About BMP & PMWS The Best Manufacturing Practices Program and the Program Manager’s WorkStation...

About BMP & PMWSThe Best Manufacturing Practices Program and the Program Manager’s WorkStation

Presented By:

Robert Hartzell & Ralph SickingerBMP Center of Excellence

October 2007

www.bmpcoe.org About BMP & PMWS 2

To provide Best Practices, To provide Best Practices,

management tools, management tools,

and technical guidelines and technical guidelines

enabling enabling

defense and commercial customers defense and commercial customers

to operate to operate

at a higher level at a higher level

of competitiveness.of competitiveness.

BMP’s Mission


Chief of Naval Research

BMP Center of Excellence

Operations & SupportWILLCOR/CSC (40)

Survey TeamSupport (150)

Associate Director

DOC

UMCP

Organizational Structure

Director of Transition

Manufacturing Technology Program

Satellite Centers(9)


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


New Orleans(Gulf Coast Region Maritime

Technology Center)

Ames(Iowa ProcurementOutreach Center)

Columbus(Edison Welding Institute)

Oak Ridge(Department of Energy)

York(MANTEC, Inc.)

Rockford(Rock Valley College)

Corona(Naval Surface Warfare Center)

Satellite Centers Leveraging Resources

Clemson(South Carolina Research Authority-Applied Research & Development

Institute)

• • • •

• •

• • • • • •

• •

• •

• •

Washington, DC(Department of Commerce)


History of the BMP Program

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 BaseBMP 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)

1960-1980

1983-1984

1985

1986

1987

1991

1993

2000


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


Sample Products and Services

• Core

– Survey Reports

– Technical Guidelines

– Program Manager’s

WorkStation

• Work For Others

– Systems Engineering

– Acquisitions and Risk

Management

– Virtual Offices

– Production Readiness

• Special Projects

– Shipyard Benchmarking Study

– Battery Products Study

– DoD Manufacturing Readiness Levels (MRLs)

– SpecRite Tool


Sample Customers

• 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

• 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

Broad Application of BMPCOE Expertise


ExperienceExperience InsightInsight

KnowledgeKnowledge

Program Manager’s WorkStation

Your Electronic Consultant!

PMWS is...


KnowHowKnowHow

“Knowledge”


Purpose:Provide a Cost-Effective Alternative to Government Military Standards

for Design and Manufacturing

Technical Guidelines Documents



DoD 4245.7-M

“Willoughby Templates”



NAVSO P-6071

“Best Practices Book”



Template Reference Guides

Produced by Bell Labs, to cover Templates in even more detail.



NAVSO P-3641

Power Supply Reliability

Switching-mode conversionSingle output {5 VDC < Output Voltage < 28 VDC}Hold-up period: 1 millisecondConduction cooledMTBF: See Table 3-4EMI: MIL-STD-461 except with RE-01 and CE-01 modifiedPrime Power: 270 VDC or 3-phase per MIL-STD-704 and/or MIL-STD-1399

TABLE 3-2. LOW-VOLTAGE BASELINE POWERSUPPLY CHARACTERISTICS



NAVSO P-3687

How to design producible products in a “sustained acquisition excellence environment.”



NAVSO P-3680

Environmental Best Practices


KnowHow KnowHow DemoDemo


KnowHow [Book] Builder

Create your own books andadd them to the library!

Create your own books andadd them to the library!


BMP DatabaseBMP Database

“Experience”


Survey ofAccel LANs, Inc.

Best Manufacturing Practices

WebSite

Accel LANs, Inc.

BMP — An Honest Broker For Technology Transfer

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


The BMP Program Defines a The BMP Program Defines a Best PracticeBest Practice as: 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 The BMP Program Defines an Information ItemInformation Item as: 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.”

BMP Validated Best Practices


BMP Is A Win-Win Opportunity

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


More Than 4,000 Practices Documented...

Management33%

Facilities12%

Logistics4%

Production29%

Test6%

Design16%

Best Practices Breakout


…Collected From More Than 150 Surveys Since 1985

Government28%

Academia3%

Small18%

Medium12%

Large 39%

BMP Survey Distribution


BMP DatabaseBMP DatabaseDemoDemo


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


TRIMSTRIMS

“Insight”


• 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

What Is TRIMS?

Process Based and Predictive


TRIMS Proactive Methodology

TRIMS

Probability Effect

• Risk Management

• Snapshot Assessments

• Multiple Program Rollups

• Automatic Updates

Milestone Dates

PersonnelAssignments

QuestionWeighting

Due Dates

References

ComplianceStatus

Risks

Next Actions

Responsibilities

Action ItemTracking

Mission ProfileScheduleQualityCost

Guidance Documents

EngineeringProcess Model

Statistics

PastExperience

Planning &Tracking

SystemArchitecture

Risk Management

Understanding The Future Effects Of Today's Decisions

Risk Assessment


Technical Issues

Process Risks

Reactive

Proactive

Proactive vs. Reactive

Schedule Slippage

Cost Overruns

TRIMS Identifies the Root Causes of Cost & Schedule Problems


Process Risks

Product Risks

Time

Problems

“A ‘Problem’ Is A Risk Whose Time Has Come”

Risk Management & Problem Tracking Continuum


The Accuracy in Predicting Consequence Varies Over Time

Process Risks Problems

Product Risks

T1 T2 T3 T4 T5 T6

Evaluating Process Risk Permits More Timely & Efficient Mitigation


Time

Cos

t to

Miti

gate

Design Test Production

$1

$100

$10

Cost To Mitigate Increases Exponentially


Process Risks

Product Risks

Problems

Risk Management or Damage Control?

Cost To Mitigate Increases Exponentially

Time

Cos

t to

Miti

gate

Design Test Production


PRODUCT TQM

FUNDING MoneyPhasing

DESIGN TEST PRODUCTION FACILITIES LOGISTICS MANAGEMENT

TRANSITION PLAN

• 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

• Integrated Test

• Failure Reporting System

• Uniform Test Report

• Software Test

• Design Limit

• Life

• Test, Analyze & Fix (TAAF)

• Field Feedback

• Manufacturing Plan

• Qualify Manufacturing Process

• Piece Part Control

• Subcontractor Control

• Defect Control

• Tool Planning

• Special Test Equipment (STE)

• CAM

• Manufacturing Screening

• 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

TRIMS Baseline Templates


PRODUCT TQM



TRANSITION PLAN



• Trade Studies

• Design Policy

• Design Process

• Design Analysis


• Software Design





• Design Reviews

• Design Release

• Integrated Test



• Software Test

• Design Limit

• Life


• Field Feedback





• Defect Control

• Tool Planning


• CAM


• Modernization







• Spares








CAM•Manufacturing Screening


PRODUCT TQM


CostAssessment


TRANSITION PLAN

New PMWSTemplatesNew PMWSTemplates



• Trade Studies

• Design Policy

• Design Process

• Design Analysis


• Software Design





• Design Reviews

• Design Release

• Concept Studies & Analysis

• Bread Board Development

• Brass Board Development

• Specification Dev/Allocation/ Validation

• Design for Assembly

• Prototype Development & Review

• Integrated Test



• Software Test

• Design Limit

• Life


• Field Feedback

• TEMP Development/ Execution

• Software Simulator





• Defect Control

• Tool Planning


• CAM


• Production Fabrication

• Environmental Issues

• Modernization



• Field Visits/Site Surveys





• Spares


• Logistics Analysis Documentation






• 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)


CAM•Manufacturing Screening

•Production Fabrication•Environmental Issues


UserAdded

Templates

UserAdded

TemplatesUser

AddedQuestions

UserAdded

Questions

3 Tiers: Category

Template

Knowledge

Base

Question

4.0 Design

4.6 Design Analysis

4.6.1 Do the contractor's corporate standards identify design analysis as an integral part of the design process?

TRIMS Tailoring

TRIMS Hierarchy

Design Test Production Facilities LogisticsManagementFunding TransitionPlan

User Added

Categories

User Added

Categories


TRIMS DemoTRIMS Demo


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


TRIMS Knowledge Models

TRIMS Has Many Applications

• 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


The Future of TRIMS


TRIMS - Total Risk Management

PP33RMRM Technical Risk

Identification Mitigation

Problem, Product & Problem, Product & ProcessProcess Risk Management, Risk Management,

in a Single Tool!in a Single Tool!


• 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

Program Manager’s WorkStation


No Surprises!!No Surprises!!


ConclusionConclusion


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


BMP Benefits

• Technology Transfer Between Organizations . . . Saves Time & Money by Reducing Repetitive Problem Solving

• Finds Best Practices, Facilitates their Diffusion and Promotes Excellence

• Government, Industry, & Academic Partnerships

• Provide Resources and Tools for Solving Technical Problems

• Free Benchmarking

• Expert Assistance


How To Get Help Using PMWS

• Go to Help Menus in Each Tool

• Use the Computer-Based Training (CBT) Videos • Available on PMWS CD and on BMP’s Website• These are Animated & Narrated Tours Showing Each Step of

Using PMWS

• Call our 24 Hour Helpdesk 301-405-9963

• E-Mail the BMP Center at [email protected]

• Arrange a Training Session• With Local BMP Satellite Center• Via VTC with College Park, MD• Other Options Available

Help Is Available


BMPCOE . . . Provides High ROI

Call 1-800-789-4BMP

www.bmpcoe.org

1998 Winner

Innovations In American Government

2000 Winner

HammerAward

About BMP & PMWS The Best Manufacturing Practices Program and the Program Manager’s WorkStation...

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