4.2.6. Production and Deployment Phase

DEFENSE ACQUISITION GUIDEBOOK
Chapter 4 -- Systems Engineering

4.2.6. Production and Deployment Phase

4.2.6. Production and Deployment Phase

The objective of the Production and Deployment (P&D) phase is to validate the product design and to deliver the quantity of systems required for full operating capability, including all enabling system elements and supporting material and services. Systems engineering (SE) in P&D delivers the final product baseline as validated during operational testing, and supports deployment and transition of capability to all end users, the warfighters, and supporting organizations. SE activities, for example maintenance approach, training, and technical manuals, should be integrated with P&D phase-specific test and evaluation and logistics and sustainment activities identified in DAG Chapter 9 Test and Evaluation and Chapter 5 Life-Cycle Logistics, respectively. This phase typically has several major efforts as shown in Figure 4.2.6.F1: Low-Rate Initial Production (LRIP), Operational Test and Evaluation (OT&E), Full-Rate Production (FRP) and Full Deployment (FD), and deployment of capability in support of the Initial and Full Operational Capabilities. The Full-Rate Production Decision Review (FRP DR) and/or Full Deployment Decision Review (FD DR) serves as a key decision point between LRIP (and OT&E) and FRP/FD.

Figure 4.2.6.F1. Production and Deployment Phase

Manufacturing development should be complete at Milestone C, but improvements or redesigns may require unanticipated, additional manufacturing process development and additional testing (e.g., delta qualification or delta first article test). For example, it may be discovered that changing the product design may provide enhancements in manufacturing or other supporting processes. At the conclusion of LRIP, all manufacturing development should be completed, with no significant manufacturing risks carried into FRP. The dynamic nature of the varied production elements requires a proactive approach to mitigate emerging risks.

Readiness for OT&E is a significant assessment of a system’s maturity (see DAG Chapter 9 Test and Evaluation). The Systems Engineer plays a key role in ensuring systems are ready to enter OT&E. Scarce resources are wasted when an operational test is halted or terminated early because of technical problems that should have been resolved before the start of OT&E.

During deployment, units attain Initial Operational Capability (IOC), then Full Operational Capability (FOC).

Besides ensuring a successful FOC, the SE activities:

• Mature manufacturing, production, and deployment procedures
• Respond to deficiencies and develop corrective actions
• Support validation of system performance associated with OT&E
• Validate the production configuration prior to FRP / FD

Roles and Responsibilities

In addition to the general responsibilities identified in DAG section 4.1.4. Engineering Resources, the Program Manager focuses on the following P&D activities, which rely on and support SE efforts:

• Conduct activities in support of the production contract award(s)
• Resource and conduct event-driven technical reviews (including the Physical Configuration Audit (PCA), Post Implementation Review (PIR), and FRP and/or FD DR) and ensure that criteria are met
• Manage and control the final product baseline
• Manage risks, in particular the manufacturing, production, and deployment risks
• Accept system deliveries (i.e., DD-250)

In addition to the general responsibilities identified in DAG section 4.1.4. Engineering Resources, the Systems Engineer is responsible to:

• Analyze deficiencies discovered from OT&E, acceptance tests, production reports, and maintenance reports and provide correction actions
• Conduct rigorous production risk assessments; plan and resource effective risk mitigation actions
• Continue conducting producibility trade studies to determine the most cost-effective fabrication/manufacturing process
• Develop approaches and plans to validate fabrication/manufacturing processes
• Assess full-rate production feasibility within program constraints. This may include assessing contractor and principal subcontractor production experience and capability, new fabrication technology, special tooling, and production personnel training requirements
• Identify long-lead items and critical materials; plan for obsolescence and implement DMSMS measures to mitigate impacts to production and sustainment
• Update production costs as a part of life-cycle cost management
• Support updates to the production schedules
• Support technical reviews and production decisions
• Support materiel readiness and logistical activities, including fielding and training
• Continue to support the Configuration Management Board to control changes to the product baseline during test and fielding
• Update and maintain system certifications and interfaces with external systems, as necessary

Inputs

Table 4.2.6.T1 summarizes the primary inputs associated with this systems acquisition part of the life cycle.

Table 4.2.6.T1. Inputs Associated with P&D Phase

Activities

The P&D phase SE activities begin when a favorable Milestone C decision has been made (see DAG section 4.2.5. Engineering and Manufacturing Development Phase) and end when FOC is achieved. Figure 4.2.6.F2 provides the end-to-end perspective and the integration of SE technical reviews and audits across the acquisition life cycle.

Figure 4.2.6.F2. Weapon System Development Life Cycle

SE activities that occur throughout the P&D phase include:

• Provide technical support to prepare for the Operations and Sustainment (O&S) phase, reviewing and providing inputs on the maintenance approach, acquisition strategy, training, and technical manuals
• Determine root cause of problems, identify corrective actions, and manage to completion
• Analyze system deficiencies generated during OT&E, acceptance testing, production, and deployment
• Address problem/failure reports through the use of a comprehensive data collection approach like a Failure Reporting, Analysis and Corrective Action System (FRACAS)
• Manage and control of configuration updates (hardware, software, and specifications) to the product baseline
• Re-verify and validate production configuration

SE provides inputs to OT&E readiness assessments including:

• Results of prior DT&E
• Analysis of the system's progress in achieving performance metrics (see DAG section 4.3.4. Technical Assessment Process)
• Assessment on satisfaction of approved OT&E entrance criteria
• Assessment of technical risk
• Assessment of software maturity and status of software trouble reports
• Identification of any potential design constraints affecting the system's expected performance during OT&E

In both the Production and Deployment and O&S phases the Systems Engineer should identify and plan for potential obsolescence impacts (i.e., Diminishing Manufacturing Sources and Material Shortages (DMSMS)). DMSMS problems are an increasing concern as the service lives of DoD weapon systems are extended and the product life cycle for high-technology system elements decreases.

The PCA is a SE audit typically conducted in the P&D phase (see DAG section 4.2.16. Physical Configuration Audit for additional information regarding the PCA).

Test activities during the P&D phase that depend on SE support and involvement include the Assessment of Operational Test Readiness (AOTR) for MDAPs, Operational Test Readiness Reviews (OTRRs), initial and follow-on OT&E (IOT&E and FOT&E), and live-fire test and evaluations (LFT&E), as appropriate (see DAG Chapter 9 Test and Evaluation). In addition, any corrective actions or design changes implemented in response to test identified deficiencies require additional regression testing.

The Systems Engineer, in collaboration with the Chief Developmental Tester, should identify technical support needed for operational assessments and document in the Test and Evaluation Master Plan (TEMP). Associated SE activities and plans should be in the SEP (see DAG section 4.1.2. Systems Engineering Plan, 4.2.8. Technical Reviews and Audits Overview, and DAG Chapter 9 Test and Evaluation).

Outputs and Products

The technical outputs and products from the P&D phase identified in Table 4.2.6.T2 are some of the inputs necessary to support SE processes in the O&S phase. They should support the program’s transition into full operations and sustainment. Technical outputs associated with technical reviews in this phase are addressed later in this chapter.

Table 4.2.6.T2. Technical Outputs Associated with P&D Phase

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