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Production Readiness Review (PRR)

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Reference Source: DAG CH 3-3.3.7 Production Readiness Review

The Production Readiness Review (PRR) for the system determines whether the system design is ready for production, and whether the developer has accomplished adequate production planning for entering Low-Rate Initial Production (LRIP) and Full-Rate Production (FRP). Production readiness increases over time with incremental assessments accomplished at various points in the life cycle of a program.

In the early stages, production readiness assessments should focus on high-level manufacturing concerns such as the need for identifying high-risk and low-yield manufacturing processes or materials, or the requirement for manufacturing development efforts to satisfy design requirements. As the system design matures, the assessments should focus on adequate production planning, facilities allocation, producibility changes, identification and fabrication of tools and test equipment and long-lead items. The system PRR, held prior to Milestone C, should provide evidence that the system can be produced with acceptable risk and no breaches in cost, schedule or performance thresholds. The PRR should also consider what production systems should be retained after system deployment to sustain and maintain the system through its life cycle. 

For complex systems, a PRR may be conducted for one or more system elements. In addition, periodic production readiness assessments should be conducted during the Engineering and Manufacturing Development phase to identify and mitigate risks as the design progresses. The incremental reviews lead to an overall system PRR. See CH 3–3.3. Technical Reviews and Audits for more on this incremental approach.

Roles and Responsibilities

Reference Source: DAG CH 3-3.3.7 Production Readiness Review

The unique Program Manager (PM) responsibilities associated with a system PRR include:

  • Approving, funding and staffing the PRR as planned in the Systems Engineering Plan (SEP) developed by the Systems Engineer.
  • Establishing the plan to Physical Configuration Audit (PCA) in applicable contract documents, including the SE Management Plan (SEMP), Integrated Master Schedule (IMS) and Integrated Master Plan (IMP).
  • Ensuring the plan includes subject matter experts to participate in each review.
  • Determining if the readiness of manufacturing processes, quality management system and production planning (i.e., facilities, tooling and test equipment capacity, personnel development and certification, process documentation, inventory management, supplier management, etc.) provide low-risk assurances for supporting LRIP and FRP.
  • Continuing to control appropriate changes to the product baseline (see CH 3–4.1.6. Configuration Management Process)

The unique Systems Engineer responsibilities associated with a system PRR include:

 

  • Developing and executing the PRR plans with established quantifiable review criteria, carefully tailored to satisfy program objectives.
  • Ensuring the pre-established review criteria have been met to make sure the production capability forms a satisfactory, affordable and sustainable basis for proceeding into LRIP and FRP.
  • Advising the PM on whether production capability forms a satisfactory, affordable and sustainable basis for proceeding into LRIP and FRP.
  • Ensuring adequate plans and resources are in place to proceed from PRR to PCA and FRP Decision Review (DR).
  • Ensuring plans to proceed to PCA and FRP DR allow for contingencies.
  • Ensuring production implementation supports overall performance and maintainability requirements.
  • Monitoring and controlling the execution of the PRR closure plans.

Inputs and Outputs

Reference Source: DAG CH 3-3.3.7 Production Readiness Review

The PRR criteria are developed to best support the program’s technical scope and risk and are documented in the program’s SEP no later than Milestone B. Table 34 identifies the products and associated review criteria normally seen as part of the PRR. The Chief Engineer should review this table and tailor the criteria for the program. The system-level PRR review should not begin until the criteria, identified by the Chief Engineer and documented in the SEP, are met, any prior technical reviews are complete and their action items closed. A resource for PRR preparation is IEEE 15288.2 “Standard for Technical Reviews and Audits on Defense Programs”. This is a best practice review.

Table 34: PRR Products and Criteria

Product

PRR Criteria

Cost Estimate
  • System, as designed, is producible within the production budget
  • Production cost model is based on the stable detailed design and supply chain, and has been validated
Risk Assessment
  • Producibility trade studies and risk assessments are completed
  • Manufacturing, production and quality risks are identified, and a mitigation plan exists to mitigate those risk(s)
  • Environment, Safety and Occupational Health (ESOH) risks are known and mitigated
Technical Baseline Documentation (Product)
  • Product baseline is stable and under proper configuration control to enable hardware fabrication in low-rate production
  • Technologies are mature and proven in the final form, in operational environments
  • Manufacturing processes are stable and have been demonstrated in a pilot line environment
  • Adequate production line processes and metrics are in place for the delivery of on-time, quality products
Technical Plans
  • Prior readiness reviews are completed and action items closed
  • Supply chain is stable and adequate to support planned LRIP and FRP
  • Program is properly staffed with qualified production, quality (engineering and assurance) and manufacturing personnel
  • Product acceptance system, including acceptance test procedures and associated equipment, has been validated and put under configuration control
  • Production facilities are ready and required personnel are trained
  • Delivery schedule is executable (technical/cost risks, long lead items)
  • Diminishing Manufacturing Sources and Material Shortages (DMSMS) plan is in place and mitigates the risk of obsolescence during LRIP and FRP

 

A follow-on PRR may be appropriate in the Production and Deployment (PD) phase for the prime contractor and major subcontractors if:

  • Changes (from the Engineering and Manufacturing Development (EMD) phase system design) in materials and/or manufacturing processes are required when entering or during the Production and Deployment (P&D) phase.
  • Production start-up or re-start occurs after a significant shutdown period.
  • Production start-up is with a new contractor
  • The manufacturing site is relocated

The PRR is designed as a system-level preparation tool and should be used for assessing risk as the system transitions from development to FRP. For more information, see the approaches described in CH 3–4.3.18. Producibility, Quality, and Manufacturing Readiness.

 

Outputs and Products

Reference Source: DAG CH 3-3.3.7 Production Readiness Review

The Technical Review Chair determines when the review is complete. Results of the PRR and associated manufacturing readiness assessments are typically documented in a written report or out-brief. The results should be reported, based on the criteria documented in the SEP, using the PRR checklist. Another source of information is the Manufacturing Readiness Level Deskbook to be used as appropriate.