A manufacturing plan identifies the processes used to
create a producible product and is developed before the individual documents
such as design drawings, tool designs, and work instructions are finalized.
During the plan's development, the IPT reviews and agrees on the processes
required to control the key characteristics of the product during production.
The manufacturing plan includes factory requirements, teaming agreements, and
supplier interface guidance.
The plan is drafted during conceptual design in order
to further the understanding of the manufacturing processes that may be
required and the maturity and availability of those processes. In order to be
able to produce products in a timely manner after final design is completed,
the manufacturing plant must have the equipment, materials, and processes
available. Planning for capital equipment must begin during conceptual design
and may require purchasing prior to the completion of the conceptual design
phase depending on acquisition and set-up lead-times. Likewise, process
development and maturation may be required. The identification of processing
capability and the importance of understanding these capabilities are
discussed in Step 2.
As in 3.3,
manufacturing planning should also include consideration of outsourcing of all
or part of production. The early development of a draft plan provides the IPT
with insight into this information. It also provides information to be used in
the trade studies (3.3
) since it provides the equipment, material, and
process development expenses related to the design concepts.
The development of the manufacturing plan continues
through the detailed design phase of the product and is not completed until
manufacturing has commenced. Updating of the manufacturing plan occurs during
production if either the design or the processes change.
The manufacturing plan should be created early during
conceptual design and be updated throughout detailed design and production. The
plan can help identify and highlight risk areas for mitigation in the planned
Staff: The IPT is
responsible for developing the manufacturing plan. Appropriate manufacturing and
assembly expertise should be added to assist as needed.
Tools and Techniques: Manufacturing Planning Tools range from very simple
spreadsheets to more sophisticated tools such as Material Requirements
Planning (MRP), Manufacturing Resource Planning (MRP II), and Enterprise
Resource Planning (ERP). Manufacturing Planning Tools are discussed in Appendix F.1.11
on any Manufacturing Planning Tools, such as MRP, MRP II, or ERP, implemented by
the organization, is required. Training is usually supplied by the vendor of the
Once the trade studies have resulted in a reasonable
set of possible designs, the development of the manufacturing plan should
begin. The purpose of this plan is to initiate the identification of
manufacturing needs that may require investment. These may include the need to
purchase capital equipment, the need to invest in maturing manufacturing
processes, the need to change the layout of the factory floor, the hiring of
personnel with specific expertise, and the need to identify vendors and
suppliers who can manufacture all or part of the product. With regard to
process maturity, the process capability guidelines discussed in Step 2
provides the corporate resource for
understanding current and future processes.Basic steps in developing a
manufacturing plan are:
1. Analyze product requirements for specific design concepts.
2. Identify fabrication and assembly
processes required and relate to the current processing capabilities (2.1
3. Identify tooling approaches.
4. Identify resource requirements (work force and equipment).
5. Identify risk areas in processes, schedule, and cost.
6. Disseminate and review the plan with the IPT.
7. Update as the product configuration matures.
It should be noted that the manufacturing plan
development continues into the production phase until full production of the
final product is underway as shown in Figure