Definition. Description. Supporting Information. 1. Basic principles observed and reported. Lowest level of technology readiness. Scientific research begins to be ...
Technology Readiness Levels (TRLs) in the Department of Defense 1 Uses of Technology Readiness Levels The primary purpose of using Technology Readiness Levels is to help management in making decisions concerning the development and transitioning of technology. It should be viewed as one of several tools that are needed to manage the progress of research and development activity within an organization. Among the advantages of TRLs: • Provides a common understanding of technology status • Risk management • Used to make decisions concerning technology funding • Used to make decisions concerning transition of technology Some of the characteristics of TRLs that limit their utility: • Readiness does not necessarily fit with appropriateness or technology maturity • A mature product may possess a greater or lesser degree of readiness for use in a particular system context than one of lower maturity • Numerous factors must be considered, including the relevance of the products’ operational environment to the system at hand, as well as the product-system architectural mismatch
1
"Technology Readiness Assessment (TRA) Guidance". United States Department of Defense. April 2011.
TRL Definitions, Descriptions, and Supporting Information TRL 1
Definition
Description
Supporting Information
Basic principles Lowest level of technology readiness. Scientific research Published research that identifies the principles that observed and begins to be translated into applied research and underlie this technology. References to who, where, reported development (R&D). Examples might include paper studies of when. a technology’s basic properties. Technology concept and/or application formulated
Invention begins. Once basic principles are observed, Publications or other references that out-line the practical applications can be invented. Applications are application being considered and that provide analysis speculative, and there may be no proof or detailed analysis to to support the concept. support the assumptions. Examples are limited to analytic studies.
3
Analytical and experimental critical function and/or characteristic proof of concept
Active R&D is initiated. This includes analytical studies and laboratory studies to physically validate the analytical predictions of separate elements of the technology. Examples include components that are not yet integrated or representative.
Results of laboratory tests performed to measure parameters of interest and comparison to analytical predictions for critical subsystems. References to who, where, and when these tests and comparisons were performed.
4
Component and/or breadboard validation in laboratory environment
Basic technological components are integrated to establish that they will work together. This is relatively “low fidelity” compared with the eventual system. Examples include integration of “ad hoc” hardware in the laboratory.
System concepts that have been considered and results from testing laboratory-scale breadboard(s). References to who did this work and when. Provide an estimate of how breadboard hardware and test results differ from the expected system goals.
Component and/or breadboard validation in relevant environment
Fidelity of breadboard technology increases significantly. The basic technological components are integrated with reasonably realistic supporting elements so they can be tested in a simulated environment. Examples include “highfidelity” laboratory integration of components.
Results from testing laboratory breadboard system are integrated with other supporting elements in a simulated operational environment. How does the “relevant environment” differ from the expected operational environment? How do the test results compare with expectations? What problems, if any, were encountered? Was the breadboard system refined to more nearly match the expected system goals?
2
5
TRL Definitions, Descriptions, and Supporting Information (Continued) TRL
Definition
Description
6
System/subsystem model or prototype demonstration in a relevant environment
Representative model or prototype system, which is well beyond that of TRL 5, is tested in a relevant environment. Represents a major step up in a technology’s demonstrated readiness. Examples include testing a prototype in a highfidelity laboratory environment or in a simulated operational environment.
Results from laboratory testing of a prototype system that is near the desired con-figuration in terms of performance, weight, and volume. How did the test environment differ from the operational environment? Who performed the tests? How did the test compare with expectations? What problems, if any, were encountered? What are/were the plans, options, or actions to resolve problems before moving to the next level?
System prototype demonstration in an operational environment.
Prototype near or at planned operational system. Represents a major step up from TRL 6 by requiring demonstration of an actual system prototype in an operational environment (e.g., in an air-craft, in a vehicle, or in space).
Results from testing a prototype system in an operational environment. Who performed the tests? How did the test compare with expectations? What problems, if any, were encountered? What are/were the plans, options, or actions to resolve problems before moving to the next level?
Actual system completed and qualified through test and demonstration.
Technology has been proven to work in its final form and under expected conditions. In almost all cases, this TRL represents the end of true system development. Examples include developmental test and evaluation (DT&E) of the system in its intended weapon system to determine if it meets design specifications.
Results of testing the system in its final configuration under the expected range of environmental conditions in which it will be expected to operate. Assessment of whether it will meet its operational requirements. What problems, if any, were encountered? What are/were the plans, options, or actions to resolve problems before finalizing the design?
Actual system proven through successful mission operations.
Actual application of the technology in its final form and under mission conditions, such as those encountered in operational test and evaluation (OT&E). Examples include using the system under operational mission conditions.
OT&E reports.
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8
9
Supporting Information
Manufacturing Readiness Levels (TRLs) in the Department of Defense 2 Why Manufacturing Readiness? • Manufacturing risk identification and management must begin at the earliest stages of technology development, and continue vigorously throughout each stage of a program’s life-cycle. • Matters of manufacturing readiness and producibility are as important to the successful development of a system as those of readiness and capabilities of the technologies intended for the system. Assessing MRLs is performed to: • define the current level of manufacturing maturity • identify maturity shortfalls and associated costs and risks • provide the basis for manufacturing maturation and risk management Immature manufacturing processes may lead to the following problems: • Inattention to manufacturing during planning and design • Poor supplier management planning • Lack of workforce knowledge and skills Assessing technology readiness levels does leave some major transition questions unanswered: • Is the level of performance reproducible? • What will these cost in production? • Can these be made in a production environment by someone without a PhD? • Are key materials and components available? Manufacturing Readiness Assessments (MRAs) address these unanswered questions in order to reduce manufacturing risk. However, it still does not address the question of whether the product is reliable or maintainable.
2
“Manufacturing Readiness Level Deskbook”. DOD. May 2, 2011. Retrieved from http://www.dodmrl.com/MRL_Deskbook_V2.pdf
Dimensions in assessing Manufacturing Readiness MRLs are assessed in multiple dimensions (referred to as "threads" within DOD): • Technology and industrial base o Industrial base o Manufacturing technology development • Design o Producibility program o Design maturity • Cost and funding o Production cost knowledge (cost modeling) o Cost analysis o Manufacturing investment budget • Materials o Maturity o Availability o Supply chain management o Special handling • Process capability and control o Modeling and simulation of production and process o Manufacturing process maturity o Process yields and rates • Quality management, including supplier quality • Manufacturing workforce (engineering and production) • Facilities o Tooling, special test equipment, special inspection equipment o Facilities • Manufacturing management o Manufacturing planning and scheduling o Materials planning
MRL Definitions Phase (as specified by DoDI [3] 5000.02
Leading to
MRL
1
Materiel Development Decision review
Materiel Solutions Analysis
Milestone B decision
Basic research expands scientific principles that may have manufacturing implications. The focus is on a high level assessment of manufacturing opportunities. The research is unfettered.
Manufacturing concepts identified
Invention begins. Manufacturing science and/or concept described in application context. Identification of material and process approaches are limited to paper studies and analysis. Initial manufacturing feasibility and issues are emerging.
Manufacturing proof of concept developed
Conduct analytical or laboratory experiments to validate paper studies. Experimental hardware or processes have been created, but are not yet integrated or representative. Materials and/or processes have been characterized for manufacturability and availability but further evaluation and demonstration is required.
Capability to produce the technology in a laboratory environment.
Required investments, such as manufacturing technology development identified. Processes to ensure manufacturability, producibility and quality are in place and are sufficient to produce technology demonstrators. Manufacturing risks identified for prototype build. Manufacturing cost drivers identified. Producibility assessments of design concepts have been completed. Key design performance parameters identified. Special needs identified for tooling, facilities, material handling and skills.
Capability to produce prototype components in a production relevant environment.
Manufacturing strategy refined and integrated with Risk Management Plan. Identification of enabling/critical technologies and components is complete. Prototype materials, tooling and test equipment, as well as personnel skills, have been demonstrated on components in a production relevant environment, but many manufacturing processes and procedures are still in development. Manufacturing technology development efforts initiated or ongoing. Producibility assessments of key technologies and components ongoing. Cost model based upon
4
5
Description
Basic manufacturing implications identified
3
Milestone A decision
Technology Development
2
Definition
detailed end-to-end value stream map. Capability to produce a prototype system or subsystem in a production relevant environment.
Initial manufacturing approach developed. Majority of manufacturing processes have been defined and characterized, but there are still significant engineering/design changes. Preliminary design of critical components completed. Producibility assessments of key technologies complete. Prototype materials, tooling and test equipment, as well as personnel skills have been demonstrated on subsystems/ systems in a production relevant environment. Detailed cost analysis include design trades. Cost targets allocated. Producibility considerations shape system development plans. Long lead and key supply chain elements identified. Industrial Capabilities Assessment for Milestone B completed.
Capability to produce systems, subsystems or components in a production representative environment.
Detailed design is underway. Material specifications are approved. Materials available to meet planned pilot line build schedule. Manufacturing processes and procedures demonstrated in a production representative environment. Detailed producibility trade studies and risk assessments underway. Cost models updated with detailed designs, rolled up to system level and tracked against targets. Unit cost reduction efforts underway. Supply chain and supplier Quality Assurance assessed. Long lead procurement plans in place. Production tooling and test equipment design and development initiated.
Pilot line capability demonstrated. Ready to begin low rate production.
Detailed system design essentially complete and sufficiently stable to enter low rate production. All materials are available to meet planned low rate production schedule. Manufacturing and quality processes and procedures proven in a pilot line environment, under control and ready for low rate production. Known producibility risks pose no significant risk for low rate production. Engineering cost model driven by detailed design and validated. Supply chain established and stable. Industrial Capabilities Assessment for Milestone C completed.
Low Rate Production demonstrated. Capability in place to begin Full Rate Production.
Major system design features are stable and proven in test and evaluation. Materials are available to meet planned rate production schedules. Manufacturing processes and procedures are established and controlled to three-sigma or some other appropriate quality level to meet design key characteristic tolerances in a low rate production environment. Production risk monitoring ongoing. LRIP cost goals met,
6
post-CDR (Critical design review) Assessment
7
Engineering and Manufacturing Development
Milestone C decision
Production and Deployment
Full Rate Production decision
8
9
learning curve validated. Actual cost model developed for Full Rate Production environment, with impact of Continuous improvement. Full Rate Production demonstrated and lean production practices in place. Operations and Support
N/A
10
This is the highest level of production readiness. Engineering/design changes are few and generally limited to quality and cost improvements. System, components or items are in rate production and meet all engineering, performance, quality and reliability requirements. All materials, manufacturing processes and procedures, inspection and test equipment are in production and controlled to six-sigma or some other appropriate quality level. Full Rate Production unit cost meets goal, and funding is sufficient for production at required rates. Lean practices well established and continuous process improvements ongoing.
3. Department of Defense Instruction 5000.02 – Operation of the Defense Acquisition System. DOD, December 8, 2008. Retrieved from http://www.dtic.mil/whs/directives/corres/pdf/500002p.pdf
