Manufacturing Technical
Assistance Production Program
(MTAPP) Pilot
TACOM Industrial Base Operations (AMSTA-LC-IO)
As of 16 July 2009
1
MTAPP Mission & Vision FY 2014
Mission
Support the affordable readiness objectives of TACOM
weapon systems by assisting critical small-to-medium sized
manufacturers within TACOM’s commercial industrial base
Vision
Enhance the US Army Industrial Base solution portfolio by
developing & deploying best-in-class supplier performance
diagnostic assessment tools and continuous process
improvement frameworks for use by the IBO
2
MTAPP Program Timeline
Army MTAPP Program - SURGE
MTAPP
Research
Study & Pilot
AIR FORCE
USAF MTAPP
Launched –2003
TACOM MTAPP
Program Office
July 2009
115 supplier engagements
2003
•
•
•
•
•
2004
2005
2006
5 Year Air Force program
Small business requirement
Growth oriented program
> $500 M incremental awards
>$100 M operational savings
2007
2008
2009
2010
2011
• 3 year Army program
• Surge contract support
• 20 suppliers
• Weapons & TWV focus
2012
2013
2014
MTAPP II Program – DRAW DOWN
AF / TACOM
Joint Projects
•
•
•
•
•
•
• Abrams
• MRAP
• Howitzer
• Gunmount
FY 14 contract – The Asaba Group
Revised mission / supplier ID criteria
Complete 32 assessments & TA
Redefine supplier capability - SRP
Critical suppliers – TWV, Small Arms
Define draw down impact on mfg skills
MTAPP FY 14 – Same Mission - New Objectives & Tool Set
3
Management & Process Overview
TACOM MTAPP Program Management
MTAPP MAJOR STAKEHOLDERS
PEO/PM
Soldier
PROCESS
1
Supplier Nomination
By Stakeholder /
ID by IBO
• TACOM LCMC supplier /
contract nomination
• Preliminary Supplier &
Contract Analysis based
on WS criticality
• FSC/NAICS filter applied
• SB preference
• Supplier acceptance
GCS
2
TACOM LCMC/ AMC
DLA
CS&CSS
Comprehensive
Assessment & Contract
Corrective Action Plan
3
Corrective Action
Implementation
Technical Assistance
• TA Examples:
• SCOR: Plan, Source, Make
Deliver & Return process and
capability assessments
• Sourcing Support
• Lean six sigma trng
• Process mapping & root
cause analysis
• MRP implementation
• QMS certification
• Contract impact review:
MRP, Quality, Production
scheduling
• Technical skills support
See attached: Revised Assessment Templates
4
4
Transfer of Continuous
Process Improvement
Ownership
• Develop performance
sustainment requirements
• Full transition to continuous
process improvement phase
• Identify long-term
operational improvement
requirements
Information & Document Flow
Contract Constraint
1 Identification
& Supplier Selection
Stakeholder
Nominations
MTAPP
No
Supplier/
Contract
Info Intake
IBO
Preliminary
Assessment
Selection
Review
MTAPP
Yes
Communication
to Stakeholders
E-mail
Notification
Supplier
No
Qualified Supplier
Contact
Supplier
Decision
Letter requesting
participation
Supplier
Yes
Request for Action to The Asaba Group
Comprehensive
2 Assessment & Contract
Corrective Action Plan
IBO
Review
Report of Findings
& Corrective Action
Plan
Technical
Assistance
Proposal
3
Corrective Action
Implementation
Technical Assistance
Exit Assessment
Report
Transition to Supplier
4 Owned Continuous
Process Improvement
Supplier Owned
Continuous
Improvement Plan
Example of Assessment Scorecard
`
MTAPP SUPPLIER ASSESSMENT DIAGNOSTIC REPORT
ENTERPRISE SUMMARY
MTAPP SUPPLIER SCORE
COMBINED SCORE
3.4
1
PERFORMANCE ATTRIBUTES
MTAPP AVG
+/-
3.1
0.3
IBO SECTOR ANALYSIS CRITERIA
ENTERPRISE SUMMARY
COMBINED SCORE
5 (Best)
MTAPP SUPPLIER SCORE
MTAPP SUPPLIER SCORE
3.9
1
MTAPP AVG
CPI
DOD PARAMETERS
5 (Best)
MTAPP SUPPLIER SCORE
RELIABILITY
2.8
2.5
END PART CRITICALITY
4.1
RESPONSIVENESS
4.2
3.5
SUPPLIER DOD VIABILITY
3.0
AGILITY
3.2
2.2
SUPPLIER CAPABILITY
4.3
2.5
3.1
SUPPLIER CAPACITY
COST & ASSETS
1
5 (Best)
MTAPP SUPPLIER SCORE
PERFORMANCE DRIVERS
CPI
BUSINESS FUNCTIONS
5 (Best)
MTAPP SUPPLIER SCORE
BUSINESS PROCESSES
3.5
3.0
ESTIMATING & QUOTING
3.4
INFORMATION LINKAGES
2.3
2.6
PURCHASING
2.8
HUMAN CAPITAL/SKILLS
4.5
3.4
ENGINEERING
3.8
MASTER PROD SCHEDULING
2.3
3.5
PRODUCTION
4.1
FINANCIAL SYSTEMS
3.3
2.7
QUALITY
1
5 (Best)
INDICATOR
3.9
1
MTAPP AVG
INDICATOR
4.2
1
5 (Best)
All Supplier Specific Data Covered By MTAPP NDA
per Contract WHZV-10-P-1035
INDICATOR
Corrective Action Technical Assistance
• Collaborative corrective action plan implemented
• Measurable improvement of contract adherence
• Transition of corrective action plan to CPI
1
Contract Constraint
Identification
& Supplier Selection
2
Comprehensive
Assessment & Contract
Corrective Action Plan
3
Corrective Action
Implementation
Technical Assistance
4
Transfer of Continuous
Process Improvement
Ownership
 Onsite TA is provided for a period of 90 days post assessment
 Where possible, remote assistance is utilized
 Suppliers can also utilize local training resources (PTAC, MEP)
 On-site technical assistance provided - Examples:
•
•
•
•
•
•
QMS AS 9100 (or like) compliance
DCMA process audit
DCAA accounting system certification
MRP system gap analysis – module implementation
Lean six sigma training
Market segmentation & DoD situational analysis
7
Example Program Metrics
Contract
Impact
Metric
(Examples)
As-Is
Baseline
Exit
Assessment
Delivery &
Schedule
Delivery % to commit date
Fill Rates
Fulfillment lead times
50%
60%
55 Days
75%
80%
45 days
Productivity
Setup Time
Non-value Added Time %
Capacity utilization
8 Minutes
30%
60%
4 Minutes
15%
80%
Material
Management
Work-in-Process Inventory
Inventory Days of Supply
Sourcing cycle time
$50K
30
6 Weeks
15
4 Weeks
Warehousing
& Logistics
% of costs
Storage and handling cost
Shipping cycle time
19%
15%
10 Days
10%
6%
5 Days
Safety
# of incidents/month
Avg. days without incident
Cost of incidents
5
15
2%
2
30
1%
Contract
Closeout
MTAPP Exit Assessment - Metrics Example
8
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Improvement
to-date
25%
14%
18%
50%
50%
20%
50%
33%
9%
9%
50%
60%
100%
50%
Supplier Transfer Scorecard
PLAN
High Level Management
Process
Impact Factor
PROCESS FACTORS IMPACTING CONTRACT
Concern
Operational strategy workshop with crossfunctional management team
Process Design
Value stream mapping using TACOM LCMC
requirements
Process Coordination
Time-based enterprise analysis of resource
utilization and smoothing
Decision Making
Document procedures and decision criteria to
expand decision capacity
Capability & Skills
Procurement 101 training
Technical /engineering
resource capacity
Temporary staffing of engineer for bid & quote to
free internal eng on TACOM
Manual / labor
efficiency
Work order documentation and traveler
development
Infrastructure
Information Systems
Expand excel based tool to cover scheduling of
production and material on TAOCM LCMC orders
External
Processes &
Resources
Sub-tier suppliers &
Outsourced process
(Ex. Heat treating)
Identify alternative sources and meet with current
provider to determine possible improvements
Process
Development /
Management
Human
Resources
Current
CPI
Recommendation / Corrective Action
Strategic objectives
aligned to management
direction
Leadership /
Strategy
Baseline
= Direct & Immediate impact
= Indirect impact or linger term
9
CPI
CPI
CPI
CPI
= No material impact