes are issued to all concerned? |
| 105 | What procedures ensure that work instructions comply with inspection and test requirements? |
| 106 | What procedures ensure that improper work instructions are corrected? |
| 107 | Are records kept by the quality organization available to the Government? |
| 108 | Do the inspection records include the number and type of defects, and indicate the quantities of acceptable and rejected items? |
| 109 | Are quality records analyzed and used as a basis for management action to correct product and system deficiencies? |
| 110 | What system is used for collecting and tracking of cost related to quality, and is this data available for Government review? |
| 111 | What procedure is utilized to remove and properly dispose of obsolete drawings from all locations? |
| 112 | Is the measuring and test equipment labeled or coded to indicate the date of last calibration and date of next calibration? |
| 113 | Are there established controls for calibration of personally owned measuring instruments? |
| 114 | Is the calibration system included as a part of the Quality Program or inspection system? |
| 115 | What is the procedure for handling unusual or state-of-the-art measuring requirements that cannot be performed? |
| 116 | What is the process to clearly define the assignments, responsibility, and authority of the personnel on the Preliminary Review, Material Review, and Corrective Action Boards? |
| 117 | What are the procedures for reporting and determining cause of product damage, and the establishment of additional procedures and controls where required? |
| 118 | Are there procedures in place to ensure that work instructions comply with inspection and test requirements? |
| 119 | Are there procedures in place (such as DA Form 2028 or other documentation) to ensure that improper work instructions are corrected? Name documentation and explain. |
| 120 | Are quality records analyzed and used as a basis for management action to correct product and system deficiencies? |
| 121 | Are there systems in place for collecting and tracking of cost related to quality? |
| 122 | Is trend analyses conducted that shows the percent of rework and repair to total man-hours? |
| 123 | 4b. Quality Assurance Organization and Personnel |
| 124 | How does the quality program provide for lines of communication among all functional organizations? |
| 125 | What is the quality assurance manager's role and authority in the elimination of deficiencies and the establishment of corrective actions regardless of the functional element responsible? |
| 126 | Does the quality organization assure that inspection and test requirements contained in work instructions are in accordance with drawings, specifications, and the contract? |
| 127 | Are only qualified / certified personnel used for manufacturing, inspection and processes that require special skills? What are those qualifications/certifications and how are they tracked/recorded? Are they available for MPF inspection? |
| 128 | Are there sufficient personnel identified to cover the following items? Please explain each item individually and name the personnel that are qualified. |
| 129 | - B130PFMEA & Control Plan requirements |
| 130 | - Inspection points built into the system on the line and audit points on the line |
| 131 | - Engineering performance testing (FAT testing, capability testing, etc) |
| 132 | - Problem resolution analysis |
| 133 | Is there a documented training program that addressed the following items? Please explain each item individually. |
| 134 | - Includes all employees (shop floor personnel, supervisors, substitutes, qa personnel, etc)? |
| 135 | - Lists that show who has been trained and on which items they were trained on/for? Where are these lists kept? |
| 136 | - Where are these lists kept? Is there a master list? |
| 137 | - How often are these listed updated and who has that responsibility? |
| 138 | - How is the training tracked to ensure an individual is not delinquent/expired on a procedure? |
| 139 | How does an individual know they have training coming due? |
| 140 | Is there an established training program(s) that addresses the following items? Please explain each item individually. |
| 141 | - Statistical process control |
| 142 | - Capability studies |
| 143 | - Problem solving (fishbone diagrams, 5W's, etc.) |
| 144 | - Mistake proofing (ensuring the operator cannot pass a mistake on to the next station/shop) |
| 145 | - Were operator/team leaders involved in developing floor instructions? |
| 146 | 4c. Completeness and Adequacy of Quality Assurance Planning |
| 147 | What is the procedure that ensures that Engineering Change Proposals (ECPs) are routed through the quality organization? |
| 148 | Who has the authority and responsibility for the accomplishment of quality program contract requirements? |
| 149 | Does the Quality Assurance Program Plan provide for the development of inspection and test planning during the earliest practical phase of the contract? |
| 150 | How is the quality assurance planning for inspection and testing compatible with manufacturing methods and processes? |
| 151 | How does the Quality Assurance Program Plan assures compliance with contract cost, schedule, and performance throughout production? |
| 152 | How does the Quality Assurance Program Plan provide for the early detection of deficiencies and timely corrective action? |
| 153 | What is quality assurance's involvement in the management of standards such as drawings, changes, and measuring equipment that are used to assure product quality? |
| 154 | Are flow charts that define the various processes, inspections, and tests traceable to materials and equipment from receiving to final shipment? |
| 155 | 4d. Manufacturer and Supplier Quality Control |
| 156 | What procedures assure the latest drawings and specifications are supplied to subcontractors? |
| 157 | How does the Quality Plan provides for the screening of electronic components? |
| 158 | Is there a bonded holding area for the segregation and storage of non-conforming material? Explain. |
| 159 | What are the procedures for inspection of material received to provide objective evidence of supplier quality control? |
| 160 | What are the procedures for monitoring special processes (e.g., soldering, heat treating, welding, plating, and etc.)? Are records available for MPF inspection? Explain. |
| 161 | Does the contractor have a system that provides for the inspection and test of preservation, packaging, and marking methods? |
| 162 | What is the system for controlling inspection stamps? If you don't use inspection stamps, what system do you use? Explain. |
| 163 | What controls are in place to assure that only those units of product that meet contract requirements are submitted to the Government for acceptance? |
| 164 | Is a continuous improvement program in place? Explain. |
| 165 | Is the incoming parts screening program effective in keeping defective parts out of the manufacturing cycle? Explain. |
| 166 | 5. Production Engineering and Planning |
| 167 | 5a. Policy and Procedure Documentation for Production Planning and Scheduling |
| 168 | Is a joint manufacturing / engineering support team available for solving problems on the factory floor? How does the team work? |
| 169 | Is a fast reacting productivity center available for off-line correction of problems, how does it operate, and is there an alternative? |
| 170 | How do the plans, schedules, and work instructions provide for inspection / test / acceptance in accordance with quality assurance requirements? |
| 171 | What is the planning that determines manpower requirements, level of skill, training of personnel, and calculation of material and components necessary to support the production rate? |
| 172 | What is the planning that provides for scheduled and unscheduled maintenance on facilities, equipment, and tools? |
| 173 | What procedures ensure that plans, schedules, and work instructions are updated to the latest approved changes? |
| 174 | What procedures identify critical / pacing items for schedule control? |
| 175 | What procedures coordinate plans and schedules with all other contractor programs for proper utilization of available resources? |
| 176 | 5b. Production Organization and Personnel |
| 177 | Have clearly defined organizations been established with the necessary span of control and levels of authority for effective management of this program? How are multiple locations owned by the same entity covered? Explain. |
| 178 | Are project managers assigned to only one major project? If no, how much time is dedicated to this program? |
| 179 | 5d. Completeness of Production Planning Tasks and Quality of Plans / Schedules |
| 180 | What is the process for breaking down the production process into discrete work packages? |
| 181 | How detailed are the work packages that fully define the work to be accomplished? |
| 182 | How are the work packages traceable to the contract WBS? |
| 183 | How are the work packages properly sequenced to completely depict the production process? |
| 184 | How are the work packages and sequence charts broken down into individual work instructions to that completely describe the operations to be performed? |
| 185 | Are pertinent tools, equipment, facilities, parts, and material requirements, identification of assemblies, quantities, and routing information all parts of the work instructions? |
| 186 | What is the master production schedule, and how does it relate to the master program schedule? |
| 187 | What are the schedules for the production / procurement of tools, test sets, assemblies, and GFE, and how are they maintained? |
| 188 | How do the production / procurement schedules relate to the overall production operations schedules? |
| 189 | 5e. Contractor Production Control Policy and Procedure Documentation |
| 190 | What are the procedures that control and measure manufacturing progress against cost estimates and schedules? |
| 191 | Have the work instructions been validated down to the station level to ensure the process is adequate for the scope of work? |
| 192 | Have work instructions been reviewed by SMEs to verify technical accuracy (e.g., proper torque values, correct temperatures, measurement conversions)? |
| 193 | What is the work progress tracking system used by management to identify deviations from the scheduled workflow? |
| 194 | What procedures assure that all required tools, materials, operating instructions and drawings are available prior to the release of work orders? |
| 195 | What are the procedures that provide for the priority fabrication of parts to offset assembly line shortages, and what is the alternative? |
| 196 | What procedure controls work center tools used in production? Tracking and calibration? |
| 197 | What is the process for modification of methods / processes as a result of approved ECPs or changes in production activity? |
| 198 | How are the development of methods and processes coordinated with all other manufacturing disciplines? |
| 199 | What are the equipment and tooling layout, workflow, receiving, and routing for each work center? |
| 200 | How are the layout diagrams traceable to production plans and schedules? |
| 201 | How do the work center supervisors and higher management use the layout diagrams to plan workloads? |
| 202 | 5f. Methods and Processes Selection Trade-Off Analysis |
| 203 | What selected methods and processes are compatible with existing equipment and supplies, and what contingencies are being considered? |
| 204 | Does the documentation for methods and processes specify necessary environmental conditions (i.e., controlled temperature or clean room)? |
| 205 | What quality assurance provisions are included in the operations / process sheets / chart? Explain. Have PL MPF/DCMA quality personnel inspected these documents? |
| 206 | What methods and processes documentation completely describes the manufacturing operation and identifies areas that are lacking? For areas that are lacking, what is the path forward? How will production for the program proceed? |
| 207 | Are the written operation / process sheets / charts written so that they are commensurate with the operator skill level? Explain. |
| 208 | Do the methods and procedures contain provisions for cleaning or elimination of foreign objects? |
| 209 | 5g. Establishment and Maintenance of Configuration Baselines |
| 210 | Are all engineering changes requiring a change to the baseline being processed as formal ECPs? |
| 211 | Does the Govt see/approve all formal ECP's? |
| 212 | Define your ECP levels. Explain difference between ECP's with internal approvals only and ECP's requiring customer approval. |
| 213 | Does the contractor's configuration accounting system document the exact configuration of each serial numbered component, assembly, or end item? |
| 214 | 6. Contracts/SOW |
| 215 | Is the contract/SOW for this program funded and awarded/signed? Explain. |
| 216 | Has a Master Integrated Program Schedule been developed that includes milestone dates for key activities necessary for program success? What level of management approved this schedule? |
| 217 | Does the schedule allow for ramp up and draw down over the life of the program? Explain. |
| 218 | Does the schedule allow for slippage or program acceleration? Explain. |
| 219 | How will performance trends be monitored managed and corrected? Will these provided to the customer? Explain. |
| 220 | What metrics will be used for the reporting of this program? Will these be provided to the customer? Explain. |
| 221 | What monitoring tools will be used by management? |
| 222 | 7. Exit Criteria - The PRR is considered complete when all draft RFAs are signed off, and an acceptable level of risk is ascertained. The program manager will approve entering LRIP or FRP based upon acceptable PRR results and manageable program risk. |
| 223 | Has the system product baseline been established and documented to enable hardware fabrication and software coding to proceed with proper configuration management? |
| 224 | Are adequate process and metrics in place for the program to succeed? |
| 225 | Are the risks known and manageable? |
| 226 | Is the program schedule executable (technical/cost risks)? |
| 227 | Is the program properly staffed? |
| 228 | Is the detailed design producible within the production budget? |
| 229 | Were PRR issues captured as action items, properly adjudicated and assigned? |
| 230 | Were all PRR action items properly completed (closed)? |
| 231 | Was the proper technical authority represented at the review and is the program properly staffed to manage production and development? |
| 232 | Can the system produced satisfy the CPD? |
&"Arial,Regular"&14(RESPONSES MUST BE APPROPRIATELY CLASSIFIED AND MARKED)
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