The key systems producibility activity in this phase
of the program was the development of a producibility plan. System
producibility design efforts generally were concerned with system-level
tradeoffs. Alternative design approaches and concepts were analyzed for
projected impact on manufacturability and affordability downstream in
production. Customer interface and review of the producibility plan were also performed.
Key responsibilities for systems producibility during
the advanced development phase were to ensure that original designs considered
production requirements and manufacturing capabilities, and to provide
proposal and cost analysis support.
The first production design review occurred at the end
of the advanced development stage. Problems with or deviations from the
producibility plan were addressed at critical design reviews. Systems
producibility support during this phase essentially consisted of system-level
analyses. For example, quantity, type and location of circuit card assemblies
were investigated to ensure that sufficient space was allocated for proposed
CCAs. Tradeoffs between production and system envelope considerations were conducted.
Engineering and Manufacturing Development
Systems producibility engineering support increased
significantly during the engineering development phase. As the hardware design
continued to evolve, producibility analysis of the assembly, and the
fabricated part design began. Actual and design-to-cost estimates (established
in the producibility plan) became critically important. Production design
reviews were held regularly, and problems or deviations from the producibility
plan were resolved at critical design reviews. The producibility plan was
continually reviewed and revised if there were changes in scope.
Prototype Hardware Production
During this phase, the systems producibility engineer
remained in close contact with the design engineering and manufacturing
organizations to resolve any unexpected problems with hardware manufacture and
performance. Design changes resulting from the findings were reviewed by the
producibility engineer to ensure the design documentation represented a
Extensive producibility design efforts occurred during
preproduction. Detailed, cost-based production design reviews were frequently
conducted to track performance against production design goals. Technical
design reviews were held on an ongoing basis until production design goals
were met. The most critical aspect of this phase was the completion of a
production design that met all system specifications and production
requirements. Producibility approval of all drawings was required prior to
Once full-scale production began, the final production
design review was conducted to validate production and previous design-to-cost
estimates and goals. The final technical design review was held to review any
start-up problems and present solutions.
Production Sustaining Support
Producibility design activities were scaled down to an
absolute minimum with most program support handled by the respective
manufacturing support organizations. All engineering changes that were
developed continued to be reviewed by the cognizant producibility engineer to
ensure that the system design remained producible.
Systems producibility engineers also supported
production efforts to effect cost reductions. These efforts included the
generation of engineering change proposals that provided step-function cost or
performance improvements through major system redesigns and application of new
or automated manufacturing technologies.