About BMP & PMWS The Best Manufacturing Practices Program and the Program Manager’s WorkStation Presented By: Rober

1. About BMP & PMWS The Best Manufacturing Practices Program and the Program Manager’s WorkStation Presented By: Robert Hartzell & Ralph Sickinger BMP Center of Excellence October 2007

2. BMP’s Mission To provide Best Practices, management tools, and technical guidelines enabling defense and commercial customers to operate at a higher level of competitiveness. About BMP & PMWS

3. Organizational Structure Chief of Naval Research Director of Transition Manufacturing Technology Program DOC Associate Director BMP Center of Excellence UMCP Operations & Support WILLCOR/CSC (40) Survey Team Support (150) Satellite Centers (9) About BMP & PMWS

4. BMP Center of Excellence • Navy’s Best Manufacturing Practices Program • Identify, Validate, Document, and Distribute Best Practices • Department of Commerce • Provide BMP to Small- and Medium-Size Companies • University of Maryland, College Park • Introduce BMP to College of Engineering About BMP & PMWS

5. Satellite Centers Leveraging Resources Ames (Iowa Procurement Outreach Center) Columbus (Edison Welding Institute) Rockford (Rock Valley College) York (MANTEC, Inc.) Washington, DC (Department of Commerce) Corona (Naval Surface Warfare Center) Clemson (South Carolina Research Authority- Applied Research & Development Institute) Oak Ridge (Department of Energy) New Orleans (Gulf Coast Region Maritime Technology Center) About BMP & PMWS

6. History of the BMP Program 1960-1980 1983-1984 1985 1986 1987 1991 1993 2000 Many programs failing or suffering cost/schedule overruns Defense Science Board studies the problem; publishes findings in DOD 4245.7-M (The “Willoughby Templates”) Best Manufacturing Practices Program established to help the U.S. Defense Industrial Base BMP conducts first Survey (Texas Instruments) BMP publishes NAVSO P-6071 (Best Practices Book) BMP contracts with Bell Labs to write more detail on each Template First version of PMWS is created BMP Center of Excellence established in College Park, MD BMP conducts 100th Survey (Northrop Grumman) About BMP & PMWS

7. Core Competencies Surveys - Technology Transfer - Benchmarking - Business Process Reengineering Systems Engineering - Expert Systems - Risk Management - Engineering Analysis - Red Team Support Web Technologies - CWE - Oracle 10g - MRL Assist About BMP & PMWS

8. Work For Others Systems Engineering Acquisitions and Risk Management Virtual Offices Production Readiness Sample Products and Services • Core • Survey Reports • Technical Guidelines • Program Manager’s WorkStation • Special Projects • Shipyard Benchmarking Study • Battery Products Study • DoD Manufacturing Readiness Levels (MRLs) • SpecRite Tool About BMP & PMWS

9. Sample Customers • DFAS – Integrated Digital Environment • MDA – Sea Based Missile Defense • DoN (Aegis BMD) – COSIP Radar • NAVSEASYSCOM – STANDARD Missile • NAVAIRSYSCOM – LINK-16 • SPAWARSYSCOM – MIDS, DMR, NMT • MARCORSYSCOM – AAAV, UOC • USCG – Rescue 21 • PICA – LW 155, M119A2 • OUSD (AT&L) – System of Systems (PEO JTRS) – JTRS Assessment • DUSD (AS&C) – Battery Products Study • ASN • DASN (RDT&E) – M&S Assessment • (DRPM EFV AAAV) – Risk Management, PRR • (PEO C4I&S) – Radio Industry Study • (PEO IWS) – SEWIP, HGHS • JCS – JWID CWE • JDMTP – MRL / MRL Assist Broad Application of BMPCOE Expertise About BMP & PMWS

10. Program Manager’s WorkStation PMWS is... Knowledge Experience Insight Your Electronic Consultant! About BMP & PMWS

11. KnowHow “Knowledge” About BMP & PMWS

12. Technical Guidelines Documents Purpose:Provide a Cost-Effective Alternative to Government Military Standards for Design and Manufacturing About BMP & PMWS

13. Technical Guidelines Documents DoD 4245.7-M “Willoughby Templates” About BMP & PMWS

14. Technical Guidelines Documents NAVSO P-6071 “Best Practices Book” About BMP & PMWS

15. Technical Guidelines Documents Template Reference Guides Produced by Bell Labs, to cover Templates in even more detail. About BMP & PMWS

16. Technical Guidelines Documents NAVSO P-3641 Power Supply Reliability TABLE 3-2. LOW-VOLTAGE BASELINE POWER SUPPLY CHARACTERISTICS Switching-mode conversion Single output {5 VDC < Output Voltage < 28 VDC} Hold-up period: 1 millisecond Conduction cooled MTBF: See Table 3-4 EMI: MIL-STD-461 except with RE-01 and CE-01    modified Prime Power: 270 VDC or 3-phase per    MIL-STD-704 and/or MIL-STD-1399 About BMP & PMWS

17. Technical Guidelines Documents NAVSO P-3687 How to design producible products in a “sustained acquisition excellence environment.” About BMP & PMWS

18. Technical Guidelines Documents NAVSO P-3680 Environmental Best Practices About BMP & PMWS

19. Technical Guidelines Documents About BMP & PMWS

20. KnowHow Demo About BMP & PMWS

21. KnowHow [Book] Builder Create your own books and add them to the library! About BMP & PMWS

22. BMP Database “Experience” About BMP & PMWS

23. Unique Survey Process – Learning From The Best • Company Makes Request and Controls Content • Emerging Technology and Best Practices Documented • All Data Is Validated by a Team of Experts • Results Distributed Nationwide Survey of Accel LANs, Inc. Best Manufacturing Practices Accel LANs, Inc. Web Site BMP — An Honest Broker For Technology Transfer About BMP & PMWS

24. BMP Validated Best Practices The BMP Program Defines a Best Practice as: “an established documented process, technique, or innovative use of equipment or resources that has a proven record of success in providing significant improvement in cost, schedule, quality, performance, safety, environment, or other measurable factors which impact the health of a company. ” The BMP Program Defines an Information Item as: “a practice that does not have a proven track record or is not significantly different from what others are doing. An Information Item could have the potential to be a Best Practice.” About BMP & PMWS

25. What’s In It For Government And Industry • Reduces Reinvention, Duplication, and Risk • Provides Higher Quality, More Reliable Products and Services • Technology Transfer • Benchmarking • Promotes What the Organization Does Well • No Cost Beyond the Organization’s Time to Participate BMP Is A Win-Win Opportunity About BMP & PMWS

26. Best Practices Breakout Design 16% Management 33% Test 6% Logistics 4% Production 29% Facilities 12% More Than 4,000 Practices Documented... About BMP & PMWS

27. BMP Survey Distribution Government 28% Large 39% Academia 3% Medium 12% Small 18% …Collected From More Than 150 Surveys Since 1985 About BMP & PMWS

28. BMP Database Demo About BMP & PMWS

29. Surveyed Organizations – For Example... • Large • Lockheed Martin, Northrop Grumman, Raytheon, Electric Boat, Rockwell Collins, Weirton Steel, JLG, Cincinnati Milacron, Texas Instruments • Government • NAVSEA PMS-422, USCG LANT/PAC-Maintenance Facilities, NASA Marshall, DOE-Oak Ridge, Sandia & Livermore National Labs, NAWC-Lakehurst, NUWC-Keyport, NADEP-North Island, 8 Army Depots • Medium • Bender Shipbuilding & Repair, Stryker Howmedica Osteonics, Applied Research Lab-Penn State University, Kurt Manufacturing, General Dynamics Armament Systems • Small • In Tolerance, ABC Virtual Communications, Frontier Electronic Systems, General Tool, Sharretts Plating, Thermacore, Dayton Parts, Hamilton Standard, Nascote, United Electric Controls, Wainwright Industries, and Orenda Turbines and Strite Industries (Canada) • Focused • Polariod Corp., City of Chattanooga, USS Carl Vinson, Elizabethtown College, Northrop Grumman About BMP & PMWS

30. TRIMS “Insight” About BMP & PMWS

31. What Is TRIMS? • TRIMS (Technical Risk Identification & Mitigation System): A Methodology for Doing Knowledge-Based, Process-Oriented Risk Management • Includes Set of Software Tools to Help Implement the Methodology (Navy-Owned, Fixed Revision Cycle) • Outgrowth of DoD 4245.7-M and NAVSO P-6071 Templates • Fully Compatible with BMPCOE-Combined Government/Industry Systems Engineering Model • Fully Supported: Training Classes, Computer-Based Training, On-line Help, 24-hour Help Desk Process Based and Predictive About BMP & PMWS

32. TRIMS Proactive Methodology Risk Assessment Probability Effect • Guidance Documents • EngineeringProcess Model • Statistics Mission ProfileScheduleQualityCost PastExperience Planning &Tracking SystemArchitecture Risk Management • Milestone Dates TRIMS Risks PersonnelAssignments Next Actions QuestionWeighting • Risk Management • Snapshot Assessments • Multiple Program Rollups • Automatic Updates Responsibilities Due Dates Action ItemTracking ComplianceStatus References Understanding The Future Effects Of Today's Decisions About BMP & PMWS

33. Proactive vs. Reactive Proactive Process Risks Technical Issues Schedule Slippage Cost Overruns Reactive TRIMS Identifies the Root Causes of Cost & Schedule Problems About BMP & PMWS

34. Problems Risk Management & Problem Tracking Continuum Product Risks Process Risks Time “A ‘Problem’ Is A Risk Whose Time Has Come” About BMP & PMWS

35. Evaluating Process Risk Permits More Timely & Efficient Mitigation T1 T2 T3 T4 T5 T6 Process Risks Product Risks Problems The Accuracy in Predicting Consequence Varies Over Time About BMP & PMWS

36. Cost To Mitigate Increases Exponentially Design Test Production $100 Cost to Mitigate $10 $1 Time About BMP & PMWS

37. Problems Cost To Mitigate Increases Exponentially Design Test Production Cost to Mitigate Product Risks Process Risks Time Risk Management or Damage Control? About BMP & PMWS

38. TRIMS Baseline Templates PRODUCT TQM Money Phasing FUNDING DESIGN TEST PRODUCTION FACILITIES LOGISTICS MANAGEMENT • Integrated Test • Failure Reporting System • Uniform Test Report • Software Test • Design Limit • Life • Test, Analyze & Fix (TAAF) • Field Feedback • Modernization • Factory Improvements • Productivity Center • Logistics Support Analysis • Manpower & Personnel • Support & Test Equipment • Training Materials & Equipment • Spares • Technical Manuals • Manufacturing Strategy • Personnel Requirements • Data Requirements • Technical Risk Assessment • Production Breaks • Design Refer. Mission Profile • Design Requirements • Trade Studies • Design Policy • Design Process • Design Analysis • Parts & Mater. Selection • Software Design • Computer-Aided Design (CAD) • Design for Testing • Built-In Test (BIT) • Configuration Control • Design Reviews • Design Release • Manufacturing Plan • Qualify Manufacturing Process • Piece Part Control • Subcontractor Control • Defect Control • Tool Planning • Special Test Equipment (STE) • CAM • Manufacturing Screening TRANSITION PLAN About BMP & PMWS

39. TRIMS Baseline Templates PRODUCT TQM Money Phasing FUNDING DESIGN TEST PRODUCTION FACILITIES LOGISTICS MANAGEMENT • Integrated Test • Failure Reporting System • Uniform Test Report • Software Test • Design Limit • Life • Test, Analyze & Fix (TAAF) • Field Feedback • Modernization • Factory Improvements • Productivity Center • Logistics Support Analysis • Manpower & Personnel • Support & Test Equipment • Training Materials & Equipment • Spares • Technical Manuals • Manufacturing Strategy • Personnel Requirements • Data Requirements • Technical Risk Assessment • Production Breaks • Design Refer. Mission Profile • Design Requirements • Trade Studies • Design Policy • Design Process • Design Analysis • Parts & Mater. Selection • Software Design • Computer-Aided Design (CAD) • Design for Testing • Built-In Test (BIT) • Configuration Control • Design Reviews • Design Release • Manufacturing Plan • Qualify Manufacturing Process • Piece Part Control • Subcontractor Control • Defect Control • Tool Planning • Special Test Equipment (STE) • CAM • Manufacturing Screening • CAM • Manufacturing Screening TRANSITION PLAN About BMP & PMWS

40. TRIMS Baseline Templates PRODUCT TQM Money Phasing CostAssessment FUNDING DESIGN TEST PRODUCTION FACILITIES LOGISTICS MANAGEMENT • Integrated Test • Failure Reporting System • Uniform Test Report • Software Test • Design Limit • Life • Test, Analyze & Fix (TAAF) • Field Feedback • TEMP Development/ Execution • Software Simulator • Modernization • Factory Improvements • Productivity Center • Field Visits/Site Surveys • Logistics Support Analysis • Manpower & Personnel • Support & Test Equipment • Training Materials & Equipment • Spares • Technical Manuals • Logistics Analysis Documentation • Manufacturing Strategy • Personnel Requirements • Data Requirements • Technical Risk Assessment • Production Breaks • Determining Defining Need for System • Prepare Requirement Documents • Quality Assurance • Design/Milestone Review Planning • Make or Buy Decisions • Technology Base Analysis • Schedule & Planning • Dim. Manuf. Sources & Mat. Shortage (DMSMS) • Design Refer. Mission Profile • Design Requirements • Trade Studies • Design Policy • Design Process • Design Analysis • Parts & Mater. Selection • Software Design • Computer-Aided Design (CAD) • Design for Testing • Built-In Test (BIT) • Configuration Control • Design Reviews • Design Release • Concept Studies & Analysis • Bread Board Development • Brass Board Development • Specification Dev/Allocation/ Validation • Design for Assembly • Prototype Development & Review • Manufacturing Plan • Qualify Manufacturing Process • Piece Part Control • Subcontractor Control • Defect Control • Tool Planning • Special Test Equipment (STE) • CAM • Manufacturing Screening • Production Fabrication • Environmental Issues • CAM • Manufacturing Screening • Production Fabrication • Environmental Issues New PMWS Templates TRANSITION PLAN About BMP & PMWS

41. Management Logistics Funding Design Test Production Facilities TransitionPlan TRIMS Tailoring User AddedCategories TRIMS Hierarchy 4.0 Design UserAddedTemplates 3 Tiers: Category Template Knowledge Base Question 4.6 Design Analysis UserAddedQuestions 4.6.1 Do the contractor's corporate standards identify design analysis as an integral part of the design process? About BMP & PMWS

42. TRIMS Demo About BMP & PMWS

43. Tailoring TRIMS To Your Needs • Identify Risks Before they Become Problems • Build YOUR Knowledge into TRIMS • Use the Systems Engineering Knowledge Base as a Starting Point for A Good Engineering Process • Create a Concrete, Repeatable Process for Evaluating & Comparing Programs & Contractors • Ease the Learning Curve for New Employees • Retain Knowledge of Lost Employees • Share Knowledge • To Maximize Benefits of Using TRIMS • Apply as Early as Possible in Program Life • Apply to All Subcontractors, Divisions & Vendors Involved • Use Tool Regularly to Prioritize Resources & Make Decisions About BMP & PMWS

44. TRIMS Knowledge Models • Existing (Released) Models • Systems Engineering • Software Risk Engineering (Carnegie Mellon) • Circuit Card Testability • Interoperability and Integration • Existing (Beta) Models • Human Factors Engineering • Development (Prototype) Models • Management • Port Security/Force Protection TRIMS Has Many Applications About BMP & PMWS

45. The Future of TRIMS About BMP & PMWS

46. TRIMS - Total Risk Management P3RM Problem, Product & Process Risk Management, in a Single Tool! About BMP & PMWS

47. Program Manager’s WorkStation • Reduce Risk Throughout Acquisition Process • KnowHow: What To Do • Database: Where To Get Help • TRIMS: Keep On Track • Tested and Used by Government and Industry • Taught at Defense Acquisition University and Industrial College of the Armed Forces • Accepted Tool/Methodology Within the DoD Acquisition Knowledge Sharing System • Acquisition Community Connection: • Program Management: http://acc.dau.mil/pm • Risk Management: http://acc.dau.mil/rm An Integrated Problem Solver About BMP & PMWS

48. No Surprises!! About BMP & PMWS

49. Conclusion About BMP & PMWS

50. Since 1985 BMP Has . . . • Conducted More Than 150 On-site Surveys • Documented More Than 4,000 Practices • Developed the Program Manager’s WorkStation • Created the BMP Center of Excellence • Opened Nine Regional BMP Satellite Centers About BMP & PMWS