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Assessing Manufacturing Risk

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Note:  DAU can provide a tailored 2-day workshop on how to assess manufacturing risk using the MRL criteria and assessment process.

Assessing Manufacturing Risk: A Best Practice

The use of Technology Readiness Levels has become a "Best Practice (tool)" that has added clarity to technical assessments and the discussion of technoloyg maturity and risk. Manufacturing Readiness Levels (MRLs) were developed to provide a similar understanding of manufacturing risk and maturity. The use of MRLs to assess manufacturing readiness can foster better decision making, program planning and program execution through improved understanding and management of manufacturing risk.

Note: This is DRAFT information. DoDI 5000.02 requires programs to assess manufacturing risk as early as Milestone A in the Analysis of Alternatives, as well as at Milestones B and C and at the Full Rate Production decision. There is no specific guidance in 5000.02 on how these assessments should be conducted. However, many companies and DoD organizations are using MRLs as a Best Practice and are incorporating MRL assessments into existing technical reviews and audits.

MRL Questions: To review the assessment questions, either click on the appropriate MRL link on the chart below that is appropriate for your phase or go to the current MRL questions found on the Air Force MRL Tool. MRL 10 focuses on Full Rate Production (FRP) and Continuous Improvement using tools like Lean and Six Sigma to optimize processes, however achievement of Lean/Six Sigma is not a requirement. 

Notes: The TRLs shown below reflect Normal Practices and at TRL 7 have a slight disconnect with MRLs. Also, the links on the new Acquisition Framework Chart link to the old definitions and will remain that way until the DAG is updated.


Milestone A Milestone B Milestone C Pre-Concept Materiel Solution Analysis Phase Technology Development Phase Engineering and Manufacturing Development Phase Production and Deployment Phase Operations and Support Phase Initial Technical Review (ITR) Alternative Systems Review (ASR) System Requirements Review (SRR) and a Technology Readiness Assessment (TRA) System Verification Review (SVR aka Functional Configuration Audit) Physical Configuration Audit (PCA) Critical Design Review (CDR) and a TRA Preliminary Design Review (PDR) System Functional Review (SFR) Integrated Baseline Review (IBR; program review not a technical review) Operational Test Readiness Review (OTRR; program review not a technical review) Production Readiness Review (PRR) and a TRA Test Readiness Review (TRR) TRL-1 TRL-2 TRL-3 TRL-4 TRL-5 TRL-6 TRL-7 TRL-8 TRL-9 MRL-1 MRL-2 MRL-3 MRL-4: Material Solution Analysis MRL-5: Component Technology Development MRL-6: System Technology Development MRL-7: Engineering and Manufacturing Development (pre-DRR) MRL-8: Engineering and Manufacturing Development (post-DRR) MRL-9: Production (pre-FDR) MRL-10: Deployment and Sustainment


MRLs as they relate to the Acquisition Framework ChartQuick Links to Additional MR Resources:


Select a program below to view a lesson learned. Army programs Advanced Precision Kill Weapon System (APKWS) Advanced Threat Infrared Countermeasure/Common Missile Warning System (ATIRCM/CMWS) CH-47F Improved Cargo Helicopter Excalibur Precision Guided Extended Range Artillery Projectile Future Combat Systems (FCS) Land Warrior Navy programs V-22 Joint Services Advanced Vertical Lift Aircraft (V-22 Osprey) Littoral Combat Ship (LCS) Extended Range Guided Munition (ERGM) DD(X) Destroyer Cooperative Engagement Capability (CEC) Advanced SEAL Delivery System (ASDS) Air Force programs Advanced Extremely High Frequency Satellites (AEHF) C-5 Avionics Modernization Program (C-5 AMP) Evolved Expendable Launch Vehicle (EELV) - Atlas V F/A-22 Raptor Global Hawk Unmanned Aerial Vehicle Space Based Infrared System High (SBIRS) United States Marine Corps programs Heavy Lift Replacement (HLR) Expeditionary Fighting Vehicle (EFV) Missile Defense Agency programs Airborne Laser (ABL) Aegis Ballistic Missile Defense (Aegis BMD) Ground-Based Midcourse Defense (GMD) Kinetic Energy Interceptors (KEI) Space Tracking and Surveillance System (STSS) Terminal High Altitude Area Defense (THAAD) Joint programs Joint Common Missile (JCM) Joint Strike Fighter (JSF) Joint Standoff Weapon (JSOW) Joint Tactical Radio System Cluster 1 (JTRS Cluster 1) Joint Unmanned Combat Air Systems (J-UCAS) Joint Air-to-Surface Standoff Missile (JASSM) Source: GAO-05-301 Report: Defense Acquisitions, Assessments of Selected Major Weapon Programs.


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Date CreatedMonday, October 17, 2005 2:23 PM
Date ModifiedMonday, June 8, 2015 9:01 AM
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