Lean Production Transition

Characteristic Lifecycle Management and Engineering Manufacturing Readiness Levels

Robert Morris Cohesia Corporation

Presentation to
Lean Aerospace Plenary Session March 25, 2003

2000 2002 Cohesia Corporation 2000 Cohesia Corporation

Lean Product Development

Successful Transition to Production
1980sDODD 4245.7, Transition from
Development to Production and DOD 4245.7-M, Willoughby Templates

1990sDODD 5000.1, The Defense Acquisition

System

2000sNext Generation of 5000.1 and GAO Best

Practices Report

A Quest Since the Reagan Era A Quest Since the Reagan Era
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Some Common Themes

Disciplined engineering . . . is of such fundamental importance that it drives all aspects of development and production in any successful material acquisition. DoD 4245.7-M A management framework for translating mission needs and technological opportunities . . . into stable, affordable, wellmanaged acquisition programs. DODI 5000.2 Successful programs had taken steps to gather knowledge that confirmed the products design was stable before the design was released to manufacturing. GAO Best Practices Report (Draft)

Technology, Engineering, and Process Capability Technology, Engineering, and Process Capability Must Come Together in a Disciplined Environment Must Come Together in a Disciplined Environment
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All the Right Words . . .

Technology Maturity Capture Design Knowledge Key System Characteristics Design for Producibility, Ensure Affordability Bring Critical Manufacturing Process Under Control Demonstrated Control of Manufacturing Processes Mature Product Design

. . . But Where is the Discipline?

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The GAO Summarizes it Well

Report: Best Practices: Capturing Design and Manufacturing Knowledge Early Improves Acquisition OutcomesJuly 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 degraded performance. 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. Key product 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 Development

Demands Seamless Transition to Production

NeedA holistic approach to transition

ResponseManage the transition at the characteristic level (knowledge) and objectively measure/document status over product lifecycle (metrics) And the ability to . . .

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. . . Connect the Dots

Over Program Lifecycle
Concept Definition Dev & Demo Production

Concept

Managing, Moving, and Measuring the Knowledge Dwgs

Flt Hdwre Op Test Hdwre Detail Dwgs Mfg Plan

Prelim

Test Hdwre

Initial Characteristics

As Built History Quality Plan Complete Characteristics Prod Hdwre Mfg/Quality Plan Links, Process Capability First Articles Product/Process Improvement Logistics Support FAI

Characteristic Lifecycle Management (CLM) & Characteristic Lifecycle Management (CLM) & Engineering Manufacturing Readiness Levels (EMRLs) Engineering Manufacturing Readiness Levels (EMRLs)
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Process Capability Feedback, Revision Record, First Article Update

Highly Engineered Products

Depend on Drawings & Specs to Communicate Detailed Characteristics Throughout the Transition Process
Technology Design Manufacturing

Diameter = 1.78" +/-0.02 Surface Finish > 60 RMS Width = 2.10" +/-0.01 Maximum Porosity < 0.01" Tensile Strength > 140 KSI Weld Bead < 0.25" Elongation < 50 KSI Packing Container is Box

Key Transition Points

CLM & EMRLCapture, Manage, CLM & EMRLCapture, Manage, Move, and Measure the Knowledge Move, and Measure the Knowledge
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EMRL 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, key characteristics needed for producible products

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Understanding Characteristics

Go far beyond simple dimensional expectations Embody everything that individually and collectively
must come together at all levels of a systemincluding performance

Include features that are readily

measurabledimensions

Include features that are not readily

measurableadherence to process specs, such as heat treat

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Characteristics Lifecycle Management

CLMIdentify Characteristics at the Earliest Possible Point in Product Development & Manage Them Throughout the Product Lifecycle

Part-specific consolidation of all characteristics from

drawings and specification documents

Electronic deployment allows for flow and real time

sharing of characteristics throughout the supply chain

Captured characteristics help create process plans

and work instructions in manufacturingfurther enabling the transition process

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EMRL 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 support

systems engineering and design processes

Focus on key characteristics necessary for producible,

affordable products

Enables Objective Assessment of Total Enables Objective Assessment of Total Product or System Maturity Product or System Maturity
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EMRLs & Development Phases

Production Off Ramp CDRBegin System Demo

CKP 3

EMRL 3
CKP 2
Begin System Integration

EMRL 2
Capability Knowledge Point (CKP) 1
System Definition

TRL at least 8 All Design Requirements Validated Interfaces Defined Materials Available Mfg Processes LRIPReady Machines Demo, Production All Key Characteristics Known

TRL at least 6-7 Engineering/Design Requirements Defined; 90% Validated Matls/Processes Demo in Production Key Characteristics Identified for 90% of Syatem

EMRL 1

TRL at least 4 or 5 Design Still Fluid Demonstrated in Lab Processes in Development Characteristics Identified for 50% of System

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Using CLM with EMRLs

Application of EMRL will identify, control, and
mitigate risk

CLM can be applied at all levelsfrom

material/component to systems; at all stages of maturation

CLM can be structured to indicate EMRL status and

objectives

CLM use will enable objective measurement along

the EMRL spectrum
The use of CLM with EMRL Can Help Programs The use of CLM with EMRL Can Help Programs Realize Engineering, Quality, and Manufacturing Realize Engineering, Quality, and Manufacturing Expectations Expectations
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Enabling 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 Electronic, Web-based Capability to Systematically Convey Design Intent at Characteristic Level Convey Design Intent at Characteristic Level

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IntelliDoc Technology
Interpretation in Computer-Sensible Form

Spec: IntelliDoc Spec: Text

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Master Specification
All Requirements in Single Part-Specific Spec

Drawing

Specifications

All dimensional Characteristics & drawing note requirements

All specs referenced on the drawing with only the pertinent Characteristics

Single electronic representation that contains all merged Characteristics

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Master Specification

Capturing and Managing Capturing and Managing the Knowledge as it Evolves the Knowledge as it Evolves

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Application at Aerojet
Proof-of-Concept
Demonstrate Master Spec application, beginning early
in product development

Use a current, real Aerojet system/component, include

Aerojet supplier participation

Demonstrate Characteristic Lifecycle Management for

the Aerojet component

Assess fit of Master Spec with ongoing systems

engineering, productivity, and production transition initiatives

Show linkage of Master Spec and EMRL

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Knowledge Transfer & Transition

Evolving the Master Specand KnowledgeAcross the Product Lifecycle
Concept Definition Dev & Demo Production

Concept

Prelim Dwgs

Test Hdwre

Initial Characteristics

Flt Hdwre

Op Test Hdwre

Detail Dwgs

Mfg Plan

As Built History Quality Plan Complete Characteristics Prod Hdwre Mfg/Quality Plan Links, Process Capability First Articles Product/Process Improvement Logistics Support FAI

Process Capability Feedback, Revision Record, First Article Update

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Design Evolution & Master Spec

Master Specs for all Components & WBS Levels

Aerojet Drawing Tree

Master Specs Evolve with & Reflect Product Changes

Smoothing the Transition as the Smoothing the Transition as the Evolving Knowledge is Captured Evolving Knowledge is Captured and Measured and Measured
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Aerojet Master Spec Demo

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