Dr. Thomas D. Fiorino Advanced Product Transitions Corporation 23 Jan 2008
Purpose Provide information on the fundamentals, criteria and metrics for Engineering Manufacturing Readiness Levels (EMRLs) 2
Need for EMRLs Successful products require the capture of design and • manufacturing knowledge early in product development • DoD acquisition policy does not require the capture of design and manufacturing knowledge or sufficiently specific criteria/metrics to enter Product Development and Demonstration (Milestone B) and Production and Deployment (Milestone C) phases • EMRLs provide the framework, with specific criteria and metrics, to capture the design and manufacturing knowledge for product development, demonstration, production and deployment 3
The Defense Acquisition Management Framework • Process entry at Milestones A, B, or C User Needs & • Entrance criteria met before entering phase Technology Opportunities • Evolutionary Acquisition or Single Step to Full Capability (Program C IOC A FOC B Initiation) Production & System Development Concept Technology Deployment & Demonstration Operations & Refinement Development FRP Design Support Decision Readiness LRIP/IOT&E Review Review Pre-Systems Acquisition Systems Acquisition Sustainment BLOCK 2 BLOCK 3 4
EMRLs and Work Breakdown Structure (WBS) EMRLs can be tailored to apply at the item, component, • subsystem and system levels • Each lower WBS product should be at a higher level EMRL (level of readiness) than the higher level product; i.e., if the missile has met the exit criteria for Milestone B, the seeker should be at or near DRR and the focal plane should be ready for LRIP. EMRL 1 Missile EMRL 1-2 Seeker EMRL 2-3 Focal Plane Array 5
EMRLs and Acquisition Milestones • Process entry at Milestones A, B, or C User Needs & • Entrance criteria met before entering phase Technology Opportunities • Evolutionary Acquisition or Single Step to Full Capability (Program C IOC A FOC B Initiation) Production & System Development Concept Technology Deployment & Demonstration Operations & Refinement Development FRP Design Support Decision Readiness LRIP/IOT&E Review Review Pre-Systems Acquisition Systems Acquisition Sustainment BLOCK 2 BLOCK 2 BLOCK 3 BLOCK 3 EMRL 1 EMRL 2 EMRL 3 EMRL 4 EMRL 5 6
EMRL Metrics and Exit Criteria System EMRL 1 System EMRL 2 System EMRL 3 Capability Knowledge Point 1 Capability Knowledge Point 2 Capability Knowledge Point 3 Milestone B System DRR Milestone C • Minimum system TRL=8-9 • Minimum system TRL=4 or 5 • Minimum system TRL=6 or 7 • All system engineering/design requirements • All system engineering/design requirements • All system engineering/design requirements defined and validated defined; 50% validated defined; 90% validated • Minimal engineering changes • Component physical and functional interfaces • Component physical and functional interfaces • All component physical and functional interfaces 50% defined at system level 90% defined at system level defined and validated at system level • Materials, machines, tooling and test equipment • System level manufacturing process and inte- • All manufacturing processes are understood and demonstrated in a lab environment (system) gration established in a production environment in control for LRIP • Manufacturing processes and system level • Materials, machines, tooling and test equipment • All materials, machines, tooling and test integration demonstrated established in a production environment equipment purchased and ready for LRIP • Quality and reliability levels identified and • Quality and reliability levels identified and • All quality and reliability levels established and established for 50% of the system established for 90% of the system verified • Key characteristics identified for 50% of the • Key characteristics identified for 90% of the • All key characteristics identified and verified system system • Follow up issues from DRR cleared • PDR complete at system level • DRR complete at system level • All subsystems, items and components • 90% of items and components for system/major • All items and components at EMRL3, CKP3, and (hardware and software) are ready for on-time subsystem are proven designs or in production; are ready for production or in production and meet delivery (or delivered) EMRL 2-3 (hardware and software) and DRR cost, quality and reliability targets • All subsystems, items and components meet cost, complete • 75% of major subsystems representing 80% of quality and reliability targets • 75% of major subsystems (those representing 80% cost meet the requirements of CKP3 and are ready • Failure modes, effects and criticality analysis of cost) meet requirements of CKP2 and complete for or in LRIP complete at system level DRR • Failure modes, effects and criticality analysis • Reliability growth plan in place at all levels • Failure modes, effects and criticality analysis complete on all items and components, 75% • Funding identified for reliability growth required for all levels complete at system level • All reliability growth testing is in place • Funding identified to proceed to CKP2 • Funding identified to proceed to CKP3 • Funding identified for LRIP • Schedule and funding profile reflects achievement • Schedule and funding profile reflects achievement • Schedule and funding profile reflects of CKP2 in 1-3 years of CKP3 in 1-3 years achievement of CPK4 in 1-2 years • Developmental test plans complete for 75% of • Developmental test complete for major subsystems • Minimal developmental tests yet to be completed major subsystems • Developmental test plans complete at system level • All IOT&E plans complete • Developmental test plans initiated at system level • IOT&E plans complete • Initial Safety Assessment Complete • Safety assessment plans initiated • Safety assessment plans complete • Design to cost goals met for LRIP 7 • Design to cost goals established • Design to cost goals validated
EMRL Metrics and Exit Criteria System EMRL 4 System EMRL 5 Capability Knowledge Point 4 Capability Knowledge Point 5 FRP Continuous Improvement • System TRL=9 • System TRL=9 • All system engineering/design requirements • All system engineering/design requirements defined validated and met defined validated and met • Essentially no engineering changes • Engineering changes are made for process or • All physical and functional interfaces defined and product improvements validated • All physical and functional interfaces defined and • All materials, machines, tooling and test equipment validated in place at system level and ready for FRP • Materials, machines, tooling and test equipment • All manufacturing processes are understood and in updated, modified or replaced for quality, cost or control for FRP schedule improvements • All quality and reliability levels or targets met • Manufacturing processes modified or changed for • All Key system characteristics met quality, cost or schedule improvements • All follow up issues from system level FRP PRR • Quality and reliability levels or targets improved cleared beyond 3 sigma • All subsystems, item and components (hardware and • All Key system characteristics met or exceeded software) are in FRP and are ready for on-time • All subsystems, item and components (hardware delivery or are delivered and software) assessed for cost, quality and • All failure modes, effects and criticality analysis performance improvements complete • Reliability growth improvements implemented • Reliability growth program implemented at all levels • Funding in place for continued reliability growth • Reliability growth testing implemented at all levels • All subsystems, items and components continue • Funding in place for reliability growth to meet or exceed design to cost goals • All subsystems, items and components meet design • Funding identified for continued production to cost goals • Funding identified for spiral improvements or • Funding identified for FRP block upgrades • System level developmental tests complete • Safety assessment complete • IOT&E complete • System design to cost goals met or exceeded • Safety assessment complete • System design to cost goals met for FRP 8
Time Certain Delivery • Process entry at Milestones A, B, or C User Needs & • Entrance criteria met before entering phase Technology Opportunities • Evolutionary Acquisition or Single Step to Full Capability (Program C IOC A FOC B Initiation) Production & System Development Concept Technology Deployment & Demonstration Operations & Refinement Development FRP Design Support Decision Readiness LRIP/IOT&E Review Review Pre-Systems Acquisition Systems Acquisition Sustainment BLOCK 2 BLOCK 2 BLOCK 3 BLOCK 3 EMRL 1 EMRL 2 EMRL 3 EMRL 4 EMRL 5 Time Certain 2-5 1-3 Development and Delivery 9 years years
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