Version 7 October 2008
DoD Manufacturing Readiness Levels (MRLs)
Acq Phase Pre CR Pre CR Pre CR CR - MS A TD MS B SDD MS C LRIP - FRP FRP
Thread Sub-Thread MRL 1 MRL 2 MRL 3 MRL 4 MRL 5 MRL 6 MRL 7 MRL 8 MRL 9 MRL 10
Technology Maturity Should be assessed at TRL 1. Should be assessed at TRL 2. Should be assessed at TRL 3. Should be assessed at TRL 4. Should be assessed at TRL 5. Should be assessed at TRL 6. Should be assessed at TRL 7 Should be assessed at TRL 7. Should be assessed at TRL 8. Should be assessed at TRL 9.
Technology & Industrial Base
Technology Potential sources identified for Industrial Base capabilities and Industrial Base assessed to Industrial Capability Assessment Industrial capability to support Industrial Capability Assessment Industrial capability is in place to Industrial capability supports FRP.
Transition to technology needs. (Understand gaps/risks identified for key identify potential manufacturing (ICA) for MS B has been production has been analyzed. (ICA) for MS C has been support start of FRP. Industrial capability assessed to
Production state of the art). technologies, components, and/or sources. completed. Industrial capability in Sole/foreign sources stability is completed. Industrial capability is support mods, upgrades, surge
key processes. place to support mfg of assessed/monitored. Developing in place to support LRIP. Sources and other potential manufacturing
development articles. Plans to potential alternate sources as are available, multi-sourcing where requirements.
minimize sole/foreign sources necessary. cost-effective or necessary to
complete. Need for sole/foreign mitigate risk.
sources justified. Potential
Manufacturing New manufacturing concepts and Manufacturing technology Mfg science & advanced mfg Required manufacturing Manufacturing technology efforts Manufacturing technology efforts Manufacturing technology efforts Manufacturing technology efforts Manufacturing technology efforts
Technology potential solutions identified. concepts identified through technology requirements technology development efforts continuing. Required continuing. Required continuing. Required continuing. Manufacturing continuing. Manufacturing
Development experiments / models. identified. initiated. manufacturing technology manufacturing technology manufacturing technology technology process improvement technology continuous process
development solutions development solutions solutions validated on a pilot line. efforts initiated for FRP. improvements ongoing.
demonstrated in a production demonstrated in a production
relevant environment. representative environment.
Producibility Relevant materials/processes Producibility & Manufacturability Producibility & Manufacturability Producibility assessments of key Detailed producibility trade studies Producibility improvements Prior producibility improvements On-going producibility
Program evaluated for manufacturability assessment of design concepts assessments of key technologies technologies/components and using knowledge of key design implemented on system. Known analyzed for effectiveness during improvements analyzed for
using experimental results. completed. Results guide and components initiated. producibility trade studies characteristics and related producibility issues have been LRIP. Producibility issues/risks effectiveness. Producibility
selection of design concepts and Systems Engineering Plan (SEP) (performance vs. producibility) manufacturing process capability resolved and pose no significant discovered in LRIP have been refinements continue. All mods,
key components/technologies for requires validation of design completed. Results used to shape completed. Producibility risk for LRIP. mitigated and pose no significant upgrades, Diminishing Mfg
Technology Development choices against manufacturing System Development Strategy enhancement efforts (e.g. Design risk for FRP. Sources & Material Shortages
Strategy. Required Test process and industrial base and plans for SDD or technology For Mfg Assembly) initiated. (DMSMS) and other changes
Evaluation Strategy (TES) capability constraints. insertion programs phase. assessed for producibility.
includes Design for Test du Manufacturing proce
Design Maturity Manufacturing opportunities Applications defined. Broad Top level performance Initial Systems Engineering Plan Identification of enabling/critical Basic system design requirements Product requirements and Detailed design of product Major product design features are Product design is stable. Design
identified. performance goals identified that requirements defined. Trade-offs and Test and Evaluation Strategy technologies and components is defined. All enabling/critical features are well enough defined features and interfaces is stable and LRIP produced items changes are few and generally
may drive manufacturing options. in design options assessed based recognize the need for the complete and includes the product technologies/components have to support detailed systems complete. All product data are proven in product testing. limited to those required for
on experiments. Product lifecycle establishment/validation of lifecycle. Evaluation of design been tested and validated. Product design. All product data essential essential for system Design change traffic is limited to continuous improvement or in
and technical requirements manufacturing capability and Key Characteristics (KC) initiated. data required for prototype for manufacturing of component manufacturing released. Major minor configuration changes. All reaction to obsolescence. All KCs
evaluated. management of manufacturing manufacturing released. A design demonstration released. product design features are KCs are controlled in production to are controlled to 6-sigma or other
risk for the product lifecycle. Initial preliminary performance as well as Potential KC risk issues have sufficiently stable such that key 3-sigma or other appropriate appropriate quality levels.
Key Performance Parameters focused logistics specification is in been identified and mitigation plan LRIP manufacturing processes quality levels.
(KPPs) id is in will be representative of those
Production Cost Cost model approach defined. Technology cost models Detailed process chart cost Detailed end-to-end value stream Cost model inputs include design Cost models updated with detailed Engineering cost model driven by Actual cost model developed for Cost model validated against
Knowledge (Cost developed for new process steps models driven by key map cost model for major system requirements, material designs and features, collected detailed design and validated with FRP environment. Variability actual FRP cost.
modeling) and materials based on characteristics and process components includes materials, specifications, tolerances, quality data, plant layouts and data from relevant environment. experiments conducted to show
experiments. variables. Manufacturing, labor, equipment, tooling/STE, integrated master schedule, designs, and obsolescence FRP impact and potential for
material and specialized reqt. cost setup, yield/scrap/rework, Work In results of system/subsystem solutions. continuous improvement.
drivers identified. Progress (WIP), and simulations and production
capability/capacity constraints. relevant demonstrations.
Component simulations drive cost
Cost & Funding
Cost Analysis Any manufacturing cost Cost elements identified. Sensitivity analysis conducted to Material, manufacturing, and Current state analysis of cost of
Cost analysis of mfg future states, Costs rolled up to system level Cost analysis of proposed LRIP cost goals met and learning FRP cost goals met. Cost
implications identified. define cost drivers and production specialized reqt. costs identified design choices, make/buy, design trades, supply and tracked against targets. changes to requirements or curve validated. reduction initiatives ongoing.
development strategy (i.e. lab to for design concepts. Producibility chain/yield/rate/SDD/technology
capacity, process capability, Detailed trade studies and configuration.
pilot to factory). cost risks assessed. sources, quality, key insertion plans. Allocate cost engineering change requests
targets. Cost reduction and
characteristics, yield/rate, and supported by cost estimates.
variability. avoidance contract incentives Cost reduction efforts underway
identified. and incentives in place.
Manufacturing Potential investments identified. Program/ projects have budget Program/ projects have budget Manufacturing technology Program has budget estimate for Program has budget estimate for Program has budget estimate for Program has budget estimate for Program has budget estimate for Production budgets sufficient for
Investment Budget estimates for reaching MRL 3 estimates for reaching MRL 4. initiatives identified to reduce reaching MRL 6 by MS B. reaching MRL 7 by Critical Design reaching MRL 8 by MS C. reaching MRL 9 by the FRP lean implementation during FRP. production at required rates and
through experiment. costs. Program has budget Estimate includes capital Review (CDR). All Risk Mitigation Estimate includes investment for decision point. Estimate includes All Risk Mitigation Plans required schedule.
estimate for reaching MRL 5. All investment for production- Plans required to raise deficient Low Rate Initial Production. All investment for Full Rate to improve deficient subsystems to
Risk Mitigation Plans required to representative equipment. All Risk elements to MRL 6 are fully Risk Mitigation Plans required to Production. All Risk Mitigation MRL 9 during FRP are fully
raise deficient elements to MRL 4 Mitigation Plans required to raise funded. raise deficient sub systems to Plans required to raise deficient funded.
are fully funded. deficient elements to MRL 5 are MRL 7 are fully funded. sub systems to MRL 8 are fully
fully funded. funded.
Maturity Material properties identified for Material properties and Material properties validated and Survey completed to determine if Materials have been Material maturity verified through Materials maturity sufficient for Materials proven and validated on Material is proven and controlled Material is proven and controlled
exploration. characteristics predicted. assessed for basic materials have been used before manufactured or produced in a technology demonstration articles. pilot line build. Material System Demonstration and to specification in LRIP. to specification in FRP.
manufacturability using in a manufacturing environment. prototype environment. Maturity Preliminary material specifications specifications approved. Development (SDD) production as
Materials (Raw Materials, Components, Sub-
experiments. Preliminary plans in place to efforts in place to address new in place. adequate to support LRIP.
address producibility risks of new material production risks for Material specification stable.
material. technology demonstration.
assemblies and Sub-systems)
Availability Material availability assessed Material scale-up issues identified. Lead times have been identified Availability issues addressed for Availability issues addressed to Availability issues addressed to Long lead procurement initiated for Long lead procurement initiated for Program is in FRP with no
for all materials. All exotic (difficult prototype build. Significant meet technology demonstration meet SDD builds. Long lead LRIP. Availability issues pose no Full Rate Production (FRP). material availability issues.
to obtain, process, or hazardous) material risks identified for all articles. SDD long lead time items procurement identified/planned for significant risk for LRIP. Availability issues pose no
materials identified. materials. Planning has begun to identified. Obsolescence issues Low Rate Initial Production. significant risk for FRP.
address scale-up issues. identified. Obsolescence plan in place.
Supply Chain Initial assessment of potential Survey completed for potential Supply chain sources identified. Supply chain plans in place (e.g., Effective supply chain Supply chain stable and adequate Supply chain is stable and Supply chain proven and
Management supply chain capability. supply chain sources. Sole/single/foreign source vendors teaming agreements, etc.) leading management process in place. to support LRIP. Completed adequate to support FRP. Long supporting FRP requirements.
have been identified and planning to an SDD contract award. Completed assessment of supply assessment of supply chain term agreements in place where
has begun to minimize risks. chain first tier. second tier. practical.
Special Handling Initial evaluation of potential Special Handling procedures Special handling procedures Special handling procedures Special handling procedures Special handling procedures Special handling procedures Special handling procedures Special handling procedures
(i.e. shelf life, regulatory requirements and applied in the lab. Special handling applied. Special handling applied. Special handling applied. Plans to address special applied. Special handling applied. Special handling applied. Special handling effectively implemented in FRP.
security, hazardous special handling concerns. concerns assessed. Material requirements identified. Material requirement gaps identified. New handling requirement gaps procedures developed. procedures demonstrated on SDD procedures demonstrated in LRIP.
materials, storage Safety Data Sheets (MSDS) Safety Data Sheets (MSDS) special handling processes complete. or technology insertion programs Special handling issues pose no
environment, etc.) prepared. reviewed and updated. demonstrated in lab environment. production. Special handling significant risk for FRP.
issues pose no significant risk for
Modeling & Initial models developed, if Identification of proposed Production modeling & simulation Initial simulation models (product Initial simulation models developed Simulation models used to Simulation models verified by Simulation model verified by LRIP Simulation model verified by FRP
applicable. manufacturing concepts or approaches for process or product or process) developed at the and validated at the technology, determine system constraints and SDD article build. Results used to build and assists in management build. Production simulation
Process Capability & Control
& Process) producibility needs based on high- are identified. component level and validated. sub-system or system level. identify improvement improve process and determine of LRIP. Determine that FRP models used as tool to assist in
level process flow chart models. opportunities. that LRIP requirements can be requirements can be met. management FRP.
Manufacturing Identification of material and/or Document high level Complete a survey to determine Maturity has been assessed on Manufacturing processes Manufacturing processes Manufacturing processes verified Manufacturing processes & Manufacturing processes &
Process Maturity process approaches. manufacturing processes. Critical the current state of critical similar processes in production. demonstrated in production demonstrated in a production for LRIP on a pilot line. Process procedures are established and procedures are established and
manufacturing processes processes. Process capability requirements relevant environment. representative environment. capability data being collected or controlled in production to 3-sigma controlled in production to 6-sigma
identified through experimentation. have been identified. estimated. or other appropriate quality level. or other appropriate quality level.
Process Capability & Co
Process Yields and Initial estimates of yields and rates Yield and rates assessment on Target yield and rates established Yield and rates evaluated in Yield and rates estimated in Yield and rates required to begin Yield and rate targets achieved. Yield and rate targets achieved.
Rates based on experiments or state of proposed processes complete and for production. Yield and rate production relevant environment. production representative LRIP verified using SDD articles. Yield improvements on-going. Yield improvements on-going.
the art. applied within the Analysis of issues identified. Improvement Improvement plans on-going and environment.
Alternatives (AoA). plans developed/initiated. updated.
Quality Management Quality strategy identified as part Quality strategy refined in the Initial Quality Plan and Quality Quality targets established. Quality targets demonstrated on Quality targets verified on Quality targets verified on
including Supplier of the Technology Development System Engineering Plan and Key Management System are in place. Demonstrate ability to collect and pilot line. production line. Continuous quality production line. Continuous quality
Quality. Strategy. Characteristics are identified Quality risks and metrics have analyze quality data (process and improvement begins. improvement on-going.
during technology demonstrations. been identified. system) in the production
New manufacturing skills Mfg skill sets identified to Skill sets identified to meet Mfg workforce skills available for Mfg workforce resource Mfg workforce resource LRIP personnel requirements met. FRP personnel requirements met.
identified. overcome production barriers prototype production runs. Special production in a relevant requirements identified for pilot requirements identified for LRIP. FRP personnel requirements Production workforce skill sets
skills certification and training environment. Training resources line. Training resources identified Ability of mfg workforce to produce identified.. maintained due to attrition of
requirements quantified identified for production workforce. for special skills deficiencies and repeatable products and measure workforce.
LEAN 6-sigma training workforce quality. Training initiated
for certification on special skills
Specialized facility General industrial base (IB) IB capabilities and gaps to support Mfg facility and facility Facility capabilities for LRIP and Mfg facilities exist and are Mfg facilities in place and Production facilities in place and
requirements/needs identified. capability identified for key SDD and LRIP identified. Plan in development plans adequate to FRP identified. Plan in place to fill adequate to begin LRIP. Plans in demonstrated in LRIP. Capacity capacity demonstrated to meet
technologies. place to fill gaps. support SDD or technology gaps. Plant layout and design place to support transition to FRP. plans adequate to support FRP maximum FRP requirements.
insertion programs. initiated. decision. Executable facilities surge plan
Mfg Planning & Mfg strategy developed and Mfg strategy refined. Prototype Initial mfg approach developed. Initial mfg plan developed. Mfg Mfg plan completed. All key Mfg plan updated and validated for All manufacturing risks have been
Scheduling integrated with acq strategy. schedule risk mitigation efforts All system design related mfg risks integrated into Risk manufacturing risks have been FRP. All manufacturing risks validated and mitigated using FRP
Prototype schedule risk mitigation initiated. events included in Integrated Mitigation Plan. validated & mitigated using SDD have been validated and mitigated articles.
efforts incorporated into Master Plan/Schedule. Mfg risk or technology insertion program using LRIP articles.
Technology Development Strategy mitigation approach for SDD or work products.
(TDS). technology insertion programs
Materials Planning Parts list in development with Parts list maturing and make/buy Most material decisions made Analyses for make/buy decisions Make/buy decisions & BOM Make/buy decisions & BOM Program is in FRP with only
associated lead time calculations. evaluations ongoing. Lead times, (make/buy), material risk identified & BOM complete. Material complete to support LRIP. complete to support FRP. process
quality, cost and other risks and plans made to mitigate. Bill Of planning systems in place for pilot Material planning systems Material planning systems improvement/obsolescence
identified. Materials (BOM) initiated. line build. validated on pilot line build. validated on LRIP build. make/buy or BOM changes
allowed. Material planning
systems validated on FRP build.
Tooling / Special Tooling / Special Test Equipment Identify tooling /STE/SIE reqts & Prototype tooling concepts Production tooling and STE/SIE All tooling, test and inspection All tooling, test and inspection Proven tooling, test and inspection
Test and Inspection (STE) / Special Inspection provide supporting rationale and demonstrated in relevant mfg design and development efforts equipment proven on pilot line. equipment proven on LRIP. equipment in place to support
Equipment (STE/SIE) Equipment (SIE) requirements are schedule. environment. initiated. Multiple tooling reqts identified for Multiple tooling reqts identified for maximum FRP.
considered. LRIP. FRP.
Public Release Case Air Force Research Laboratory Materials & Manufactuing Directorate
#88ABW-2008-1197 AFRL/RXM ManTech's
Manufacturing Readiness Assessment Tool
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