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Reference Source: DoD Risk, Issue, and Opportunity Management Guide for Defense Acquisition Programs, Jan 2017 The decision to enter EMD should be made when the design is mature, the requirements are stable, and the risks are acceptable. By entering this phase, a program commits to a product. It initiates the Department’s efforts for full-scale development and testing of a product to support verification of all operational and derived requirements so the program can begin production and deployment. During the EMD phase, the program manages the remaining risk, builds and tests production representative prototypes or first articles to verify compliance with requirements, and prepares for production and fielding. It includes the establishment of the product baseline for all configuration items. The program should conduct a Critical Design Review (CDR), a System Verification Review (SVR), a Functional Configuration Audit (FCA), and a Production Readiness Review (PRR) as part of its ongoing systems engineering and risk management efforts to assess and manage risk. These SETRs are technical milestones to assess the product and processes to ensure the system can perform as desired and proceed into the next phase within cost and schedule constraints at an acceptable level of risk. The PM should focus the risk management activities on the transition from development to production. The program should consider conducting a manufacturing readiness assessment before Low-Rate Initial Production (LRIP) and again before Full-Rate Production (FRP) to identify risks related to critical manufacturing processes and product characteristics. Examples of specific risk areas include requirements/design stability, integration and inter-dependency risks, and manufacturing/supply chain quality. Suggested Activities in the EMD Phase to Reduce Risk
Reference Source: DAG CH 3-3.2.4 Engineering and Manufacturing Development Phase The primary objective of the Engineering and Manufacturing Development (EMD) phase is to develop the initial product baseline, verify it meets the functional and allocated baselines and transform the preliminary design into a producible design, all within the schedule and cost constraints of the program. Systems engineering (SE) activities support development of the detailed design, verification that requirements are met, reduction in system-level risk and assessment of readiness to begin production and/or deployment (see Figure 14). Primary SE focus areas in EMD include:
The EMD phase includes technical assessment and control efforts to effectively manage risks and increase confidence in meeting system performance, schedule and cost goals. SE activities should be integrated with EMD phase-specific test and evaluation, and logistics and sustainment activities identified in CH 8–4.3. and CH 4–3.3., respectively. The planning, scheduling and conduct of event-driven technical reviews (Critical Design Review (CDR), Functional Configuration Audit (FCA), System Verification Review (SVR), and Production Readiness Review (PRR)) are vital to provide key points for assessing system maturity and the effectiveness of risk-reduction strategies. A well-planned EMD phase Systems Engineering Plan (SEP) builds on the results of previous activities and significantly increases the likelihood of a successful program compliant with the approved Acquisition Program Baseline (APB). The Limited Deployment Decisions in program Model 3 are the points at which an increment of capability is reviewed for Limited Deployment. Approval depends in part on specific criteria defined at Milestone B and included in the Milestone B ADM. Implementing the technical planning as defined in the approved SEP guides the execution of the complex and myriad tasks associated with completing the detailed design and integration, and supports developmental test and evaluation activities. The SEP also highlights the linkage between Technical Performance Measures (TPM), risk management and earned-value management activities to support tracking of cost growth trends. Achieving predefined EMD technical review criteria provides confidence that the system meets stated performance requirements (including interoperability and supportability requirements) and that design and development have matured to support the initiation of the Production and Deployment (P&D) phase.
Reference Source: DAG CH 3-3.2.4 Engineering and Manufacturing Development Phase In addition to the general responsibilities identified in CH 3–2.5. Engineering Resources, the Program Manager (PM) focuses on the following EMD activities, which rely on and support SE efforts:
In addition to the general roles and responsibilities described in CH 3–2.5. Engineering Resources, during this phase it is the Systems Engineer’s responsibility for:
Reference Source: DAG CH 3-3.2.4 Engineering and Manufacturing Development Phase
Reference Source: DAG CH 3-3.2.4 Engineering and Manufacturing Development Phase The EMD phase activities begin when a favorable Milestone B decision has been made (see CH 3–3.2.3. Technology Maturation and Risk Reduction Phase) and end with a successful Milestone C decision. Figure 15 provides the end-to-end perspective and the integration of SE technical reviews and audits across the acquisition life cycle. SE activities to support the EMD effort include:
The Systems Engineer uses technical reviews and audits to assess whether preplanned technical maturity points are reached during the acquisition life cycle as the system and system elements mature. A key method for doing this is to identify technical risks associated with achieving entrance criteria at each of these points (see the DoD Risk, Issue and Opportunity Management Guide for Defense Acquisition Programs available on the DASD(SE) web site.) Technical reviews and audits typically conducted in EMD:
Test activities during the EMD phase that depend on SE support and involvement include Test Readiness Reviews (TRRs), Developmental Test and Evaluation (DT&E) and Operational Assessments (OAs). The Systems Engineer, in collaboration with the Chief Developmental Tester, should identify system evaluation targets driving system development and support operational assessments as documented in the Test and Evaluation Master Plan (TEMP). Associated SE activities and plans should be in the SEP (see CH 3–2.2. Systems Engineering Plan, 3.3. Technical Reviews and Audits, and CH 8–3.5.).
Reference Source: DAG CH 3-3.2.4 Engineering and Manufacturing Development Phase The technical outputs and products identified in Table 23 are some of the inputs necessary to support SE processes in the P&D phase. They should support the technical recommendation at Milestone C that manufacturing processes are mature enough to support Low-Rate Initial Production (LRIP) and generate production-representative articles for operational test and evaluation (OT&E). Technical outputs associated with technical reviews in this phase are addressed later in this chapter. Technical Outputs from EMD Phase
Reference Source: DAG CH 4-3.3 Engineering and Manufacturing Development Phase The sustainment focus during the Engineering and Manufacturing Development (EMD) phase is to plan for development, testing, and delivery of the product support package. As the system design matures, the PM continues to influence the design to reduce risks in reliability, maintainability, availability and O&S Cost. The PM also conducts additional analyses to refine the Product Support Strategy and plans for the initial fielding of the weapon system and the transition to O&S.
Reference Source: DAG CH 4-3.3.1 Sustainment Planning: Product Support Package Development The PM’s sustainment focus during EMD is the product support package. The product support package is further defined by assigning sustainment requirements to specific subsystems and equipment. Support plans for both the system and its logistic support system are developed as the system design matures. The PM ensures the program documentation, and planning, programming, and budgeting actions are put into place to develop, field, and sustain the product support package. Technical Performance Measures are established to monitor the linkage between design and supportability; they may be jointly developed by the systems engineering and product support teams at the start of the program and managed during EMD. The PM ensures the sustainment metrics are achievable by Full Operational Capability (FOC). Key elements include: Support equipment requirements, unique support equipment (organic, intermediate, depot), and provisioning for common and unique support equipment In the EMD phase, the PM ensures that testing validates that the design meets the sustainment requirements. The Systems Engineering Plan (SEP) includes the processes to validate the required product support package performance. The PM also ensures that sustainment metrics are estimated based on the latest configuration and test results. Finally, the PM ensures that the approved product support package’s capabilities, including supply chain and other logistics processes and products, are demonstrated and validated. Reference Source: DAG CH 4-3.2.1.1.2 Product Support Package Development Some additional Product Support Package elements that warrant consideration include:
Reference Source: DAG CH 4-3.2.3.2 LCSP and Product Support Strategy LCSP and Product Support Strategy The PM participates in the Pre-Milestone B RFP development and the review of industry proposals prior to award. The PM’s goal is to ensure that the RFP conveys the sustainment strategy, specified sustainment requirements, and required data and deliverables to industry. The RFP includes requirements for the contractor to propose data development and delivery, and sustainment metrics. The PM should consider sustainment outcomes in developing incentive or award fees. The PM uses the LCSP to assist in the development of the RFP Statement of Work (SOW), which articulates product support requirements to the Contractor for the EMD phase that will allow a product support package to be delivered during production. The SOW includes the requirements for analyses, design interface, and product support development and test activities. Reference Source: DAG CH 4-3.2.3.3 Reliability and Maintainability in the EMD RFP Reliability and Maintainability in the EMD RFP Any R&M requirements that remain medium or high risk after TMRR phase testing should be reflected in the incentive planning. The RFP for EMD should include a contractor sustainment support Contract Data Requirements List (CDRL) to provide all test failure data (to include vendor and sub-vendors) and report all repair work and repair cost data for each warranty (if applicable) repair. Contractor repair data will inform cost estimates and organic sustainment planning. Reference Source: DAG CH 4-3.3.1.5 Core Workload and Depot Source of Repair Core Workload and Depot Source of Repair Prior to Milestone C, the PM refines core depot workload estimates based on the CDR. The PM also works with DoD Component stakeholders to identify potential depots for all components/sub-components of the program. The Depot Source of Repair analysis and decision process helps select the location for the depot workload and helps ensure effective use of commercial and organic depot maintenance resources that deliver best value to the program. The PM also projects the date and the funding for those depots to commence operation (IOC plus four years). Reference Source: DAG CH 4-3.3.1.6 Supply Chain Evaluation Supply Chain Evaluation The supply chain is finalized to reflect the product support strategy. Every aspect of the supply chain supports the Warfighter required performance and cost metrics. Processes are put in place to automatically and electronically share data and information between all Services, agencies, and commercial entities in the supply chain. The supply chain evaluation focus is on ensuring operational supportability and verifying performance. It includes a comprehensive description of the elements and fielding plan. Reference Source: DAG CH 4-3.3.1.7 Development of PSAs Development of PSAs Most product support strategies depend on product support arrangements (PSAs) with both organic and commercial industry. The PM determines the blend of public and private providers, and the relationship between them, to achieve an effective product support strategy that delivers Warfighter operational readiness. Programs should seek to effectively deliver the requirements of the product support package at best value to the government while attractive to commercial providers. Performance metrics used to measure achievement of the required outcomes and the solution (and associated product support package) are adjusted as required to effectively and affordably sustain the weapon system. Reference Source: DAG CH 4-3.3.1.10 Software Sustainment Transition Plan Software Sustainment Transition Plan During the transition to post-production software support (Milestone C), fielding occurs, the hardware production line ends, and software maintenance reaches steady state. For post-production software support, the PM should be sure to program funding for the cost of government labor to include field service engineers (government and contractor), certification and accreditation, lab operation, license updates, and the risk management process. (Office of the Secretary of Defense has replaced the information assurance process with updated cybersecurity requirements and the risk management process). By Milestone C, the Intellectual Property Strategy documents how much technical data is optimal for the government to purchase. |