F. Process Capability and Control |
F.1–Modeling and Simulation |
Scale-down models and simulation approaches and tools identified to support manufacturing and quality activities. Relevant mass and energy balances identified. |
Scale-down models and simulation in development initiated. Detailed mass and energy balance equations developed. |
Manufacturing and quality gaps for system concepts identified using simulation and laboratory experiments utilizing scale-down models. |
Scale-down models and simulation tools utilized to define manufacturing and quality requirements for preferred materiel solution. Laboratory experiments and simulation results considered in the AoA. |
Initial scale-down models and simulations (product or process) developed for each unit operation and used to determine constraints. First systems implemented to facilitate routine monitoring of mass and energy balances. |
Revised scale-down models and simulations developed for each unit operation and used to refine system constraints. Initial scale-down data review and release processes utilizing control charts are formalized. |
Simulations and laboratory experiments utilizing scale-down models used to determine system constraints and identify improvement opportunities. |
Scale-down models and simulations verified by production line build. Results used to improve process and determine that LRIP requirements can be met. |
Scale-down models and simulation verified by LRIP build, assists in management of LRIP, and determines that FRP requirements can be met. |
Scale-down models and simulation verified by FRP build. Production simulation models used as a tool to assist in management of FRP. |
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F.2–Manufacturing Process Maturity |
Hypotheses developed regarding cause–effect relationships between process variables and process stability and repeatability. Failure Modes and Effects Analysis (FMEA) conducted to estimate Risk Priority Numbers (RPNs) |
Studies performed to test high-RPN hypotheses regarding cause–effect relationships. Initial process approaches identified. |
Cause–effect relationships between process control variables and process stability and repeatability validated through laboratory experiments. Critical process control variables identified. |
Maturity of critical processes for preferred materiel solution assessed. Process capability requirements and improvement plans developed and documented in the SEP. |
Process Maturity assessed on similar processes in production. Process capability requirements identified for production line, LRIP and FRP. FMEA revisited and RPNs revised. |
Manufacturing processes demo'd in production relevant environment. Collection or estimation of process capability data from prototype build and refinement of process capability requirements initiated. Work to mitigate high-RPN failure modes ongoing. |
Manufacturing processes demonstrated in a production representative environment. Collection and/or estimation of process capability data and refinement of process capability requirements ongoing. Work to mitigate high-RPN failure modes concluded. |
Manufacturing processes for LRIP verified on a production line. Process Capability data from production line meets target. Process capability requirements for LRIP and FRP refined based upon production line data. |
Manufacturing processes are stable, adequately controlled, capable, and have achieved program LRIP objectives. Variability experiments conducted to show FRP impact and potential for continuous improvement. |
Manufacturing processes are stable, adequately controlled, capable, and have achieved program FRP objectives. |