NCAT: A New View

Table of Contents

AFFORDABILITY

NCAT INDUSTRY AFFORDABILITY TASK FORCE

DEFENSE MANUFACTURING COUNCIL SUPPORT

Characterization of Commercial Parts
Process Maturity
Cost As An Independent Variable
Quick Review of DODD 5000.1 And DODI 5000.2

RELATED ACTIVITIES

Integrated Product Process Development
Dual -Use Technology
Defense Manufacturing Conferences
S & T Affordability Workshop
Roundtables

SUMMARY

SUMMARY OF PRODUCTS DELIVERED

INTRODUCTION

Now in its ninth year of existence, the National Center for Advanced Technologies (NCAT) was founded as a non-profit research and education foundation to provide a bridge between government, industry and academia, and to encourage cooperative efforts on technology development.

NCAT's initial years were dedicated to the development and publication of eight national strategic plans for technology development under the umbrella program "Key Technologies for the Year 2000." On completion of that program in 1992, NCAT turned its efforts toward affordability. This paper describes NCAT's affordability activity in recent years and offers a view of future discussion topics.

While commercial industry understands affordability, government agencies generally accord top priority to performance, and cost becomes a secondary consideration. To reconcile these different perspectives, NCAT developed a "big picture" view of affordability that centers on the efficient application of product and process technology. The original objectives were expanded to include:

• Facilitating cooperative efforts for accelerating technology transition to products.
• Fostering timely, cost-effective implementation of modern techniques of technology/process development.

While NCAT was growing, it developed a process which provides both a top-down and a bottom-up perspective on issues of interest. This process which includes a high level policy group and a series of subgroups working specific topics, has been applied effectively to activities for DoD, National Air and Space Administration (NASA) and the National Science and Technology Council (NSTC). Figure 1 shows graphically how the activity has grown and blossomed. The top branches are generally activities that were being worked with many organizations aiming for consensus issues. The lower branches describe NCAT activities for DoD that are also of interest to other agencies.

Figure 1: NCAT Activities in Retrospect

The technology transfer activity was part of a NASA grant effort aimed at reviewing the agency's Integrated Technology Plan for space. It produced support for a NASA/industry survey of facilities, workshops and discussions of specific topics, and a briefing to the NASA Advisory Council by NCAT and the Aerospace Industries Association (AIA) Space Committee.

The Aeronautics Materials and Manufacturing Technologies (AMMT) effort, a new approach to government/industry cooperation, was undertaken for the NSTC. NCAT was asked to determine industry's needs in the area of aircraft structures (through a workshop and development of white papers), then an AMMT government/industry/academia working group reviewed ongoing government activities that were responsive to industry's needs. The obvious gaps were in the area of affordability, an "ility" well understood in the commercial marketplace, but not necessarily in government programs. The working group developed a final report that was briefed to a major conference (about 80 experts) and, with additional conference comment, delivered to the NSTC. The AMMT effort took five months from workshop announcement to final report and showed that cooperative industry/government activities could be both effective and efficient.

NCAT participated in planning meetings for the four (1994 - 1997) National Institute of Standards & Technology (NIST) spring manufacturing conferences, made presentations, and assisted in the workshops of the manufacturing program. Asked to support the activities of the NSTC in the preparation and performance of the second phase of the Manufacturing Infrastructure effort, NCAT assisted in planning sessions and in activities to form teams for the workshop. A two day workshop involving approximately 75 industry and government participants was orchestrated.

Cooperative effort continued in the NSTC activity on Manufacturing Infrastructure and the Next Generation Manufacturing (NGM) project. In NGM, industry is leading the concerted work of ten separate organizations to develop a view of a typical 21st century manufacturing enterprise and a guide to help companies prepare for the future. NCAT is providing industry leaders for an Executive Advisory Group and administrative support to the project. A major roll-out conference on NGM was held in January 1997. Details of specific enabling efforts will be discussed at the 1997 NIST spring manufacturing conference.

AFFORDABILITY

Figure 2 Replicating the Key Technology Process for Manufacturing Capability

Figure 3 The Executive Committee

Figure 4 The Defense Manufacturing Council Interface

NCAT INDUSTRY AFFORDABILITY TASK FORCE

The task force originally was supported with voluntary resources from seven industry associations; Aerospace Industries Association (AIA), Electronics Industry Association (EIA), American Defense Preparedness Association (ADPA), American Electronics Association (AEA), Society of Manufacturing Engineers (SME), Association of Manufacturing Technology (AMT), and National Security Industrial Association (NSIA). That core group has been expanded to embrace a wider spectrum of industry, including private sector commercial firms and their respective industry associations. Volunteer industry/government teams have been operating together, under the coordination and orchestration of NCAT, to perform studies and workshop activities to address problematic areas of concern to both government and industry. Typically, the industry groups would respond or input an "industry viewpoint" to government operational activities. NCAT's value-added activity resulted in an "honest broker" effort to coalesce the consensus opinions and make input to the DoD as objective, non-parochial industry opinions. These "sounding board" opinions have provided helpful inputs to many government decision makers.

DEFENSE MANUFACTURING COUNCIL SUPPORT

The Defense Manufacturing Council/Industry Affordability Task Force workshop (January 19, 1995) started with briefings by each of the DMC Team Leaders, followed by discussion among the industry contingent. The industry team selected four from the group to become "spokesmen" to respond to each of the initiatives -- John DeCaire, President, National Center for Manufacturing Sciences (NCMS) (Pilots as Agents of Change); John Ramsey, Vice President, Operations, Space & Strategic Missiles Sector, Lockheed Martin (Process Maturation); Jerry Ennis, Vice President, Prototype Center, McDonnell Douglas (Cost as an Independent Variable), Mike Robinson, Director of Business Development, Rockwell (Cost Incentives). Each consolidated the views of the entire group and presented these views during the afternoon session.

The four topic areas were reviewed in open discussion for the balance of the afternoon. The proceedings of the meeting were published as a "White Paper" by NCAT in March 1995.

While this activity was the start of joint efforts between the industry task force and the Defense Manufacturing Council, several similar efforts over the past two years developed an excellent working relationship between industry and the government participants. Some examples are:

• Characterization of Commercial Parts

  The "Multi-Use" team of the Affordability Task Force has completed the work involved in the characterization of commercial Integrated Circuits (ICs) for military use, and has expanded their efforts to include optics manufacturing standards and the characterization of passive electronics (capacitors, resistors, etc.) and optical components. The importance of these efforts to the DoD will be greater than the Commercial ICs project which was of primary concern to the Principal Deputy Assistant Secretary of Defense, Dual Use Technology Policy and International programs.

• Process Maturity

  NCAT was asked by the Defense Manufacturing Council to provide insight into the discussion regarding the maturation of processes from an industry perspective. Sixty days later NCAT delivered a white paper, "An Approach to Process Maturity", outlining discussions of process maturity at the enterprise level and on the shop floor. The paper targeted the areas of what should be the DoD approach to process maturity in terms of: requests for proposals, contract incentives, source selections, criteria, and funding profiles; it generated further discussion and involvement between the industry task force and DoD throughout the last half of 1995, resulting in a policy paper for possible use by the DoD.

  The policy paper was briefed to the Systems Engineering Steering Group under the Defense Manufacturing Council in February 1996 and it was forwarded to DoD officially in April 1996.

• Cost As An Independent Variable

  The DMC asked NCAT to provide input to the Cost As an Independent Variable (CAIV) activity being directed by Dr. Spiros Pallas, Deputy Director for Strategic and Tactical Systems, Office of the Secretary of Defense. A two day workshop was held with briefings by Rockwell International and Georgia Tech. Rockwell briefed on "Management Incentives for Cost Reduction" and Georgia Tech on "Life Cycle Cost Modeling" and "Metrics for Evaluating Economic Affordability". A draft white paper was reviewed and Dr. Pallas presented the final white paper to the DMC in November 1995.

• Quick Review of DODD 5000.1 And DODI 5000.2

  As a result of interactions with the DMC, NCAT was asked to make a quick review of the draft DoD acquisition directives. NCAT held two meetings with DoD representatives and industry; they resulted in a matrix comparing DoD policy letters and the new directive and instruction. This short term response to the request was followed by a secondary (long term) response, a paper titled Evolutionary Defense Acquisition (EDA) that suggested changing to a 3-5 year acquisition cycle while developing subsystem or systems to allow tactics and doctrine evaluation in field conditions. This activity would significantly change the acquisition cycle and simplify the process.

  The EDA white paper was put into the DoD deskbook and on January 27, 1997 Deputy Undersecretary of Defense Acquisition & Technology Dr. Kaminski signed out a policy memorandum encouraging Program Managers to use EDA and other non-traditional methods of acquisition. This is an excellent example of industry government interaction on a topic of mutual interest namely acquisition reform.

  In addition to these examples, NCAT participated in ad hoc groups on Value Engineering Change Proposals (VECP) and Acquisition Reform week II, and also provided support for the Performance Based Business Environment (PBBE) activity, the Single Process Initiative (SPI) discussions, and also discussion of the International Cooperative Opportunities Group (ICOG). NCAT also played a major role in the development of a singular philosophy of IPPD (see Related Activities).

RELATED ACTIVITIES

• Integrated Product Process Development

  Early in 1993 Integrated Product Process Development (IPPD) was recognized as a key element of affordability. NCAT, along with the Georgia Institute for Technology (GIT) and the National Technological University (NTU) developed an educational video series on IPPD that ran for two hours each week from July to December 1993. GIT provided some of the theory and some useful examples. NCAT provided industry leaders from companies in electronics, mechanical components, and system development, together with government leaders representing the Army, Navy, Air Force, ARPA, NASA and Department of Commerce (DoC). NTU furnished the satellite links and recording facilities. This course provided industry, government laboratories and universities with examples of how IPPD was being used. The video series led to the idea of promoting a singular IPPD philosophy throughout DoD and extending its use to advanced technology demonstrations. The NCAT team on IPPD also started the work on Capability Maturity Models (CMM) for Systems Engineering and IPPD. The Systems Engineering CMM has been published and the IPPD CMM is under review and should be published shortly.

  NCAT, in cooperation with team members Georgia Tech and Texas Instruments, created a syllabus of instruction for IPPD. A course of instruction for Advanced Concept Technology Demonstrations (ACTDs), and Advanced Technology Demonstrations (ATDs), at the Science and Technology spectral end of the acquisition process was then developed from the team outcome. Presentations of course content and planning were made to DoD. A three-day pilot course was presented to Army ATD managers in July 1995, and follow-on efforts for developmental and executive level programs are anticipated with the Army, Air Force, Navy and OSD. The Navy has held two 3-day workshops on IPPD in late 1996, one 3-day workshop in January 1997 and an awareness briefing was presented in March 1997. The DDR&E "seed funds" invested in cataloging industry's methodology in IPPD has returned the investment with a singular approach to IPPD for mid-management and executive levels of the Services and OSD.

  In March 1997, an interactive video series for training in IPPD was completed for the Navy Acquisition Reform Office. The leading section was a half hour description of the course and selected comments from DoD and Navy leaders. This tape was distributed for use in Acquisition Reform week II.

  In conjunction with this training activity NCAT participated in a joint effort with Defense Week/King Communications to present a series of 2-day workshops (on a monthly basis) related to IPPD. For these meetings, Defense Week provided the venue and NCAT helped provide speakers.

  Training in IPPD is probably the most important aspect of changing the culture for tomorrow's work force. Organizations need to embrace life-long learning and see that teaming and multidisciplinary efforts are incorporated into university and community college curricula.

• Dual -Use Technology

  In 1996, executive committee and team chairmen of the task force met to review and discuss the "Dual Use" strategic plan prepared by OSD. This document was mailed out for review by each member of the teams and the executive committee, plus other ad hoc members of the Task Force. The Deputy Assistant Secretary of Defense for Dual-Use Technology Policy and International Programs and his staff were in attendance to receive comments and suggestions the task force offered at the Executive Committee meeting. Industry participation in the "Dual Use" review included a broader perspective than is normally involved in task force activities.

  NCAT hosted a workshop for discussing the FY97 Dual-Use program Commercial Operations & Support Savings Initiative (COSSI). Government and industry people discussed the issues in some detail and NCAT provided an industry white paper on COSSI prior to the bidders meeting in mid-February 1997.

• Defense Manufacturing Conferences

  Task Force Teams participated in presentations in the plenary session of the Defense Manufacturing Conferences in `93 - `96. NCAT helped provide speakers for the plenary sessions such as sessions on ManTech and collaborative efforts. The Multi-Association Task Force on Affordability cosponsored awards luncheon where the Distinguished Colleague Award was presented to Bill Andahazy for his support of Manufacturing Technology while he was a congressional staffer. NCAT also hosted a Rountable meeting where industry, government and academia worked to develop a consensus effort for the ManTech program.

• S & T Affordability Workshop

  At the request of DDR&E, NCAT, along with the DoD Science and Technology (S&T) Affordability Task Force, arranged for a two day workshop where S&T managers were briefed on examples of IPPD use in technology demonstrations and also on affordability in major systems (Boeing 777).

  This type of workshop complements the NCAT activity on IPPD training. Evaluation of the workshop resulted in strong recommendations that another workshop be held in 1997 (scheduled June 10-11).

• Roundtables

  NCAT hosted, or caused to be hosted by other participants, a series of "Roundtable" meetings that attempted to resolve budget and programmatic issues with the manufacturing technology program. For the first time, the Centers of Excellence were brought into a broader discussion of their role in the Manufacturing Science (MS&T) planning process. The three sessions were designed to display the extent of program "jointness" to select Congressional staff involved in authorizations and appropriations. Orchestrating this series of meetings spanned six months and the accomplishments were significant in that industry, Congressional staff, service sponsors of ManTech, OSD directors of S&T, and the MS&T Centers of Excellence shared ideas and concerns at the same table for the first time in the history of the program. While all the goals were not attained, a successful plan for next year's programmatic activities was initiated and the sessions provided a common framework for discussing issues impacting the budget.

SUMMARY

Industry and government can cooperate and learn from each other, but there is need for a better way to accelerate change. Commercial industry is drastically reducing cycle time while government programs seem to be unduly stretched. However, with increased emphasis on simulation and modeling, information technology and management concepts including Integrated Product Process Development, Integrated Product Teams, Cost As an Independent Variable and Evolutionary Defense Acquisition, the idea of a few "stalking horse" programs looks attractive. Advanced Technology Demonstrations and Advanced Concept Technology Demonstrations could be used as examples, both good and bad, for future acquisition efforts. NCAT can provide a good discussion forum for such topics.

SUMMARY OF PRODUCTS DELIVERED

• Technology for Affordability Report (1994)
• Multi-Association Industry Task Force's Top Ten Issues (1995)
• Aerospace Technology Policy Forum Proceedings
• Aeronautics Material & Manufacturing Technologies Report to the National Science and Technology Council (1994)
• Video course and brochure "Technology for Affordability through IPPD" (1993)
• IPPD Syllabus (1995)
• Defense Manufacturing Council/Industry Affordability Workshop (1995)
• Process Maturity White Paper (1995)
• Roundtables
• Industry/Government Dialogue on R&D (two conferences) (1992, 1993)
• Pilot Programs for Sustainment White Paper (1995)
• Comments on DoDD 5000.1 and DoDI 5000.2 (1996)
• Summary Report and Recommendations for Accelerating the Use of Commercial Integrated Circuits in Military Systems (1995)
• Proceedings of the October 2 - 3, 1996 S & T Affordability Workshop
• International Cooperative Opportunities White Paper (1996)
• Dual Use Applications Program - Commercial Operations & Support Savings Initiative (COSSI) White Paper (1997)
• Evolutionary Defense Acquisition White Paper (1996)
• Process Effectiveness recommendations to DoD (1996)

GLOSSARY

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