MC-P-10-53

This paper provides a set of scales indicating the state of technological development of a
technology and its readiness for manufacture, derived from similar scales in the military and
aerospace sectors and developed in consultation with the Automotive Council. It is for approval
prior to adoption by Automotive Council.

Technology and
Manufacturing Readiness
Levels [Draft]
A Guide to Recognised Stages of Development

Version 5.3
Published by Automotive Council

Produced by LowCVP
The authors Roy Williamson (LowCVP) and Jon Beasley (GKN) wish to thank and acknowledge the support
contributed by the UK automotive sector in developing this guide.

Introduction to Technology and Manufacturing Readiness Levels

A recurring issue to developers and adopters of new technologies lies in managing and communicating the
expectations for different stages of technology development and establishment of manufacturing capability.

The aim of a set of Automotive TRLs and MRLs is to help facilitate technology commercialisation, engaging
suppliers, partners and customers at suitable stages, accelerating time to market and reducing costs, through
the use of a common understanding. Readiness levels have proven their usefulness in the aerospace and
defence sectors, which involve similar supply chain structure to those of the automotive sector. TRLs and
MRLs provide a common language to define technology from concept, to commercial production and
through to End of Life disposal. The use of standard terminology and understandings can assist with self-
review, programme development, knowledge and research transactions and collaboration.

Benefits
Using common scales and terms allows:
• Emergent supply chain companies to have a framework through which they can better understand
the engagement needs of TIer1s/VMs.
• VMs, Tier1s and Funding agencies are presented with clearer definition of propositions and their
development status.
• A framework which can be used to provide clearer direction regarding engagement of the most
appropriate public sector support
• An investment Framework for angels/VC investor engagement.
• Self assessment provides guidance on next steps (trials, certification etc) relevant to their Level and
could also signpost sources of support suitable to the various stages.
• Industry bodies to better define the status of development portfolios in supporting industry
roadmaps.

Integrated Assemblies
When technologies are brought together and integrated, TRL and MRLs of individual components contribute
to the readiness of the assembly overall, helping to assess risks, develop strategies and plan resources. It
could be the case that integrated systems may hold more than one TRL / MRL status, recognising the
development of the next generation or derivatives of a product with respect to the currently established
product.
TRL Technology Readiness MRL Manufacturing Readiness
1 • Basic Principles have been observed and
reported.
• Scientific Research and beginning of
translation into applied research and
development.
• Paper studies and experimentation
• Performance/capabilities have been
predicted.
2 • Speculative applications have been identified • High level assessment of manufacturing
• Ongoing exploration into key principles opportunities
• Application specific simulations/experiments
• Performance predictions have been refined
3 • Analytical and experimental identify critical 1 • Basic Manufacturing Implications Identified.
functionality and/or characteristics • Materials for manufacturing characterised
• Analytical and laboratory studies physically and assessed.
validate predictions of separate elements of
the technology.
• Examples include components that are not yet
integrated or representative.
• Performance is investigated through analytical
experimentation and/or simulations.
4 • Technology component and/or basic 2 • Manufacturing Concepts Identified.
subsystem have been validated in the • Manufacturing feasibility determined and
laboratory / test house environment. processes identified.
• Basic concept has been observed in other • Produce-ability assessments commenced,
industry sectors (eg Space, Aerospace), including advanced design for
potential transition opportunity if it can manufacturing considerations.
adapted to industry requirements (Volume
and cost)
• Examples include integration of ad hoc
hardware in a laboratory / test house.
• Requirements and interactions with relevant
vehicle systems determined.
5 • Technology component and/or basic 3 • Manufacturing Proof of Concept developed
subsystem validated in relevant environment • Analytical or laboratory experiments
(potentially through a mule or adapted validate paper studies.
current production vehicle). • Experimental hardware or processes have
• Basic technological components are been created, but are not yet integrated or
integrated with reasonably realistic supporting representative.
elements so that the technology can be tested • Materials and/or processes have been
with equipment that can simulate and validate characterized for manufacturability and
all system specifications within a laboratory / availability.
test house / test track setting with integrated • Initial Manufacturing cost projections
components • Supply chain requirements determined.
• Design rules established.
• Performance results demonstrate viability and
confidence to select for new vehicle
programme consideration.
6 • Technology system/ subsystem model or 4 • Capability to produce the technology in a
prototype demonstration as part of a vehicle laboratory or prototype environment.
that can simulate and validate all system • Required Series production investments,
specifications within a test house, test track or such as manufacturing technology
similar operational environment. development identified.
• Performance results viability for specific • Processes to ensure manufacturability,
vehicle class. producibility and quality are in place and
are sufficient to produce demonstrators.
• Manufacturing risks identified for
prototype build.
• Cost drivers confirmed.
• Design concepts optimised for production.
• APQP processes scoped and initiated.
7 • Multiple prototypes demonstrated in an 5 • Capability to produce prototype
operational, on-vehicle environment. components in a production relevant
• Performance of technology meets environment.
requirements. • Critical technologies and components are
• Limit testing and ultimate performance identified.
characteristics now determined. • Prototype materials, tooling and test
• Technology suitable to be incorporated into equipment, as well as personnel skills have
specific vehicle platform development been demonstrated on components in a
programmes. production relevant environment
• FMEA and DFMA initiated.
8 • Test and demonstration phases completed to 6 • Capability to produce integrated system or
customer satisfaction. subsystem in a production relevant
• Technology has been proven to work in its environment.
final form and under expected conditions. • Majority of manufacturing processes have
• Performance is validated, and confirmed been defined and characterized.
• Pre-production vehicle status. • Preliminary design of critical components
completed.
• Prototype materials, tooling and test
equipment, as well as personnel skills have
been demonstrated on subsystems/
systems in a production relevant
environment.
• Detailed cost analysis includes design
trades.
• Cost targets allocated and approved as
viable.
• Producibility considerations shape system
development plans.
• Long lead and key supply chain elements
identified.
9 • Actual technology system qualified through 7 • Capability to produce systems, subsystems
operational experience. or components in a production
• Actual application of the technology in its final representative environment.
form and under real-world conditions. • Material specifications are approved.
• Real-world performance of the technology is • Materials available to meet planned pilot
successful. line build schedule.
• Vehicle / product launch into the market place • Pilot line capability demonstrated including
• Scaled up/down technology in development run at rate capability
for other classes of vehicle. • Unit cost reduction efforts underway.
• Supply chain and supplier QA assessed.
• Long lead procurement plans in place.
• Production tooling and test equipment
design & development initiated
• FMEA and DFMA completed.
8 • Initial production underway
• Manufacturing and quality processes and
procedures proven in production
environment,
• Initial / Early supply chain established and
stable.
• Manufacturing processes are validated.
9 • Full / Volume rate Production capability
demonstrated.
• Major system design features are stable
and proven in test and evaluation.
• Materials are available to meet planned
rate production schedules.
• Manufacturing processes and procedures
are established and controlled to three-
sigma or some other appropriate quality
level to meet design key characteristic
tolerances in a low rate production
environment.
• Manufacturing control processes validated.
• Actual cost model developed for full rate
production
10 • The technology is successfully in service in 10 • Full Rate Production demonstrated
multiple application forms vehicle platforms • Lean production practices in place and
and geographic regions. In-service and life continuous process improvements on-
time warranty data is available, confirming going.
actual market life time performance and • Engineering/design changes limited to
reliability quality and cost improvements.
• System, components or items are in rate
production and meet all engineering,
performance, quality and reliability
requirements.
• All materials, manufacturing processes and
procedures, inspection and test equipment
are in production and controlled to six-
sigma or some other appropriate quality
level.
• Unit cost meets goal, applicable to multiple
markets, manufacturing capability globally
deployable.
• Continuous improvement to processes and
planning.
Examples

Composite Structures (for automotive applications)

TRL Technology Readiness MRL Manufacturing Readiness

8 • Customer test and demonstration 4 • Capability to produce the technology in a
phases successfully completed. laboratory or prototype environment.
• Technology has been proven to work in • Required Series production investments,
its final form and under expected such as manufacturing technology
conditions. development identified.
• Performance is validated, and • Processes to ensure manufacturability,
confirmed design rules established. producibility and quality are in place and
• Pre-production vehicle status. are sufficient to produce demonstrators.
• Manufacturing risks identified for
prototype build.
• Cost drivers confirmed.
• Producibility assessments of design
concepts have been completed.
• Key design performance parameters
confirmed through testing.
• APQP processes scoped and initiated.

ABS (for multiple vehicle class, automotive applications)

TRL Technology Readiness MRL Manufacturing Readiness

10 • The technology is successfully in service 10 • Full Rate Production demonstrated
in multiple application forms vehicle • Lean production practices in place and
platforms and geographic regions. In- continuous process improvements on-
service and life time warranty data is going.
available, confirming actual market life • Engineering/design changes limited to
time performance and reliability quality and cost improvements.
• System, components or items are in rate
production and meet all engineering,
performance, quality and reliability
requirements.
• All materials, manufacturing processes and
procedures, inspection and test equipment
are in production and controlled to six-
sigma or some other appropriate quality
level.
• Unit cost meets goal, applicable to multiple
markets, manufacturing capability globally
deployable.
• Continuous improvement to processes and
planning.