PRR Technical Guide.doc - Defense Acquisition University...

Defense Acquisition University
Technical Guide to Production Readiness
Reviews and Manufacturing
Risk Assessment
REV 17 Mod 01
UPDATED JANUARY 2005
MAJ Mark McNabb, USAF
FD-TED-MM
W.T. Motley, CDSC
CDR F.F. Schulz, USN Ret.
Defense Acquisition University
Fort Belvoir, Virginia

Table of Contents
Page
Forward ...................................................................................................................... 4-5
I. Introduction ............................................................................................................ 6
A. Production Readiness and Reviews ......................................................... 6-7
B. Production Readiness Review Organization ............................................ 7-8
C. Pre-Production Readiness Review Activities ........................................... 8
D. Production Readiness Review Plan ......................................................... 8
E. On-site Production Readiness Review Activities .................................... 8
F. Production Readiness Review Definition ................................................ 9
II. Common Production Risks and Concerns ............................................................. 9-15
III. Production Readiness Review Checklist ............................................................. 15
A. Product Design ......................................................................................... 15-16
B. Plant Facilities, Production Equipment, Test Equipment, and Tooling...16-18
C. Producibility/IPPD Practices ................................................................... 18-20
D. Cost .......................................................................................................... 20
E. Personnel .................................................................................................. 21
F. Defense Priorities and Allocation System ................................................ 21
G. Manufacturing Planning and Scheduling ................................................. 21-23
H. Production Control ................................................................................... 24-25
I. Manufacturing Management .................................................................... 25-26
J. Work Instructions ..................................................................................... 26-27
K. Material .................................................................................................... 27-28
L. Tooling/Test Equipment ........................................................................... 28-29
M. Work Measurement .................................................................................. 29
N. Schedule Performance ............................................................................. 29-30
O. Vendor Delivery ....................................................................................... 30-31
P. Scrap, Rework, and Repair (SRR) ........................................................... 31-32
Q. Industrial Engineering .............................................................................. 32-33
R. Manpower/Training/Labor Relations ....................................................... 33-34
S. Quality Assurance .................................................................................... 34-35
T. Supplier Quality Assurance ...................................................................... 36
U. Metrology/Variation Reduction ............................................................... 37
V. Software Issues ........................................................................................ 37-38
W. Non-Conforming Materials ...................................................................... 39
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X. Manufacturing Processes and Control ..................................................... 39-40
Y. Manufacturing Stress Screening .............................................................. 40
Z. Subcontractor Management and Selection ............................................... 40-41
AA. Manufacturing Technology ................................................................... 41
BB. Low Rate Initial Production (LRIP) ...................................................... 42
CC. Modeling and Simulation ...................................................................... 42-43
DD. Product Data Management (PDM) ........................................................ 43
IV. References ........................................................................................................... 44-45
V. Appendix A (GAO/NSIAD-85-34) ....................................................................... 47-52
VI. Appendix B (Excerpts from DoD 5000.2R) ....................................................... 53-62
VII. Appendix C (Generic Production Plan) ............................................................. 63-64
VIII. Appendix D Deleted
IX. Appendix E (Diminishing Manufacturing Sources/Material Shortages) ............ 68-72
IXX. Appendix F (Government Instructions for Archival Material Purposes) ......... 73-82
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Forward
There are four key concepts that form the basis for this document:
1. Be an informed world-class customer. Be able to ask the right questions.
2. Do not tell the contractor what to do—but do understand what he is doing. Be
sensitive to manufacturing related risks. Make sure the contractor has the
appropriate management and technical processes in-place.
3. Planning for production must be part of the following: 1) program acquisition
strategy; 2) the systems engineering process; and 3) the design process.
4. Manufacturing planning and operations are systems management issues.
There are common manufacturing misconceptions in the government concerning
manufacturing:
 The “Manufacturing Problem” has been solved: It has not!
Producibility and quality issues still remain in both defense and
commercial manufacturing firms.