Welcome to the Defense Manufacturing Management Guide for Program Managers
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Table of Contents
1.0 Overview of Manufacturing Management 1.1 Objective 1.2 Background 1.3 Introduction 1.4 DOD Policy 1.5 Organizational Structure 1.6 DOD Responsibilities 1.7 Government Program Manager Responsibilities 1.8 Relationship Between Government and Contractor Program Managers 1.9 Government Program Management Office Personnel Selection 1.10 Summary 1.11 Related Links and Resources
2.0 Industrial Base 2.1 Objective 2.2 Background 2.3 Introduction 2.4 DOD Law/Policy 2.5 Industrial Base Concerns 2.6 Industrial and Manufacturing Capability Assessments in the Acquisition Lifecycle 2.7 Industrial Analysis Center (IAC) 2.8 Industrial Base Planning 2.9 Industrial Base Investments 2.10 Defense Priorities System and Defense Materials System 2.11 Summary 2.12 Related Links and Resources
3.0 Acquisition Environment for Manufacturing 3.1 Objective 3.2 Background 3.3 Introduction 3.4 Manufacturing Management for Major DOD Acquisition Programs 3.5 Material Solution Analysis (MSA) Phase 3.6 Technology Development (TD) Phase 3.7 Engineering and Manufacturing Development (EMD) Phase 3.8 Production and Deployment (P&D) Phase 3.9 Operations and Support (O&S) Phase 3.10 Summary 3.11 Related Links and Resources
4.0 Manufacturing Strategy 4.1 Objective 4.2 Background 4.3 Introduction 4.4 The Roles and Goals of Manufacturing 4.5 Elements of a Manufacturing Strategy 4.6 Competition 4.7 Multi-Year Contracting 4.8 Summary 4.9 Related Links and Resources
5.0 Continuous Process Improvement (CPI) / Lean / Six Sigma 5.1 Objective 5.2 Background 5.3 Introduction 5.4 Continuous Process Improvement (CPI) 5.5 Continuous Process Improvement (CPI) Tools 5.6 Reliability, Availability and Maintainability 5.7 Quality in Contract Language 5.8 Summary 5.9 Related Links and Resources
6.0 Manufacturing Planning 6.1 Objective 6.2 Background 6.3 Introduction 6.4 Manufacturing Feasibility and Capability Analysis 6.5 Capacity Analysis 6.6 Risk Assessment 6.7 Developing the Manufacturing Plan 6.8 Contractor Manufacturing Plan 6.9 Production Rate Discussion 6.10 Manufacturing Planning and Control Systems 6.11 Summary 6.12 Related Links and Resources
7.0 Producibility 7.1 Objective 7.2 Background 7.3 Introduction 7.4 Integration of Design Considerations 7.5 Producibility Goals and Objectives 7.6 Producibility Engineering and Planning 7.7 Contractor Producibility Efforts 7.8 Value Engineering (VE) 7.9 Summary 7.10 Related Links and Resources
8.0 Technology Development and Investments 8.1 Objective 8.2 Background 8.3 Introduction 8.4 Technology Development in OSD 8.5 Programs That Facilitate Manufacturing/Technology Readiness 8.6 Technology Development Challenges and Considerations 8.7 Implementing A Technology Development Program 8.8 Summary 8.9 Related Links and Resources
9.0 Manufacturing Cost Estimating 9.1 Objective 9.2 Background 9.3 Introduction 9.4 Nature of Manufacturing Costs 9.5 Cost Accounting 9.6 Importance of Cost Estimating 9.7 Estimating Methodologies 9.8 The Learning Curve 9.9 Manufacturing Rate and Quantity Cost Relationship 9.10 Other Cost 9.11 Some Interesting Points 9.12 Summary 9.13 Related Links and Resources
10.0 Contracting Issues in Manufacturing 10.1 Objective 10.2 Background 10.3 Introduction 10.4 Contracting 10.5 Acquisition/Contracting Process 10.6 Manufacturing and Quality Assurance Program 10.7 Contractor Data 10.8 Subcontract Management 10.9 Make-or-Buy Program 10.10 Summary 10.11 Related Links and Resources
11.0 Transition from Development to Production 11.1 Objective 11.2 Background 11.3 Introduction 11.4 Transition Process Overview 11.5 DOD 4245.7-M: Transition From Development to Production 11.6 Transition Plan 11.7 Transition Challenges 11.8 Transition to Production Tools 11.9 Prodcution Risk Reduction Strategies 11.10 Summary 11.11 Related Links and Resources
12.0 Technical Reviews and Audits 12.1 Objective 12.2 Background 12.3 Introduction 12.4 The Role of Manufacturing 12.5 Technical Reviews and Audits 12.6 Managing the Technical Review Process 12.7 Gaps in Knowledge 12.8 Survey/Review Guidance 12.9 Summary 12.10 Related Links and Resources
13.0 Manufacturing Controls 13.1 Objective 13.2 Background 13.3 Introduction 13.4 Manufacturing Management System Evaluation 13.5 Performance Evaluation 13.6 Configuration Management (CM) 13.7 Measures of Contractor Effectiveness 13.8 Work Measurement 13.9 Cost/Schedule Control System Criteria (C/SCSC) 13.10 Earned Value Management (EVM) 13.11 Line of Balance (LOB) 13.12 Maturity Measures 13.13 Summary 13.14 Related Links and Resources
14.0 Factory of the Future 14.1 Objective 14.2 Background 14.3 Introduction 14.4 Trends in Technology 14.5 The Future of the 5Ms 14.6 The Future of Design 14.7 Summary 14.8 Related Links and Resources
15.0 Supply Chain Management and Sustainable Manufacturing 15.1 Objective 15.2 Background 15.3 Introduction 15.4 Supply Chain Operations Reference (SCOR®) Model 15.5 Transforming the Defense Supply Chains 15.6 The Future of Suppliers 15.7 Sustainable Manufacturing 15.8 Summary 15.9 Related Links and Resources
16.0 Manufacturing Problems and Organic Capabilities 16.1 Objective 16.2 Background 16.3 Introduction 16.4 Manufacturing Problems 16.5 Organic Capabilities 16.6 Random Thoughts 16.7 Summary 16.8 Related Links and Resources
17.0 Manufacturing Readiness 17.1 Objective 17.2 Background 17.3 Introduction 17.4 Assessment of Manufacturing Readiness 17.5 Policy and Guidance 17.6 Manufacturing Readiness Definitions 17.7 The MRL Matrix 17.8 The MRL Assessment 17.9 The Manufacturing Maturation Plan 17.10 Contract Language 17.11 Summary 17.12 Related Links and Resources
List of Figures
Figure 1-1 The Impact of Design Decisions on Life Cycle Cost
Figure 1-2 The Role and Goal of Manufacturing
Figure 1-3 Program Manager’s Reporting Chain (source ACQ 101)
Figure 1-4 The ACAT ID Reporting Chain
Figure 2.1 NASA Constellation Boosters
Figure 2-2 Consolidation of the Aircraft Industrial Base
Figure 2-3 Industrial Base Requirements Flow
Figure 2-4 Annual Industrial Capabilities Report to Congress
Figure 3-1 Life Cycle Framework View
Figure 3.2 Notional Integrated Product Team Structure
Figure 3.3 Systems Engineering Process Model (New)
Figure 3.4 Manufacturing Considerations during the MSA Phase
Figure 3.5 Manufacturing Considerations for the TD Phase
Figure 3.6 Manufacturing Considerations for the EMD Phase
Figure 3.7 Manufacturing Considerations for the P&D Phase
Figure 4-1 The Role and Goal of Manufacturing
Figure 4-2 Manufacturing Constraints and Risks
Figure 4-3 Strategy Development Process
Figure 4-4 DOD ManTech Structure
Figure 5-1 The DMAIC Cycle
Figure 5-2 House of Quality
Figure 5-3 Design of Experiment Orthogonal Array
Figure 5-4 A Stable Process
Figure 5-5 An Unstable Process
Figure 5-6 A Capable Process
Figure 5-7 Cause and Effect Diagram
Figure 5-8 Control Chart
Figure 5-9 Pareto Chart
Figure 5-10 Scatter Diagrams
Figure 5-11 PCB Fabrication Process Flow Chart
Figure 5-12 Seven Quality Management Tools
Figure 5-13 Four Keys to Achieving RAM
Figure 5-14 Reliability Growth Curve
Figure 6-1 Manufacturing Planning
Figure 6.2 Manufacturing Strategies
Figure 6-3 Manufacturing Resources
Figure 6-4 Risk Management Process
Figure 6-5 Cost Estimating Techniques
Figure 6-6 JSF Production Schedule
Figure 6-7 JSF Manufacturing Sequence Flow
Figure 6-8 PCB Fabrication Process
Figure 6-9 Master Phasing Chart for a Typical DOD Production Program
Figure 6-10 First Unit Flow
Figure 6-11 Integrated Master Plan (IMP) and Integrated Master Schedule (IMS)
Figure 6-12 Hierarchy of Schedules
Figure 6-13 Lead Times
Figure 6-14 Economic Production Rate
Figure 6-15 Material Requirements Planning (MRP) Information Flow
Figure 6-16 Manufacturing Resource Planning II (MRP II) Information Flow
Figure 7-1 Producible Weapon Systems
Figure 7-2 A-10 Aircraft
Figure 7-3 Goldberg Device for Remembering to Mail a Letter
Figure 7-4 Spider Diagram
Figure 7-5 Modular Open Systems Approach
Figure 7-6 Error Proofing a Bracket Design
Figure 7-7 The Systems Engineering Process Flow
Figure 7-8 Producibility Impact
Figure 7-9 F-18 Oxygen Tank Bottle Holder Redesign
Figure 7-10 Producibility in Design Intersection
Figure 7-11 Things to Maximize and Minimize
Figure 7-12 The Five Steps of Producibility
Figure 7-13 Producability Assessment Worksheet
Figure 8-1 Valley of Death
Figure 8-2 DoD Technology Investment Areas
Figure 8-3 Technology Readiness Levels
Figure 8-4 Technology Programs
Figure 8-5 ATD Process
Figure 8-6 Defense Acquisition Challenge Program Legislated Process
Figure 8-7 Joint Experimentation Program
Figure 8-8 DoD ManTech Strategic Thrust
Figure 8-9 DoD Small Business Innovation Research Program
Figure 9-1 Manufacturing Cost
Figure 9-2 Variable Cost
Figure 9-3 Shed Bill of Materials
Figure 9-4 Indirect Cost
Figure 9-5 Aircraft Work Breakdown Structure
Figure 9-6 Cost Estimating Methodologies
Figure 9-7 Maturity as a Considerations
Figure 9-8 Learning Curve Concept
Figure 9-9 Learning Curve Comparisons
Figure 9-10 Unit vs. Cum Learning Curves
Figure 9-11 Various Learning Curve Slopes by Industry
Figure 9-12 Impact of Production Breaks
Figure 9-13 Rate vs. Quantity Cost Relationship
Figure 9-14 Rate/Quantity Boundaries
Figure 9-15 Will Cost
Figure 9-16 Should Cost
Figure 9-17 Activity Based Cost Accounting
Figure 9-18 Work Measurement
Figure 9-19 Learning Curve Points
Figure 10-1 Contract Types
Figure 10-2 Sample Work Breakdown Structure
Figure 10-3 Incentive Improvement Goals
Figure 10-4 The Acquisition Process
Figure 10-5 The RFP Process
Figure 11-1 F-22 Timeline
Figure 11-2 V-22 Osprey Timeline
Figure 11-3 Acquisition Processes for Major Weapon Systems
Figure 11-4 Development/Production Environments
Figure 11-5 Old and New Acquisition Framework Chart
Figure 11-6 DoDI 4245.7-M Transition from Development to Production
Figure 11-7 Critical Path Template
Figure 11-8 Transition Timelines
Figure 11-9 Best Practices
Figure 11-10 JSF Hole Drilling Modernization
Figure 11-11 PRR Template Relationship
Figure 11-12 Cost Estimating Techniques
Figure 11-13 TRLs/MRLs/SMLs in the Acquisition Framework Chart
Figure 12-1 The Role of Manufacturing
Figure 12-2 Systems Engineering Technical Review Timing
Figure 12-3 Typical Format for a Technical Review
Figure 12-4 Technical Review Activities
Figure 12-5 GAO Identified Knowledge Points
Figure 12-6 Missile Risk Chart
Figure 13-1 Planning and Control over Manufacturing
Figure 13-2 Programs with Problems
Figure 13-3 The Role and Goal of Manufacturing
Figure 13-4 Configuration Management Technical Baselines
Figure 13-5 Configuration Item Map
Figure 13-6 Cost of Quality
Figure 13-7 Work Measurement Components
Figure 13-8 Work Breakdown Structure Extended to the Cost Account and Work Package Levels
Figure 13-9 Earned Value Management (EVM) Examples
Figure 13-10 Line of Balance Objectives Chart (A), Production Plan (B) and Program Status (C)
Figure 13-11 Technology Readiness Levels
Figure 13-12 Manufacturing Readiness Levels
Figure 14-1 Gork’s Digital Factory
Figure 14-2 The Factory of the Future
Figure 14-3 Connected Workforce
Figure 14-4 From Factory to Foxhole
Figure 14-5 From Factory to Foxhole
Figure 14-6 Robotic Arm
Figure 14-7 Predictive Maintenance
Figure 14-8 Bio-Based Design
Figure 14-9 Sustainable Materials
Figure 14-10 Custom Painted Model T's
Figure 14-11 Taguchi Loss Function
Figure 14-12 Molecular Measurement
Figure 14-13 Product Development Cycle Times
Figure 15-1 For Want of a Nail
Figure 15-2 Supply Chain
Figure 15-3 The SCOR® Model
Figure 15-4 The SCOR® Hierarchy
Figure 15-5 The DOD SCOR® Model - Logistics Focus
Figure 15-6 The JSCA Process Model
Figure 15-7 The DOD SCOR® Model - Acquisition Focus
Figure 15-8 NIST Sustainable Manufacturing Model
Figure 16-1 Brick making in the Tomb of King Rekhmire the Visor in Thebes
Figure 16-2 Product Life Cycle Chart
Figure 16-3 Tin Whiskers
Figure 17-1 GAO Assessment of Knowledge-Based Practices
Figure 17-2 The MRL Matrix
Figure 17-3 MRL Assessment Process
List of Tables
Table 1-1 Manufacturing Considerations by Phase
Table 3.1 Manufacturing Inputs to the Technology Development Strategy
Table 3.2 Manufacturing Management Contract Considerations for EMD
Table 4-1 Major Elements of a Manufacturing Strategy
Table 4-2 Critical Design Disciplines
Table 4-3 Leader/Follower Contracting Objectives
Table 4-4 Leader/Follower Conditions for Use
Table 4-5 Multi-Year Contracting Objectives
Table 4.6 Multi-Year Contracting Criteria
Table 5-1 Quality Management System Elements
Table 5-2 Deming’s 14-Points
Table 5-3 Keys to Achieving RAM
Table 6-1 MRP II Modules
Table 7-1 Producibility Tools and Techniques
Table 8-1 Manufacturing Readiness Levels - Definitions
Table 8-2 Sustainment Maturity Levels (SMLs)
Table 9-1 Cost Accounting Standards
Table 9-2 Cost Estimating Matrix
Table 9-3 Factors Leading to Manufacturing Improvement
Table 10-1 Uniform Contract Format
Table 10-2 Manufacturing Areas of Emphasis
Table 10-3 Elements of Manufacturing Strategy
Table 10-4 Contract Data Requirements List Objectives
Table 10-5 Typical Manufacturing Management Data Items
Table 10-6 Uses of Technical Data
Table 10-7 Contractor Purchasing System Review Special Concerns
Table 11-1 Technology and Manufacturing Considerations
Table 11-2 Production Planning - Template Relationship
Table 12-1 Pre-Award Survey Factors
Table 12- 2 DMCA Expertise
Table 13-1 Benefits of Work Measurement
Table 13-2 Performance Measurement Baseline Development Steps
Table 13-3 Work Breakdown Structure Level Identification
Table 15-1 Potential Supply Chain Metrics
Table 16-1 Defense Science Board Recommendations
Table 16-2 Types of DOD Suppliers
Table 17-1 GAO Assessment of Production Programs
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