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