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7/31/2019 PLN 0303 B1 Morr CharLfcyclMgmt[1]

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2Cohesia Corporation Confidential Information

Lean Product DevelopmentLean Product Development

1980sDODD 4245.7, Transition fromDevelopment to Production and DOD 4245.7-M,Willoughby Templates

1990sDODD 5000.1, The Defense AcquisitionSystem

2000sNext Generation of 5000.1 and GAO BestPractices Report

Successful Transition to Production

A Quest Since the Reagan Era

A Quest Since the Reagan Era


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All the Right Words . . .All the Right Words . . .

Technology Maturity

Capture Design Knowledge

Design for Producibility, Ensure Affordability

Key System Characteristics

Bring Critical Manufacturing Process UnderControl

Demonstrated Control of ManufacturingProcesses

. . . But Where is the Discipline?

Mature Product Design


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The GAO Summarizes it WellThe GAO Summarizes it Well

Report: Best Practices: Capturing Design and

Manufacturing Knowledge Early Improves AcquisitionOutcomesJuly 2002 (Draft)

Product variation has been called the silent killer . . .Because it can result in defects. If products are fielded with

defects, they may surface in the form of degradedperformance.

New product development success factors

--Capture of specific design knowledge

--Capture of specific manufacturing and product reliability

knowledge

--Determine if the appropriate knowledge was captured

Design engineers . . . must identify key characteristics. Keyproduct characteristics and critical manufacturing processes

are noted on the engineering drawings.

A Matter of Knowledge and Metrics

A Matter of Knowledge and Metrics


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Lean Product DevelopmentLean Product Development

Demands Seamless Transition to Production

NeedA holistic approach to transition

ResponseManage the transition at thecharacteristic level (knowledge) and objectivelymeasure/document status over productlifecycle (metrics)

And the ability to . . .


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. . . Connect the Dots. . . Connect the Dots

Concept Definition Dev & Demo Production

Concept PrelimDwgs

Test Hdwre

Flt Hdwre Op TestHdwre

DetailDwgs

Mfg Plan

Quality Plan FAI

Prod Hdwre Product/ProcessImprovement

Logistics

Support

Initial Characteristics

As Built History

Mfg/Quality Plan Links,

Process Capability

Complete

Characteristics

First Articles

Process Capability Feedback, RevisionRecord, First Article Update

Over Program Lifecycle

Managing, Moving, and Measuring the Knowledge

Characteristic Lifecycle Management (CLM) &

Engineering Manufacturing Readiness Levels (EMRLs)

Characteristic Lifecycle Management (CLM) &

Engineering Manufacturing Readiness Levels (EMRLs)


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Highly Engineered ProductsHighly Engineered Products

DesignTechnology Manufacturing

Depend on Drawings & Specs to Communicate Detailed

Characteristics Throughout the Transition Process

Diameter = 1.78" +/-0.02

Surface Finish > 60 RMS

Width = 2.10" +/-0.01

Maximum Porosity < 0.01"

Tensile Strength > 140 KSI

Elongation < 50 KSI

Weld Bead < 0.25"

Packing Container is Box

CLM & EMRLCapture, Manage,Move, and Measure the Knowledge

CLM & EMRLCapture, Manage,Move, and Measure the Knowledge

Key Transition Points


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EMRL and CLMEMRL and CLM

Characteristics Lifecycle Management--Method to define, capture, and manage characteristics over

the life of a product

--Captures design intent knowledge at building block level to

ensure product consistency can process repeatability

Engineering Manufacturing Readiness Levels--Systematic metrics to support assessments of engineering

design process

--Assess maturity of design, manufacturing processes, keycharacteristics needed for producible products


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Understanding CharacteristicsUnderstanding Characteristics

Go far beyond simple dimensional expectations

Embody everything that individually and collectivelymust come together at all levels of a

systemincluding performance

Include features that are readilymeasurabledimensions

Include features that are not readilymeasurableadherence to process specs, such asheat treat


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Characteristics Lifecycle ManagementCharacteristics Lifecycle Management

Part-specific consolidation of all characteristics fromdrawings and specification documents

Electronic deployment allows for flow and real timesharing of characteristics throughout the supplychain

Captured characteristics help create process plansand work instructions in manufacturingfurtherenabling the transition process

CLMIdentify Characteristics at the Earliest Possible

Point in Product Development & Manage ThemThroughout the Product Lifecycle


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EMRL ConceptEMRL Concept

Clearly defined levelsgeared to production readiness-- Of products and processes

-- Of hardware and software

-- For components, subsystems and systems

Systematic metric/measurement system to supportsystems engineering and design processes

Focus on key characteristics necessary for producible,affordable products

Enables Objective Assessment of TotalProduct or System Maturity

Enables Objective Assessment of TotalProduct or System Maturity


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EMRLsEMRLs & Development Phases& Development Phases

EMRL 1

EMRL 2

EMRL 3

Capability Knowledge Point (CKP) 1

CKP 2

CKP 3CDRBegin System Demo

System Definition

Begin System Integration

Production Off Ramp

TRL at least 4 or 5 Design Still Fluid

Demonstrated in Lab Processes in Development

Characteristics Identified for 50%of System

TRL at least 6-7 Engineering/Design Requirements

Defined; 90% Validated

Matls/Processes Demo inProduction

Key CharacteristicsIdentified for 90% of Syatem

TRL at least 8 All Design Requirements

Validated Interfaces Defined

Materials Available Mfg Processes LRIP-

Ready Machines Demo,

Production

All Key Characteristics

Known


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Using CLM withUsing CLM with EMRLsEMRLs

Application of EMRL will identify, control, andmitigate risk

CLM can be applied at all levelsfrommaterial/component to systems; at all stages ofmaturation

CLM can be structured to indicate EMRL status andobjectives

CLM use will enable objective measurement alongthe EMRL spectrum

The use of CLM with EMRL Can Help ProgramsRealize Engineering, Quality, and Manufacturing

Expectations

The use of CLM with EMRL Can Help ProgramsRealize Engineering, Quality, and Manufacturing

Expectations


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Enabling CLMEnabling CLM

MASS--Management & Application of Specifications &

Standardsoverarching software system

IntelliDoc

--Engine for distillation of specifications and standards

Master Specification--Combination of IntelliDoc-derived specs, notes, and other

characteristic data for a specific component

Electronic, Web-based Capability to Systematically

Convey Design Intent at Characteristic Level

Electronic, Web-based Capability to Systematically

Convey Design Intent at Characteristic Level


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Spec: Text

Spec: IntelliDoc

IntelliDocIntelliDoc TechnologyTechnology

Interpretation in Computer-Sensible Form


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MasterSpecification

Master SpecificationMaster Specification

All specs referencedon the drawing withonly the pertinent

Characteristics

All dimensionalCharacteristics& drawing note

requirements

Drawing Specifications

All Requirements in Single Part-Specific Spec

Single electronicrepresentation thatcontains all merged

Characteristics

Capturing and Managingthe Knowledgeas it Evolves

Capturing and Managingthe Knowledgeas it Evolves


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Application atApplication at AerojetAerojet

Demonstrate Master Spec application, beginning earlyin product development

Use a current, real Aerojet system/component, includeAerojet supplier participation

Demonstrate Characteristic Lifecycle Management forthe Aerojet component

Assess fit of Master Spec with ongoing systems

engineering, productivity, and production transitioninitiatives

Show linkage of Master Spec and EMRL

Proof-of-Concept


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Knowledge Transfer & TransitionKnowledge Transfer & Transition

Concept PrelimDwgs

Test Hdwre

Flt Hdwre Op TestHdwre

DetailDwgs

Mfg Plan

Quality Plan FAI

Prod Hdwre Product/ProcessImprovement

Logistics

Support

Initial Characteristics

As Built History

Mfg/Quality Plan Links,Process Capability

Complete

Characteristics

First Articles

Process Capability Feedback, RevisionRecord, First Article Update

Evolving the Master Specand KnowledgeAcross the

Product Lifecycle

Concept Definition Dev & Demo Production


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Design Evolution & Master SpecDesign Evolution & Master Spec

Aerojet Drawing Tree

Master Specs for allComponents & WBS Levels

Master Specs Evolve with &

Reflect Product Changes

Smoothing the Transition as theEvolving Knowledge is Captured

and Measured

Smoothing the Transition as theEvolving Knowledge is Captured

and Measured


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Aerojet Master Spec Demo

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