4.2.5. Engineering and Manufacturing Development Phase

4.2.5. Engineering and Manufacturing Development Phase

4.2.5. Engineering and Manufacturing Development Phase

The primary objective of the Engineering and Manufacturing Development (EMD) phase is to develop the product baseline, verify it meets the system functional and allocated baselines, and transform the preliminary design into a producible design, all within the schedule and cost constraints of the program. Systems engineering (SE) activities support development of the detailed design, verification that requirements are met, reduction in system-level risk, and assessment of readiness to begin production and/or deployment. The core SE activities support the two efforts associated with the EMD phase as defined in DoDI 5000.02 for weapon systems acquisition and identified in figure 4.2.5.F1: integrated system design and system capability and manufacturing process demonstration.

Figure 4.2.5.F1. Systems Engineering Activities in the Engineering and Manufacturing Development Phase

Primary SE focus areas in EMD include:

The EMD phase includes technical assessment and control efforts, including value engineering techniques described in DAG section 4.3.19.3. Value Engineering, to effectively manage risks and increase confidence in meeting system performance, schedule, and cost goals. SE activities should be integrated with EMD 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. The planning, scheduling, and conduct of event-driven technical reviews (Critical Design Review (CDR), Functional Configuration Audit (FCA), System Verification Review (SVR), and Production Readiness Review (PRR)) are vital to provide key points for assessing program maturity and the effectiveness of risk-reduction strategies.

A well-planned EMD phase Systems Engineering Plan (SEP) builds on the results of previous activities and significantly increases the likelihood of a successful program compliant with the approved Acquisition Program Baseline (APB).

Implementing the technical planning as defined in the approved SEP guides the execution of the complex and myriad tasks associated with completing the detailed design and integration, and supports developmental test and evaluation activities. The SEP also highlights the linkage between Technical Performance Measures (TPM), risk management, and earned-value management activities to support tracking of cost growth trends. Achieving predefined EMD technical review criteria provides confidence that the system meets stated performance requirements (including interoperability and supportability requirements) and that design and development have matured to support the initiation of the Production and Deployment (P&D) phase.

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 EMD activities, which rely on and support SE efforts:

• Conduct activities in support of the EMD contract award
• Resource and conduct event-driven CDR, FCA, SVR, and PRR, and assess whether review criteria are met
• Establish and manage the initial product baseline established at the CDR
• Determine path forward on all major (Class I) baseline changes (see DAG section 4.3.7. Configuration Management Process for definition of Class I)
• Accept system deliveries (i.e., DD-250), as appropriate

In addition to the general roles and responsibilities described in DAG section 4.1.4 Engineering Resources, during this phase it is the Systems Engineer’s responsibility to:

• Manage the system design to satisfy the operational requirements within the constraints of cost and schedule and to evaluate the system design, identify deficiencies, and make recommendations for corrective action
• Conduct or support the technical evaluation in support of source selection for the EMD contract award
• Maintain requirements traceability and linkage to the initial product baseline
• Conduct event-driven technical reviews, advising the Program Manager on review criteria readiness
• Lead preparation and conduct of technical reviews
• Track and report major (Class I) baseline changes and recommend the path forward in accordance with the Configuration Management (CM) process (see DAG section 4.3.7. Configuration Management Process for definition of Class I)
• Support determination of production rates and delivery schedules
• Support test and evaluation activities: identify system evaluation targets driving system development and support operational assessments as documented in the Test and Evaluation Master Plan (TEMP) (see DAG Chapter 9 Test and Evaluation)
• Align the SEP with the TEMP on SE processes, methods, and tools identified for use during test and evaluation
• Analyze deficiencies discovered from operational assessments and verification methods (developmental test and evaluation); develop and implement solutions to including, but not limited to, rebalancing of system requirements
• Support logistics and sustainment activities as documented in the Life-Cycle Sustainment Plan (LCSP) (see DAG Chapter 5 Life-Cycle Logistics)
• Maintain the SEP including generating the update in support of Milestone C
• Ensure manufacturing process development and maturation efforts
• Develop approaches and plans to verify mature fabrication and manufacturing processes and determine manufacturing readiness (see the Manufacturing Readiness Level (MRL) Deskbook as one source for assessing manufacturing readiness)
• Conduct a rigorous production risk assessment and determine risk mitigation plans
• Identify system design features that enhance producibility (efforts usually focus on design simplification, fabrication tolerances, and avoidance of hazardous materials)
• Conduct producibility trade studies to determine the most cost-effective fabrication and manufacturing process
• Assess Low-Rate Initial Production (LRIP) feasibility within program constraints (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
• Support update to production costs as a part of life-cycle cost management
• Continue to support the configuration management process to control changes to the product baseline during test and fielding

Inputs

Table 4.2.5.T1. summarizes the primary inputs associated with this systems acquisition part of the life cycle (see DoDI 5000.02).

Table 4.2.5.T1. Inputs Associated with EMD Phase

Activities

The EMD phase activities begin when a favorable Milestone B decision has been made (see DAG section 4.2.4. Technology Development Phase) and end with a successful Milestone C decision. Figure 4.2.5.F2 provides the end-to-end perspective and the integration of SE technical reviews and audits across the acquisition life cycle.

Figure 4.2.5.F2. Weapon System Development Life Cycle

SE activities to support the integrated system design effort include:

• Realization of the system architecture
• Performance of system element trade-offs
• Use of prototypes to mature system designs and drawings. If the program strategy includes competitive development, this may include competitive prototyping during the EMD phase.
• Development of the initial product baseline and a stable design that conforms to program cost, schedule, and performance requirements
• Support for the establishment of the developmental test and evaluation environment and associated resources (e.g., people, equipment, test cases, and test ranges)
• Support of materiel readiness and logistical support efforts
• Preparation for production by identifying critical manufacturing processes, key product characteristics, and any manufacturing risks

SE activities to support the system capability and manufacturing process demonstration effort include:

• Build, integrate, and test system elements
• Fabricate and assemble the system elements and system to the product baseline
• Identify the process to proactively manage and mitigate Diminishing Manufacturing Sources and Material Shortages (DMSMS) issues in future life-cycle phases
• Integrate the system and verify compliance with the functional and allocated baselines through developmental test and evaluation (DT&E) efforts (see DAG Chapter 9 Test and Evaluation for more on DT&E)
• Determine the root cause of problems, identify corrective actions, and manage to completion
• Address problem/failure reports through the use of a comprehensive data-collection approach such as Failure Reporting, Analysis and Corrective Action System (FRACAS)
• Refine the initial product baseline and support the development of the Capability Production Document (CPD)
• Complete producibility activities supporting manufacturing readiness or implementation and initial deployment activities for information systems
• Support initiation of materiel readiness and logistical support activities including fielding options and training development
• Perform Environment, Safety, and Occupational Health (ESOH) risk management analyses and ESOH risk acceptance
• Produce NEPA/EO 12114 documentation
• Perform corrosion risk assessment
• Complete certifications as appropriate (see DAG section 4.1.5. Certifications)

Technical reviews and audits typically conducted in EMD:

• Critical Design Review (CDR) (mandated, establishes initial product baseline, see DAG section 4.2.13. Critical Design Review)
• System Verification Review/Functional Configuration Audit (SVR/FCA) (see DAG section 4.2.14. System Verification Review/Functional Configuration Audit)
• Production Readiness Review (PRR) (DAG section 4.2.15. Production Readiness Review)

Test activities during the EMD phase that depend on SE support and involvement include Test Readiness Reviews (TRRs), Developmental Test and Evaluation (DT&E), and Operational Assessments (OAs). The Systems Engineer, in collaboration with the Chief Developmental Tester, should identify system evaluation targets driving system development and support operational assessments as documented 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 identified in Table 4.2.5.T2 and are some of the inputs necessary to support SE processes in the P&D phase. They should support the technical recommendation at Milestone C that manufacturing processes are mature enough to support Low-Rate Initial Production (LRIP) and generate production-representative articles for operational test and evaluation (OT&E). Technical outputs associated with technical reviews in this phase are addressed later in this chapter.

Table 4.2.5.T2. Technical Outputs Associated with EMD Phase