Defense Manufacturing Management Guide for Program Managers

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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