Design-Build

(Producibility)
 THE ROLE OF MANUFACTURING
MSC
• EXECUTE THE
• INFLUENCE THE DESIGN MANUFACTURING PLAN
PROCESS • REFLECT DESIGN INTENT
• REPEATABLE PROCESSES
• PREPARE FOR • PROCESS IMPROVEMENT
PRODUCTION

PRODUCIBLE DESIGN + FACTORY FLOOR CHARACTERIZED

UNIFORM, DEFECT-FREE PRODUCT

• CONSISTENT PERFORMANCE
• LOWER COST
 Technical Impacts of Mfg
• A design constraint; can design be physically realized?

• A risk driver; can mfg meet cost and schedule?

• A set of enabling/critical technologies; will required processes

be available, capable (Q), and adequate (capacity)? How well
characterized are the processes and materials?

• Design phase obligates at least 80% of LCC;

design establishes materials, tolerances, tooling, derived
production processes and required employee skills.

What functional group(s) should have the most responsibility for

producibility?
 Production Issues
Risks And Concerns
• Unstable Requirements & Engineering Changes
• Unstable Production Rates & Quantities
• Insufficient Process Proofing of New Processes
• Insufficient Materials Characterization
• Variability of Processes and Components
• Producibility
• Real Production Readiness Reviews of Value
• Changes in Proven Materials, Processes, Subcontractors, Vendors &
Components
• Configuration Management
• Subcontractor Management
• Special Tooling (ST) & Test Equipment (STE)
• Special Processes; welding and composites
 Insufficient Materials
Characterization & Process Proofing
M1 Tank: Unable To Cut Armor Plate To Net
Shape. Process Not Tested At
Production Sizes And Rates.

C-17 Aircraft: Aluminum-Lithium Cracking.

Anisotropy Not Detected.

Seawolf HY100 Weld Cracking. Undetected

Submarine: Interaction Between Filler Wire
Carbon Equivalent And Weld Preheat
due to process parameter
extrapolation.
 PRODUCIBILITY
• A measure of the relative ease of
production.
• Is the primary responsibility of the
SE/design functions w/strong input from
mfg (remember lean 3P methodology).
• Required by the DoD 5000 Series.
• Can be measured – how?
• In many design situations requires
a trade-off.
 Product & Process Design for
Producibility (DFSS)
• Reduce the number of times that people and machines touch the product
• Reduce unnecessary process steps
• Design workspaces and tooling for unobstructed access and vision
• Minimize the total number and types of parts
• Use standard components
• Design multifunctional/multiple use parts
• Avoid separate fasteners
• Maximize compliance in assembly. Make parts easy to align and locate.
• Minimize adjustments and re-orientations during fabrication and assembly
• Single direction assembly
• Ease the handling of parts and tools (waist high vs. overhead)
• Minimize special materials and processes
• Use open standards
• Ensure new materials are properly and completely characterized
• Ensure new processes are proven at full-rates in production representative
conditions
• Develop trade-off data for different volumes, materials, processes and related
tooling
• Develop quantitative measures of process capability (Cp & Cpk) and maintain
process control
F-18 E/F Ejection Seat Bailout Oxygen Bottle Bracket

BEFORE
 AFTER

Number of parts -33%

Number of operations -31%
Number of fasteners -38%
Assembly time -20%
 Every Part Creates Overhead $
• Every part, no matter how small, has significant O/H costs:
– Ordering
– Receiving
– Stocking
– Delivering to Point of Use
– Reworking
– Reordering
– Maintaining Spares
– Writing & Updating Technical Manuals
– Supplying to Field Service
– Packaging & Shipping
• Multiply this overhead cost by the number of times it is repeated
during the life cycle of a product this equals the total cost of the
part.
 Producible Systems
• Model T
• Liberty Ships
• Higgins Boats
• Soviet AK-47
• Soviet RPG
• Soviet T-34 Tank
• F-16
• A-10
A-10
Airframe 95% aluminum by weight
Flush rivets only on forward 1/3 of airframe
Minimized compound curvature – minimizes need for special tooling
External landing gear pods – simplifies load paths and internal structure
Constant chord wind box – minimum machining with emphasis on 3 axis machines
Heavy use of extrusions – minimum machining
Standardization of empennage components – no left-hand and right-hand parts

\\\\\\ Single Curvature

*

* Compound curvature of tub and nacelles only. The rest of

the fuselage is single (developable) curvature.
Location of a subassembly break can increase interface complexity,
increase assembly time and decrease worker access during assembly.
Critical and Key Characteristics

There is some confusion over the two terms –

ask if you are not sure

Critical Characteristic = Critical Safety

Characteristic = Flight Safety Characteristic:

Any feature throughout the lifecycle that if

nonconforming, missing or degraded may cause
the failure or malfunction of a Critical Safety
Item. Critical Characteristics address product
safety issues.
 Key Characteristic
A feature of a material, process or
part/assemblies whose variation within the
specified tolerance has a significant influence on
product fit, performance, service life or
manufacturability.

KCs identify opportunities for improvement

though the management of variation. KCs are
usually managed at > 1.33 Cpk. This is an
arbitrary number.
 TPMs

Product Key Characteristics

Manufacturing Key Characteristics

Assembly Key Characteristics

 Boeing 777
Rudder Assembly

Critical & Key: Critical & Key:

Hinge attach points Contour of surface
alignment

Hinge Attach Points Alignment Key Feature & Mfg Characteristics:

• Rib Width
• Spar Width
• Flange Thickness
• Hinge Fitting Hole Location
• Hinge Fitting Flatness
 Production Readiness Reviews

• Incremental, proactive, preventative reviews spread

over development
• Identify Risks, issues, and opportunities Early
• Assess Capability to deliver on time, within cost
• Assess actual Performance (develop metrics)
• Assess Effectiveness of corrective actions
• Measure performance and continuous improvement
• Use your DCMA/CAS resources
Production Readiness Reviews

• Get a Charter that the PMO and Contractor Understand

• Coordinate with DCMA/CAS
• Establish Areas of Assessment
– Producibility Problems & Opportunities
– Engineering changes/Design stability
– Cost of scrap, rework and repair
– Sub-contractor performance
– Cost and Delivery performance
– Manufacturing Process Control
– Status of corrective actions
– Tooling status
• Develop Metrics
• Ask questions, touch things, speak to shop floor workers
- PRRs are a contact sport
- Go to the Gemba
 PRR Metrics Summary
1. Design Maturity? TRL?
2. Is as-built feasible? How producible is design?
3. Manufacturing processes are available, proven,
adequate capacity, capable and in-control. MRL?
4. Facilities are available and adequate.
5. Suppliers are available, capable and reliable.
6. Risk areas and proposed mitigation?
 There is no formal requirement for
production plans or production related
CDRLs. The PM does have to meet
requirements for cost,
schedule,performance, quality,
producibility, validated production
processes, adequate production
facilities and production-representative
test items. Manufacturing issues should
be included in the Risk Management
Plan.
Generic Production Plan
Generic Production Plan
I. Production Management
Organization
Functional Responsibilities
Master Schedule
Production Control
Change Management
Product Data Management/Digital Data Exchange/Records

II. Manpower Plan

Manpower Level
Skills Availability
Training

III. Industrial Facilities

Description
Layouts
Shop Floor Control

IV. Surge and Mobilization Capacity Assessment - ICA Issues

Generic Production Plan
V. Manufacturer Risk Assessment
Design Stability Assessment
Process Proofing/Materials Characterization
Key Processes
Producibility Issues

VI. Capital Investment Plan

VII. Producibility Program

Design & Manufacturing Integration (IPT Process)
Key Characteristics Plan
Trade-off Process
Sub-contractor Producibility

VIII. Materials Management

Make vs Buy
Long - Lead
Inventory Control/MRP

IX. Sub-contractor/Supplier Management

Communications & Change Control
Generic Production Plan
X. Manufacturing Methods & Production Flow
Process Planning
Process Flow, Sequencing and Routing
Work Instruction Process
Computer Simulations
XI. Quality Assurance
ISO 9000/AS 9100: compliance or registration
Process Control Methods
AQS Techniques
Process Improvement/Variation Reduction
Corrective Action Process/Non-Conforming Material
Cost of scrap, rework or repair

XII. Metrology
Facility & Equipment
Standards

XIII. Special Tooling & Test Equipment

XIV. Environmental Compliance, Scrap Management & Reclamation

XV. Internal Audits & Reviews

XVI. Labor Relations

 The Role of Manufacturing in the Acquisition Process

CURRENT DOD 5000 PROCESS

REMEMBER: LRIP is Now Mostly funded
with Procurement $, Not RDT&E $
A B C
DRR FRPDR
Full
CR TD Integration Demonstration LRIP Sustainment
Rate
RDT&E PRODUCTION
• Influence the Design Process • Execute the Manufacturing Plan
• Prepare for Production • Reflect Design Intent
• Repeatable Processes
•Continuous Process Improvement

Production Readiness Reviews, PRRs

(Minimum recommended number)

By Milestone C, Need to have Proven you have: Net Result:

Producible Designs + Factory Floor Characterized • Uniform, Defect Free Product
and per • Consistent Performance
DoDI 5000.2: No significant manufacturing risks! • Lower Cost
 Production
Production&&Deployment
Deployment
DODI
DODI5000.2,
5000.2,12
12May
May2003
2003 and
and
Defense
DefenseAcquisition
AcquisitionGuidebook,
Guidebook,19
19Oct
Oct04
04

C
Full-Rate
Production &
LRIP FRP Deployment
Decision
Review

Full-Rate Production & Deployment

LRIP To Enter: Beyond LRIP (ACAT I) and LFT&E
To Enter: System matured for production; Industrial reports (covered systems) submitted to
Capabilities Reasonably Available (to exit SDD); Congress. Demonstrated control of
NO SIGNIFICANT MANUFACTURING RISKS. manufacturing and other critical processes.
REQUIRES STABLE DESIGN, PROVEN
Major Activities: Low-rate initial production MANUFACTURING PROCESSES AND
(provides test assets for IOT&E, initial production RESOURCES TO SUPPORT PRODUCTION.
base, & ramp-up to full rate production); IOT&E; Major Activities: Full rate production. Deploy
LFT&E of production-representative articles. system. Start support.
Establish full manufacturing capability. Exit: Full operational capability; deployment
Exit: System operationally effective, suitable and complete.
ready for full rate production.