Version 7 October 2008

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					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

                                                  Simulation (Product
                                                  & 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
                                                                                                                                                                                                      representative environment.

                                                  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.
  Mfg Personnel

                                                  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
  Mfg Management

                            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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Description: Production Skill Matrix Chart document sample