NDIA Manufacturing Council: DoD Systems Engineering / Manufacturing Update

Transcription

1 NDIA Manufacturing Council: DoD / Manufacturing Update 12 May 2010 Nicholas Torelli Director, Mission Assurance Office of the Secretary of Defense 05/12/2010 Page-1 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

2 Department of Defense Soldiers, Sailors, Airmen, Marines We are a nation at war Over 1.3 million active duty men and women Over 684,000 civilians Over 1.1 million Guard & Reserves DoD Mission: Provide the military forces needed to deter war Protect the security of our country 05/12/2010 Page-2 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

3 Key DoD Themes 1. Take care of our people 2. Rebalancing the Military 3. Reforming what and how we buy 4. Supporting our troops in the field Secretary of Defense HASC Budget Rollout Brief February /12/2010 Page-3 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

4 Rebalance the Force 2010 Quadrennial Defense Review 1. Defend the United States and Support Civil Authorities at Home 2. Succeed in Counterinsurgency, Stability, and Counterterrorism Operations 3. Build the Security Capacity of Partner States 4. Deter and Defeat Aggression in Anti-Access Environments 5. Prevent Proliferation and Counter Weapons of Mass Destruction 6. Operate Effectively in Cyberspace 05/12/2010 Page-4 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

5 Our Guidance Quadrennial Defense Review Executive Summary, February 2010 Further rebalance the capabilities of America s Armed Forces to prevail in today s wars, while building the capabilities needed to deal with future threats Further reform the Department s institutions and processes to better support the current needs of the warfighter; buy weapons that are usable, affordable and truly needed; and ensure that taxpayer dollars are spent wisely and responsibly Preserve and enhance the All-Volunteer Force Improve how it matches requirements with mature technologies, maintains disciplined systems engineering approaches, institutionalizes rapid acquisition capabilities, and implements more comprehensive testing Quadrennial Defense Review Report Preface Secretary of Defense Robert M. Gates, February 2010 United States needs a broad portfolio of military capabilities with maximum versatility across the widest possible spectrum of conflict 05/12/2010 Page-5 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

6 Outline How DoD is organized to improve manufacturing affordability Manufacturing affordability policy and guidance Competitive prototyping Willoughby Templates 05/12/2010 Page-6 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

7 Director, Defense Research & Engineering (DDR&E) DDR&E is the principal staff advisor to the USD (AT&L)and to the SecDef for research and engineering matters. DDR&E serves as the CTO for the DoD Director, Defense Research and Engineering (DDR&E) Honorable Zachary J. Lemnios Principal Deputy Mr. Alan R. Shaffer Defense Advanced Research Projects Agency (DARPA) Defense Technical Information Center (DTIC) Dr. Regina Dugan Mr. Paul Ryan Director, Research Dr. David Honey Director, Mr. Stephen Welby Director, Rapid Fielding Mr. Earl Wyatt Director, al Test & Evaluation (DT&E) Mr. Edward Greer. Principal Deputy Dr. André van Tilborg Principal Deputy Mr. Terry Jaggers Principal Deputy Mr. Ben Riley Principal Deputy Mr. Chris DiPetto 05/12/2010 Page-7 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

8 DDR&E Imperatives 1. Accelerate delivery of technical capabilities to win the current fight Our Focus: Support the current fight, manage risk with discipline 2. Prepare for an uncertain future Our Focus: Grow engineering capabilities to address emerging challenges 3. Reduce the cost, acquisition time and risk of our Major Defense Acquisition Programs Our Focus: Champion as a tool to improve acquisition quality 4. Develop World Class Science, Technology, Engineering and Mathematics capabilities for the DoD and the Nation Our Focus: Develop future technical leaders across the acquisition enterprise 05/12/2010 Page-8 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

9 Mission Execute substantive technical engagement throughout the acquisition life cycle with major and selected acquisition efforts across DoD to apply best practices to: Help program managers identify and mitigate risks Shape technical planning and management Support and advocate for DoD Component initiatives Provide insight to OSD stakeholders Identify systemic issues for resolution above the program level We are the E in in DDR&E 05/12/2010 Page-9 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

10 Director, Director, Steve Welby Terry Jaggers, Principal Deputy System Analysis Kristen Baldwin System Complexity Analysis Red Teaming Modeling & Simulation Coordination Office Planning SE for Systems of Systems Program Protection/Acquisition Cyber Security SE Research Center Major Program Support James Thompson Program Support Reviews Plans Program Technical Auditing OIPT/DAB/DSAB Support DAES Database Analysis and Support Performance Measurement Systemic Root Cause Analysis Mission Assurance Nicholas Torelli Systems and Software Engineering Policy, Guidance, Standards System Safety Reliability, Availability, Maintainability Quality, Manufacturing, Producibility Human Systems Integration (HSI) Technical Workforce Organizational Capability Assessment (WSARA) RTOC and Value Engineering Providing Providing technical technical support support and and systems systems engineering engineering leadership leadership and and oversight oversight to to USD(AT&L) USD(AT&L) in in support support of of planned planned and and ongoing ongoing acquisition acquisition programs programs 05/12/2010 Page-10 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

11 Improving Acquisition Program Performance Innovation, Speed and Agility Acquisition Programs Opportunities for Improvement Program Performance and Outcomes Acquisition Workforce Workforce Competency Assessments Systems Analysis Acquisition Innovation Major Program Support Mission Success Enablers Policy, Guidance, Mission Assurance Program Assessments 05/12/2010 Page-11 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

12 Outline How DoD is organized to improve manufacturing affordability Manufacturing affordability policy and guidance Competitive prototyping Willoughby Templates 05/12/2010 Page-12 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

13 Acquisition Lifecycle Comparisons Defense Acquisition Management System, December 8, 2008 (new DoDI ) Materiel Decision Materiel Decision Defense Acquisition Management System, May 12, 2003 (DoDI ) Concept Refinement Concept Decision Materiel Solution Analysis Materiel Solution Analysis (Program Initiation) A B C Technology A B C Technology Competitive Prototyping PDR Technology Or (Program Initiation) Engineering and Manufacturing PDR System and Demonstration Production and Deployment Operations and Support CDR PDR after B w/ Post-PDR Assessment (Program Initiation) Design Readiness Review Post-CDR Assessment A B C Engineering and Manufacturing CDR Full-Rate Production Decision Review Production and Deployment FRP Decision Review Defense Acquisition Management System, May 22, 2009 (WSARA) Technological Maturity and Integration Risk Assessment Competitive Prototyping PDR Production and Deployment FRP Decision Review Operations and Support Operations and Support Post-PDR Assessment Post-CDR Assessment 05/12/2010 Page-13 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

14 Defense Acquisition Management System December 8, 2008 Assess the manufacturing feasibility and risk of alternatives being evaluated in the Analysis of Alternatives, Assess the manufacturing feasibility and risk of the proposed materiel solution for use in the Milestone A decision, Conduct assessments to identify manufacturing risks and ensure manufacturing processes have been demonstrated in a relevant environment in conjunction with the Preliminary Design Review (PDR) for use in the Milestone B decision, Conduct assessments to ensure the maturity of critical manufacturing processes in conjunction with the Critical Design Review (CDR), Conduct assessments to ensure that manufacturing processes have been effectively demonstrated in a pilot line environment and that there are no significant manufacturing risks prior to Milestone C, Ensure adequate and efficient manufacturing capability is available to provide production or production-representative articles for IOT&E during LRIP, and Provide evidence of demonstrated control of the manufacturing process prior to Full-Rate Production Decision Review. 05/12/2010 Page-14 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

15 Weapon Systems Acquisition Reform Act of 2009 (PL ) Contains provisions that will address problems with: Unreasonable performance requirements by requiring DOD to reestablish systems engineering organizations and developmental testing capabilities; make trade-offs between cost, schedule and performance early in the program cycle; and conduct preliminary design reviews before giving approval to new acquisition programs; Unreasonable cost and schedule estimates by establishing a new, independent director of cost assessment to ensure that unbiased data is available for senior DOD managers; The use of immature technologies by requiring the Director of Defense Research and Engineering (DDR&E) to periodically review and assess the maturity of critical technologies and by directing the Department to make greater use of prototypes, including competitive prototypes, to prove that new technologies work before trying to produce them; and Costly changes in the middle of a program by tightening the so-called Nunn-McCurdy requirements for underperforming programs. President Barack Obama hands a pen to U.S. Rep. Robert Andrews (D-NJ) as he signs the Weapons Systems Acquisition Reform Act in the Rose Garden at the White House Friday, May 22, Standing from left are: Andrews, Rep. John McHugh (R-NY), Sen. Carl Levin (D- MI), Rep. Ike Skelton (D-MO) and Rep. Mike Conaway (R-TX). Official White House Photo by Samantha Appleton 05/12/2010 Page-15 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

16 DoD and PL the Changed Acquisition Landscape Renewed Emphasis on al Planning and Early Engineering Engagement New 2366a & 2366b Certifications* MS A MS B LCSP MS C CBA ICD Materiel Decision (MDD) MDD Planning * Director, SE supports MDA certifications including PDR Report assessment at MS B Materiel Solution Analysis Mandatory Competitive Prototypes Technology PDR PDR, PDR Report to the MDA, and Post-PDR- Assessment before MS B Engineering and Manufacturing CDR System-level CDR with an initial product baseline and a Post-CDR Report to the MDA 05/12/2010 Page-16 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090 CDD CPD Production and Deployment Renewed emphasis on manufacturing and reliability across the lifecycle Post-CDR Assessment by the MDA between EMD sub- phases O&S Full Rate Production Decision Review Knowledge-based Decision Making... making acquisition decisions when you you have solid evidence and and acceptable risk risk

17 Planning and Early SE Critical Activities A B CBA ICD MDD Materiel Solution Analysis Technology CDD SE Input to MDD CONOPS Awareness of Strategic Context Engagement with S&T Engagement with JCIDS Guidance Prototyping & Risk Reduction Prototyping (Technology and Design) CTE TRL Maturation Trade Studies SE Support for Technology Risk Reduction Oversight of Competitive Designs Risk Assessment Engagement in AoA Engineering Analysis Plan Analysis Activity Report Consideration of SOS/Interdependency, Interoperability Context SEP for Milestone A Input to TDS (CTE, CPI), TES Input to Acquisition/ Planning, CARD, Budget & Other Evidence of Strong SE Activity SE in Contract Requirements SE into the PDR Report to MDA, Acquisition Strategy, TEMP, CARD, and ICE PDR and PDR Report and Assessment Technical Reviews up to and including PDR Plan Strong Reliability, Availability and Maintainability (RAM) SE in TD Contract Requirements System Requirements Definition Tech Reviews (ASR, Early SE Requirements) Inputs to Requirements RAM and Sustainability Requirements Traceability Matrices Translation of Requirements to Contract *Reference DAG Sections and Capability Document (CDD) 05/12/2010 Page-17 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

18 Critical SE Support for Manufacturing Affordability (1 of 4) MS A MS B MS C CBA ICD MDD Materiel Solution Analysis Technology PDR CDD Engineering and Manufacturing CDR CPD Production and Deployment O&S Full Rate Production Decision Review Materiel Solution Analysis (ASR) Have the preliminary manufacturing processes and risks been identified for prototypes? Have required investments for technology development, to mature design and manufacturing related technologies, been identified and funded? Have initial producibility assessments of design concepts been completed? 05/12/2010 Page-18 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

19 Critical SE Support for Manufacturing Affordability (2 of 4) MS A MS B MS C CBA ICD MDD Materiel Solution Analysis Technology PDR CDD Engineering and Manufacturing CDR Technology (PDR) Have the majority of manufacturing processes been defined and characterized? Are initial manufacturing approaches documented? Have producibility assessments of key technologies been completed? Has a production cost model been constructed? Can the industrial base support production of development articles? Have long-lead and key supply chain elements been identified? CPD Production and Deployment O&S Full Rate Production Decision Review 05/12/2010 Page-19 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

20 Critical SE Support for Manufacturing Affordability (3 of 4) MS A MS B MS C CBA ICD MDD Materiel Solution Analysis Technology PDR CDD Engineering and Manufacturing CDR Production and Deployment O&S Full Rate Production Decision Review Engineering and Manufacturing (CDR) Have the critical manufacturing processes that affect the key characteristics been identified and their capability to meet design tolerances determined? Have process control plans been developed for critical manufacturing processes? Have manufacturing processes been demonstrated in a production representative environment? Are detailed trade studies and system producibility assessments underway? Are materials and tooling available to meet pilot line schedule? Has the system production cost model been updated, allocated to subsystem level, and tracked against targets? Are long-lead procurement plans in place and has the supply chain been assessed? CPD 05/12/2010 Page-20 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

21 Manufacturing Design Considerations for Affordability Leverage a component-focused approach Use fewer parts/standardize where possible: improves supply chain and training Leverage economies of scale through common/standard parts Use self-locating parts Design for ease of fabrication, assembly, installation and test Redesign components to eliminate processing steps Leverage available facilities, resources, and tools Point-of-use tools Mistake-proof the design Take a modular architecture design approach Minimize complexity of design Strive for quality and reliability targets 05/12/2010 Page-21 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

22 Critical SE Support for Manufacturing Affordability (4 of 4) MS A MS B MS C CBA ICD MDD Materiel Solution Analysis Technology PDR CDD Engineering and Manufacturing CDR CPD Production and Deployment O&S Full Rate Production Decision Review Production and Deployment (PRR) Is the detailed design producible within the production budget? Are the production facilities ready and required workers trained? Is detail design complete and stable enough to enter low rate production? Is the supply chain established and stable with materials available to meet planned low rate production? Have manufacturing processes been demonstrated and proven in a pilot line environment? Have all producibility trade studies and risk assessments been completed? Is the production cost model based upon the stable detailed design and been validated? 05/12/2010 Page-22 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

23 Outline How DoD is organized to improve manufacturing affordability Manufacturing affordability policy and guidance Competitive prototyping Willoughby Templates 05/12/2010 Page-23 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

24 New Competitive Prototyping Challenge PL ( Acquisition Reform ), Section 203: Requires the Secretary of Defense to modify acquisition policy to require each MDAP s acquisition strategy provides for competitive prototypes prior to a MS B decision Allows prototyping to occur at the system or subsystem level Includes provision for MDA waiver only on the basis that the cost of producing the competitive prototypes exceeds the expected life-cycle benefits (in constant dollars) of producing the prototypes or for critical national security objectives Programs receiving a waiver must still produce a prototype before MS B be reported in writing by the MDA to the congressional defense committees and the Comptroller General of the US 05/12/2010 Page-24 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

25 Competitive Prototyping: Some Recommended Practices Decide what should be prototyped: program risk issues should drive the prototyping scope Encourage alternate choices on solutions to achieving capability If you can model, you may not need as many prototypes Know the purpose for prototyping (is it risk reduction, i.e., cost, size, technology maturation, assess design viability, schedule, manufacturability, demonstrate integration, ) Prototype the items that are unique to the program or project Address Technology Readiness Level (TRL) maturity concerns 05/12/2010 Page-25 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

26 Competitive Prototyping: Some Recommended Practices Ensure competition and use prototyping as part of the overall program risk management Use competitive prototyping to create increased corporate interest Do proof of concept but also address the other critical risks Shape prototyping strategy at pre-milestone A by identifying the key things that must be solved; build prototypes and find the problems early Doing the right prototyping is key; determine the right time for prototyping Know your prototyping purpose; decompose the requirements -- prototype to create and sell the product 05/12/2010 Page-26 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

27 Outline How DoD is organized to improve manufacturing affordability Manufacturing affordability policy and guidance Competitive prototyping Willoughby Templates 05/12/2010 Page-27 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

28 Willoughby Templates DoD M and NAVSO P-6071 Evaluate benefits of collaborative industry/gov t updating & modernizing the publications Identify Gov t-industry leads & initial volunteers Identify obsolete material, content voids, and errors Information scan for recent, relevant alternative issuances Identify/analyze alternatives Scope project (workload level of effort, time commitment, approach, logistics etc.) Full revision or incremental releases Content style & format, publication media, etc. Coordination & comment resolution process Publication authorship/ownership (i.e., DoD, NDIA, Combined) Assess value & provide go-no go recommendation for August Division meeting POC is Jeff Allan: (301) ; [email protected] 05/12/2010 Page-28 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090

29 : Critical to Program Success Innovation, Speed and Agility 05/12/2010 Page-29 DISTRIBUTION STATEMENT A -- Cleared for public release by OSR on 11 May SR Case 10-S-2090