Original Date: 02/19/2007
Revision Date: / /
Best Practice : Production Readiness Review
Raytheon’s Network Centric Systems Manufacturing Center in Largo, Florida, has standardized and implemented a Production Readiness Review process that confirms a production baseline definition and affordability and authorizes proceeding with either low-rate initial production or full-rate production. Thorough gate reviews and discipline subchecklists provide a complete review and eliminate the subjectivity in establishing pass/fail criteria for determining preproduction readiness and management authorization to proceed to production.
Prior to the implementation of a standardized Production Readiness Review (PRR), Raytheon’s Network Centric Systems (NCS) Manufacturing Center in Largo, Florida, lacked a formal preproduction readiness review process. There were no standard checklists or formal review requirement, pass/fail criteria was largely dependent on the knowledge of the reviewer, fewer topics were generally reviewed, and a less formal and rigorous process resulted in products being transitioned to manufacturing before they were ready.
In 2005, Raytheon Largo developed the Integrated Product Development System (IPDS) to standardize a formal Production Readiness Review (PRR) system in its Gate-10 PRR process. An extensive and comprehensive PRR checklist was developed to cover all aspects of production, including program management, structure, resources, and development as well as integration, verification, and validation plans. As part of the checklist, the Largo facility included a supply chain review to ensure obsolescence risks were addressed and mitigation plans were in place prior to production. All areas on the checklist were reviewed during the various IPDS stages so that all documentation and planning were thoroughly assessed at the Gate-10 review.
To eliminate program bias from influencing the Gate-10 PRR, Raytheon developed a system in which five or six independent subject matter experts (SMEs) were assigned to each PRR. By assigning the PRR to SMEs who were not part of the program and did not work on the earlier gate reviews, Raytheon Largo gained a fresh perspective and an independent review of a product’s readiness for production. If the PRR team was unable to find necessary documentation or plans identified in the PRR checklist, program team members would be contacted and assigned action items as necessary.
The results of implementing the PRR process have been documented and Raytheon Largo is now able to conduct consistent and thorough reviews prior to production. In 2006, the Largo facility conducted 30 PRRs of which 22 programs passed, 5 conditionally passed (i.e., action items were given), and 3 did not pass. These mandatory reviews have significantly reduced the risk in transitioning products to production, benefiting both Raytheon Largo and its customers.
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