||DoD 4245.7-M: Transition from Development to Production
OUTLINE FOR REDUCING RISK
The organization has a "corporate
level" policy statement attaching highest priority to the principles of TQM.
This policy statement defines TQM in terms relevant to the individual
enterprise or activity and its products or outputs.
The corporate policy statement is
supported by a TQM implementation plan that sets enduring and long range
objectives, lists criteria for applying TQM to new and on-going
programs, provides direction and guidance, and assigns responsibilities.
Every employee at each level plays a functional role in implementing the
All personnel are given training
in TQM principles, practices, tools, and techniques. Importance is placed on
self-initiated TQM effort.
TQM effort begun in the conceptual
phase of the acquisition cycle is vitally concerned with establishing a
rapport between the producer and the user or customer and a recognition of
the latter’s stated performance requirements, mission profiles, system
characteristics, and environmental factors. Those statements are translated
into measurable design, manufacturing, and support parameters that are
verified during demonstration and validation. Early TQM activity is outlined
in the Design Reference Mission Profile template and Design Requirements
template. The Trade Studies template is used to identify potential
characteristics which would accelerate design maturity while making the
design more compatible with and less sensitive to variations in
manufacturing and operational conditions.
Design phase TQM activity is
described in the Design Process template. Key features enumerated include:
design integration of life-cycle factors concerned with production,
operation, and support; availability of needed manufacturing technology;
proof of manufacture ng process; formation of design and design review teams
with various functional area representation; and use of producibility
engineering and planning to arrive at and transition a producible design to
the shop floor without degradation in quality and performance. The Design
Analysis template and Design Reviews template provide guidance in
identifying and reducing the risk entailed in cent rolling critical design
characteristics. Both hardware and software are emphasized (reference the
Software Design template and Software Test template). A high quality design
includes features to enhance conducting necessary test and inspection
functions (reference the Design for Testing template).
An integrated test plan of
contractor development, qualification, and "production acceptance testing
and a test and evaluation master plan (TEMP) covering Government-related
testing are essential to TQM. The plans detail sufficient testing to prove
conclusively the design, its operational suitability, and its potential for
required growth and future utility. Test planning also makes efficient use
of test articles, test facilities, and other resources. Failure reporting,
field feedback, and problem disposition are vital mechanisms to obtaining a
Manufacturing planning bears the
same relationship to production success as test planning bears to a
successful test program (reference the Manufacturing Plan template). The
overall acquisition strategy includes a manufacturing strategy and a
transition plan covering all production related activities. Equal care and
emphasis is placed on proof of manufacture as on proving the design itself.
The Qualify Manufacturing Process template highlights production planning,
tooling, manufacturing methods, facilities, equipment, and personnel.
Extreme importance is attached to subcontractor and vendor selection and
qualification including flow down in the use of TQM principles (reference
the Subcontractor Control template). Special test equipment, computer-aided
manufacturing, and other advanced equipments and statistical based methods
are used to qualify and control the manufacturing process.