Manufacturing Readiness Levels: What They Are and Why They’re Important
Manufacturing isn’t an activity that happens overnight. Taking a new idea from conception to fruition is a multistage, highly complex process requiring forethought at every step. Nowhere is this more important than in critical production sectors like pharmaceuticals, aerospace, and food production, where the products are vital for national economic health and stability.
Enter manufacturing readiness levels. These benchmarked steps are designed to roadmap production from its earliest stages to its most sustainable operation levels.
An overview of manufacturing readiness levels
Manufacturing readiness levels (MRLs) are a measure utilized primarily by the United States Department of Defense (DoD) to assess the maturity of manufacturing readiness. It’s similar to how the government uses technology readiness levels (TRLs) to evaluate the maturity of technological innovations.
MRLs provide a common metric for understanding and communicating the relative maturity and risk of manufacturing processes and systems. They’re critical factors in the decision-making process for product development and manufacturing planning. They help decision-makers comprehend the risks involved in proceeding with manufacturing at various stages of development. MRLs are also used to identify areas where further development or maturation is required.
Different levels of manufacturing readiness
The MRL framework typically consists of a scale from 1 to 10, with each level having specific criteria that must be met before a manufacturing process can be considered to have reached that level. Here’s an outline of what each level generally looks like:
- Basic manufacturing implications identified: An initial understanding of the basic manufacturing principles is established.
- Manufacturing concepts identified: Broad concepts of the manufacturing approach are identified.
- Manufacturing proof of concept developed: Preliminary plans for the manufacturing process are in place.
- Capability to produce the technology in a laboratory environment: The manufacturing process can be demonstrated in a lab.
- Capability to produce prototype components in a production-relevant environment: The process can produce viable prototypes in a relevant environment.
- Capability to produce a prototype system or subsystem in a production-relevant environment: The process can be integrated into a larger system for prototype creation.
- Capability to produce systems, subsystems, or components in a production-representative environment: Full-scale, relevant systems can be produced.
- Pilot-line capability demonstrated; ready to begin low-rate initial production: The manufacturing process is ready for initial production at a low rate.
- Low-rate production demonstrated; capability in place to begin full-rate production: The process is proven through low-rate production and is ready to scale up.
- Full-rate production demonstrated and lean production practices in place: The process is fully mature, and lean manufacturing practices ensure efficient production.
Each MRL is defined by specific criteria that must be met regarding the maturity of the technology, the quality of the design, the readiness of the production line, and the management of the supply chain, among other factors.
Why MRLs are essential
MRLs are important standards for determining viability in manufacturing at the highest levels. They’re particularly useful in complex and high-risk projects, such as defense and aerospace, where understanding manufacturing readiness can help in making informed decisions about investments and production issues.
Ultimately, the goal of MRLs is to ensure a system progresses through the development phases with an appropriate manufacturing plan for the system’s level of maturity. The focus is on reducing manufacturing risk as much as possible — from conception to fruition.
