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Mission Context Resilience Lifecycle Cost Tradespace Big Data Manufacturability Reliability Affordability Distribution Statement A Approved for public release by DOPSR. Distribution is unlimited. Tonya G. McCall, Emily Salmon and Larry Dalton MAKE Development of a Manufacturability Assessment Methodology and Metric Manufacturability Assessment Knowledge-Based Evaluation

Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

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Page 1: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Tonya G. McCall, Emily Salmon and Larry Dalton

MAKE

Development of a Manufacturability Assessment Methodology and Metric

Manufacturability Assessment

Knowledge-Based Evaluation

Page 2: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Outline

Intro and Background

Methodology

Case Study Overview

Benefits to Customer

2

Page 3: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Project Team “Working Group”

• Research team with 180 combined years of industry

experience.

• Areas of Experience:

Aerospace

Automotive• all-terrain vehicles

• consumer road vehicles

• military vehicles

Consumer & Personal

Care Products

Healthcare

Electronics

Electronic Test Equipment

Elevators

Industrial Parts

Logistics

Medical Devices

Musical Instruments

Networks

Office Furniture

Plant Equipment

Quality Assurance

Residential Appliances

Shipbuilding

Transportation

Utility

3

Page 4: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Connecting to the ERS Tradespace

4

Page 5: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

What is MAKE?

Manufacturability – ease in which a component or product can be

manufactured.

Assessment – detailed review of how the design impacts

manufacturing.

Knowledge-Based – judgment based assessment by subject

matter experts (SMEs).

Evaluation – identification of cost drivers and prescriptive measures to

improve manufacturability.

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Page 6: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

What is the need for MAKE?

Product Cost vs. Phase of Product

Life, D.M. Anderson 2014

Improvements in cost,

design, and

manufacturability of the

product

Risk mitigation

Reduction in time-to-market

Provide mechanism for

trade off analysis

6

Page 7: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

* MRL 7-8

PDR, CDR, PRR

“Potential” Metrics During the Product Life Cycle (ref: Defense Acquisition Life Cycle Chart (DoD Directive 5000.02, 2015)

* MRL 4

Pre-Milestone A

7

Page 8: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Ease of Assembly

Requires Special Tooling?

Key issues

Scale driven

Identify cost

drivers

Feeds into MFG readiness

DEFINE

Volume

Product Plan

Product Specs

Bill of Materials

E-D-P Cycle

Key Elements

Framework for Manufacturability Assessment

Recommendations

8

Page 9: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Judgment Based Assessment

Proper execution of the MAKE assessment requires

input by subject matter experts (SME) pertaining to the

aspects of manufacturing specified in the matrix in

relation to a particular engineering designed product.

A SME is a person who is generally recognized as an

authority in a particular field by peers/ colleagues who

are also knowledgeable in that field.

9

Page 10: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

A SME’s Role

10

INPUTS

Evaluate:

• Bill of Materials

• Experience/Body of

Knowledge

• Design Data and

Characteristics

Diagnosis:

• Best Practices

• Body of Knowledge

Prescription:

• Best Practices

• Body of Knowledge

OUTPUTS

Evaluate:

• What are the critical

aspects of the design?

Diagnosis:

• How do the critical

aspects of design interact

with the aspects of

manufacturing?

Prescription:

• What are the

recommendations to

improve

manufacturability?

Page 11: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

SME Challenges

11

Full access to engineering design data,

design concepts, mfg information.

Balance mfg process expertise, best practices with tribal knowledge of company and product.

Awareness of tribal

knowledge and impact to

assessment

Thorough knowledge of supply chain and quality

issues

Team of 2-3 SME’s per assessment…objectivity…checks and balances

Knowledge of company’s product and

manufacturing plan

Insight into possible

manufacturing site…available equipment, etc.

Knowledge of organization

structure culture

Page 12: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Affinity Diagram Exercise Grouped ideas were translated into the following:

91 elements

Observed interactions/overlap

between the elements and the grouped categories

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Page 13: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Development of Key Elements

The assessor’s intent would be to understand the impact

of characteristics of the “design” on particular areas

of “manufacturing”?

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Page 14: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Evaluation Phase

Manufacturability Interaction Matrix

► Understand “impact of the design” on

“particular aspects of manufacturing”

► Original matrix was 15 x 9 but was

reduced after 1st case study due to

overlap of the aspects of design and

manufacturing

► Shows the interactions (X) between the

“aspects of design” and the “aspects of

manufacturing”.

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Page 15: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Evaluation – Rating Scales

SME Rating system* (1 – 100) based on the following criteria:

* Based on prior work with a large defense contractor – needs to be further

validated with subsequent research

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Page 16: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Evaluation PhaseMAKE Tool

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Page 17: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Diagnosis PhaseUnderstand cost drivers and areas of risk.

17

74.775

75.9

These scores

are derived

from the

weighting

algorithm in the

tool.

Proposed manufacturability score would

be lowest scoring part = 74.7

Page 18: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Diagnosis PhaseInvestigate into specific part #s with lower scores ultimately pursuing root

causes.

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Page 19: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Diagnosis PhaseDive deeper into PMI to understand the impact of the design on

particular aspects of manufacturing.

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Page 20: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Prescriptive Phase

Example of a typical recommendation

Concern Recommendation

Standardization of fasteners - Various different fasteners used within the

assembly requiring the operator to use multiple

types of tools. Evaluate the fasteners and

standardize across the assembly

Use of a socket that touches the resistor. 1) Adhere to design for manufacturability guidelines –

design must account for tooling needed for

manufacturing and assembly process.

2) If design cannot be changed to accommodate

tooling, specify tools in mfg that accommodate the

design concern. In this case, use thin walled

sockets or specify the use sockets with protective

coating.

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Page 21: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Prescriptive Phase

Recommendations to improve the manufacturability scores

Qualify these based on effort and risk to the company

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Page 22: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Case Study

R&D company (contractor to DoD) preparing to enter low-

rate production stage of product manufacturing

Focus of the team was to review CAD drawings and

physical prototype to provide client with a

manufacturability assessment of the product

Long term strategy for increased production rate and/or

transition to commercial manufacturing

Study conducted by SME’s from the MAKE team.

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Page 23: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Evaluation

Two products were evaluated: Product A (main product),

and Product B (accessory to Product A)

A total of 32 parts included in the assessment

Consisted of injection molded parts, fabricated metal parts,

MIL-SPEC hardware and connectors, wiring harnesses,

circuit boards with modules

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Page 24: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Diagnosis – Product A*

24

123

4

567

8

9

10

11

12

1314

151617

19

2120

22

18

*only Product A will be discussed in this presentation

Part 1: 82.9

Page 25: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Diagnosis – Product APart 1 deep dive

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Page 26: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Prescription Phase – Product A

Priority 1: 18

Priority 2: 26

Priority 3: 15

Priority 4: 99

Recommendation matrix

(included in final client

package) addresses 158

concerns

SME team evaluated the

effort associated with each

recommendation.

Prioritization of the

recommendations was

provided.

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Page 27: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Recommendation Summary

Product Score # of concerns # of recommendations Agreement*

A 74.7 158 80 67%

B 82.9 69 49 66%

27

* Based on feedback from case study client as results were presented. This

information will be verified/updated after additional review of the assessment

details by the client.

Page 28: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Benefits of Structured Manufacturing Assessments Throughout the Product

Lifecycle Better determination and mitigation of risks

More consideration of manufacturing issues earlier in the design

phase and throughout the design review process

Reduction of costs throughout the product lifecycle

Better decision making (mfg processes, suppliers, etc.)

More considered Make/Buy Supply Chain Decisions

More concise determination of TRL & MRL Status

Provides approach for producibility analysis in support of

AS6500

Enhanced resilience of product

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Page 29: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Acknowledgements

This material is based upon work supported by the U.S. Army

TACOM Life Cycle Command under Contract No. W56HZV-08-C-

0236, through a subcontract with Mississippi State University,

and was performed for the Simulation Based Reliability and

Safety (SimBRS) research program. Any opinions, findings and

conclusions or recommendations expressed in this material are

those of the author(s) and do not necessarily reflect the views of

the U.S. Army TACOM Life Cycle Command.

• This research is also partially supported by Mississippi State

University, the Center for Advanced Vehicular Systems

Extension, and the Institute for Systems Engineering Research.

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Page 30: Development of a Manufacturability Assessment Methodology … · 2017. 1. 10. · design, and manufacturability of the ... *only Product A will be discussed in this presentation Part

Mission ContextResilienceLifecycle CostTradespace

Big DataManufacturabilityReliabilityAffordability

Distribution Statement A – Approved for public release by DOPSR. Distribution is unlimited.

Thank you!!

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