If you were embarking on a long road trip, would you rely on GPS or just “wing it” when planning your route? Of course, it’s always better to have a plan. The same can be said in manufacturing. In our industry, the trusty map is called the Manufacturing Readiness Levels assessment.
Manufacturing Readiness Levels (MRLs) is a systemic approach for developing and executing a manufacturing plan. Basically, it’s a series of steps and tasks to take your production from 0 to 10 (quite literally, as we’ll get to in a bit). MRLs were first developed by the United States Department of Defense and have since become an industry-recognized tool.
MRLs also have a close relationship with Technology Readiness Levels (TRL), which focus on technology development. While MRL and TRL can run on parallel tracks, the steps share similar objectives (from different perspectives), and projects typically progress at similar paces on both sides.
Utilizing MRLs is an effective way to
MRL uses a 10-step scale that indicates the maturity of the manufacturing program. Each step has set criteria that need to be met before moving on to the next step.
The first level of manufacturing readiness includes basic research, identifying manufacturing concepts, and assessing manufacturing feasibility.
Based on the research of MRL 1, manufacturing concepts are defined, including feasibility, materials analysis, and risk assessment.
Through analytical or laboratory environments, validation of manufacturing concept begins, including determining manufacturing feasibility, identifying manufacturing and key processes, and initiating producibility assessments.
Level exit criteria (for MRL levels 1-3):
Small-scale prototyping begins while conducting on-going producibility assessments as well as identifying manufacturing cost-drivers and design performance parameters.
Level exit criteria:
Based on initial prototyping, the manufacturing strategy is refined, including demonstrating processes, analyzing cost-drivers, and other areas.
Level exit criteria:
With the preliminary design completed and the majority of manufacturing processes defined, prototype development can begin. Prototype data is analyzed and producibility improvement is explored.
Level exit criteria:
Manufacturing design is finalized, including material specifications, updating cost models, developing manufacturing plans and quality targets, and developing production tooling and test equipment.
Level exit criteria:
A pilot line demonstration is conducted with the intended facility, materials, equipment, and skilled labor. Results are evaluated on target quality, cost, and performance.
Level exit criteria:
Manufacturing production commences with lean/Six Sigma practices in place. Production is continuously evaluated against cost, schedule, and performance goals.
Level exit criteria:
All manufacturing areas are monitored and managed at Six Sigma level. Minimal engineering or design changes are made for quality or cost improvements.
As a general rule of thumb, the earlier you get your manufacturer involved in the process, the more expertise and value they’ll be able to provide. At Tapecon, even though we may not have an active role until MRL 3 or 4, we can provide consulting services during the early development phases that can be beneficial later down the road.
If you’re interested in learning more about MRLs, tune in to our recent podcast with Dave Shoemaker, Senior Manufacturing Engineering Manager at Tapecon.
With over 100 years of manufacturing experience, Tapecon works with product teams to solve challenges, create products, and enhance lives. Learn more about our contract manufacturing services.