Since the original Manufacturing Guide was written several new risk assessment tools have been developed. These include:
- Technology Maturity Levels (TRLs),
- Manufacturing Readiness Levels (MRLs), and
- Sustainment Maturity Levels (SMLS).
11.8.1 Technology Maturity Levels (TRLs)
TRLs provide a systematic metric/measurement system to assess the maturity of a particular technology. TRLs enable a consistent comparison of maturity between different types of technologies. The TRL approach has been used for many years in the National Aeronautics and Space Administration (NASA) and is now being used on most DOD programs where new technologies are being developed. TRLs have been divided into nine (9) maturity levels as follows:
- TRL 1: Basic Principles observed and noted.
- TRL 2: Technology concept or application formulated.
- TRL 3: Experimental and analytical critical function and characteristic proof of concept.
- TRL 4: Component or breadboard validation in a laboratory environment.
- TRL 5: Component or breadboard validation in a relevant environment.
- TRL 6: System or subsystem model or prototype demonstrated in a relevant environment.
- TRL 7: System prototype demonstration in an operational environment.
- TRL 8: Actual system completed and "flight qualified" through test and demonstration.
- TRL 9: Actual system "flight proven" through successful mission operations.
11.8.2 Manufacturing Readiness Levels (MRLs)
Manufacturing Readiness Levels (MRLs) and assessments of manufacturing readiness have been designed to manage manufacturing risk in acquisition while increasing the ability of the S&T projects to transition new technology to weapon system applications. MRL definitions create a measurement scale and vocabulary for assessing and discussing manufacturing maturity, risk and readiness. Using the MRL definitions, an assessment of manufacturing readiness is a structured evaluation of a technology, component, manufacturing process, weapon system or subsystem. It is performed to:
- Define current level of manufacturing maturity;
- Identify maturity shortfalls and associated costs and risks; and
- Provide the basis for manufacturing maturation and risk management.
There are ten (10) MRLs that are correlated to the nine TRLs currently in use. The final level (MRL 10) is used to measure and foster Lean practices and continuous improvement for systems in production. The MRLs are defined as follows:
- MRL 1: Basic manufacturing implications identified.
- MRL 2: Manufacturing concepts identified.
- MRL 3: Manufacturing proof of concept developed.
- MRL 4: Capability to produce the technology in a laboratory environment.
- MRL 5: Capability to produce prototype components in a production relevant environment.
- MRL 6: Capability to produce a prototype system or subsystem in a production relevant environment.
- MRL 7: Capability to produce systems, or subsystems, or components in a production representative environment.
- MRL 8: Pilot line capability demonstrated; ready to begin low rate initial production.
- MRL 9: Low rate production demonstrated; capability in place to begin full rate production.
- MRL 10: Full rate production demonstrated and lean production practices in place.
11.8.3 Sustainment (Logistics) Maturity Levels (SMLs)
The Sustainment Maturity Level (SML) concept was established to help the Product Support Manager (PSM) identify the appropriate level of maturity the support plan should achieve at each milestone and the extent to which a program's product support implementation efforts are "likely to result in the timely delivery of a level of capability to the Warfighter. The SMLs provide a uniform metric to measure and communicate the expected life cycle sustainment maturity as well as provide the basis for root cause analysis when risks are identified and support OSD's governance responsibilities during MDAP program reviews. There are twelve (12) SMLs as follows:
- SML 1: Supportability and sustainment options identified.
- SML 2: Notional product support and maintenance concept identified.
- SML 3: Notional product support, sustainment and supportability requirements defined and documented to support the notional concept.
- SML 4: Supportability objectives and KPP/KSA requirements defined. New or better technology required for system or supply chain identified.
- SML 5: Supportability design features required to achieve KPP/KSA incorporated in design requirements.
- SML 6: Maintenance concepts and sustainment strategy complete. Life cycle sustainment plan approved.
- SML 7: Supportability features embedded in design. Supportability and subsystem maintenance task analysis complete.
- SML 8: Product support capabilities demonstrated and supply chain management approach validated.
- SML 9: Product support package demonstrated in an operational environment.
- SML 10: Initial product support package fielded at operational sites. Performance measured against availability, reliability and cost metrics.
- SML 11: Sustainment performance measured against operational needs. Product support improved through continual process improvement.
- SML 12: Product support package fully in place including depot repair capability.
The following figure depicts the three maturity models against the acquisition framework chart.
Figure 11-13 TRLs/MRLs/SMLs in the Acquisition Framework Chart
11.8.4 Producibility Engineering Planning (PEP)
The purpose of PEP is to ensure that product designs reflect good producibility considerations prior to release for manufacturing. Although there is no commonly accepted starting point for PEP, it is prudent to anticipate production system requirements as early in the program as in the material solution analysis phase, when only a small percentage of the total expected program life cycle costs has been incurred.
PEP involves the engineering tasks necessary to ensure timely, efficient and economic production of essential material. It includes efforts related to development of the Technical Data Package (TDP), Quality Assurance (QA) procedures, and evaluation of special production processes through trade studies. Also included are development of unique processes essential to the design and manufacture of the material and details of performance ratings; dimension and tolerance data; manufacturing methods; sequences; assembly; schematics; physical characteristics including form, fit and function; inspection test and evaluation requirements; calibration information and quality control procedures.
PEP is, in effect, a qualification process that will confirm the adequacy of the production planning, tool design, manufacturing process, and procedures before rate production begins.
It is DOD policy that factors affecting producibility and supportability shall be fully integrated during EMD. The design and test cycle shall be structured to provide a continuum in development for production, as opposed to discrete phases that cause iterative and redundant activities. The PEP program should be defined contractually and contain specific tasks and measurable performance that will support an orderly transition. PEP progress should be tracked by means of production readiness reviews required before initial or full production decisions. The objective of a transition plan is to provide visibility of how well each activity is being executed. Progress should be regularly compared against the transition plan.
11.8.4.1 Integrate Initial Production Facilities with Producibility Engineering and Planning
Only minimum manufacturing tools are required in the development phase to build and assemble prototype or test articles to be used for testing and evaluation of the engineering design. Off-the-shelf tools are utilized as much as possible and often prototype articles are, for all practical purposes, hand assembled. At some point in the development phase, consideration must be given to production tooling requirements. The Initial Production Facilities (IPF) effort is performed during the initiation of the Production Phase and provides the special tooling and test equipment needed to enter the production phase. The design and supporting documents for special tooling and test equipment are provided under Producibility Engineering & Planning. IPF translates these designs into a functioning production facility. Specific tasks include:
- Fabrication and validation of special manufacturing equipment;
- Fabrication and validation of Special Acceptance and Inspection Equipment (SAIE);
- and other special inspection equipment and gages;
- Initial set-up manufacturing of the line, if appropriate; and
- Maintenance of special equipment.
11.8.4.2 Integrate Long Lead Items with Producibility Engineering and Planning
Manufacturing documentation is prepared as a part of the PEP effort, and includes the master tooling plan, the manufacturing line layout and identification of long lead time items. Product design specifications should be relatively mature, at least with regard to special or scarce material requirement, major production equipment and special purpose production tooling which has to be ordered well in advance of start-up time. The early stages of development characteristically produce many Engineering Change Proposals (ECPs) and the PM must ascertain that the contractor is doing the necessary planning for manufacturing with special consideration for the long lead items.
