DARPA’s Call to Action: Mobilizing Industrial Capacity for Crisis Manufacturing

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The Defense Advanced Research Projects Agency (DARPA) has recently issued a Request for Information (RFI) under the title “Industrial Mobilization for Crisis Manufacturing” (DARPA-SN-24-68). This initiative reflects a growing recognition of the critical need for the U.S. industrial base to rapidly scale production capabilities in response to unforeseen crises, such as natural disasters, pandemics, or armed conflicts. The RFI seeks innovative solutions that can enhance the agility and responsiveness of the manufacturing sector, particularly in producing critical goods on short notice.

The Challenge: Scaling Production in a Crisis

The COVID-19 pandemic exposed a glaring vulnerability in the U.S. supply chain. The sudden and overwhelming demand for medical supplies, personal protective equipment (PPE), and ventilators overwhelmed the nation’s manufacturing capabilities, leading to significant delays and shortages. This crisis highlighted the critical importance of having a robust industrial base that can quickly pivot to meet emergent needs.

DARPA’s latest RFI aims to address these challenges by focusing on how the U.S. industrial base can be better prepared to surge production by tenfold or more in less than 30 days, and then quickly return to normal operations after the crisis has subsided.

This challenge is multifaceted. While the U.S. is a leading producer of manufactured goods, and about 20% of its industrial capacity remains unused, this potential cannot be easily or quickly converted into actual surge capacity. Existing production systems are often highly specialized and optimized for efficiency under normal conditions, not for rapid expansion during a crisis.

Historical Lessons and Modern Complexities

Looking back at history, during World War II, the U.S. faced the largest manufacturing crisis since the Industrial Revolution. Critical systems were often produced rapidly with the understanding that they might have defects or limited lifespans due to the exigencies of war. These systems served their immediate purpose, but post-war, the focus shifted to producing more stable and reliable products as the need for rapid, large-scale production waned.

Currently, across many defense and commercial products that would be critical in a crisis, systems are significantly over-constrained with requirements (range, design-life, etc.) and specifications (tolerances, etc.) that include additional margin for storage and maintenance to
support stockpiling. These constraints are inconsistent with needs during crisis production; however, impacts of deviation are difficult to quantify. It is likely that the systems we produce at the start of a crisis will look different than those with which we end a crisis. As our systems have become more complex and integrated, it becomes pertinent that we capture the impacts of  requirements deviations on system performance and manufacturability as they accumulate. ‘Good enough’ is likely required in a crisis, but not currently quantifiable.

Overcoming the Challenges

Achieving this level of agility and responsiveness is no easy feat. Traditional manufacturing systems are optimized for efficiency and cost-effectiveness in normal operating conditions. Adapting them for rapid surge capacity requires a fundamental rethink of production processes, supply chains, and workforce strategies.

Key challenges include:

• Identifying and accessing idle capacity: While the U.S. possesses significant manufacturing capacity, much of it lies dormant or is dedicated to specific products.
• Retooling for new products: Quickly converting production lines to manufacture critical goods requires flexible equipment and skilled labor.
• Ensuring quality and consistency: Rapid scaling often comes at the expense of quality control. Maintaining high standards while ramping up production is essential.
• Building resilient supply chains: Diversifying suppliers and reducing reliance on foreign sources can mitigate risks during a crisis.

Key Areas of Focus: Technology and Implementation

DARPA’s RFI is seeking input on several key areas:

1. Defining the Complexity of the Problem: This includes understanding the logistical, quality, and supply chain challenges that impede rapid scaling of production.
2. State-of-the-Art Approaches: Exploring current methods of surge production and how they can be applied more broadly across defense-critical items.
3. Risk and Mitigation Strategies: Identifying ways to expand the supplier base, utilize unused capacity, and define acceptable performance vs. production rate trade-offs.
4. Product Changes and Disaggregated Production: Investigating how changes in product design can increase manufacturability during a crisis and how production can be spread across different locations to increase resilience.
5. Implementation Solutions: Considering how non-Department of Defense (DoD) entities can be integrated into the supply chain, how the Defense Production Act (DPA) can be leveraged, and what contracting structures can facilitate rapid integration of new suppliers.

A Call for Innovation

DARPA is seeking groundbreaking ideas to address these challenges. The RFI encourages submissions from a wide range of stakeholders, including manufacturers, technology developers, academia, and government agencies. Potential solutions could include:

• Advanced manufacturing technologies: Leveraging technologies like additive manufacturing (3D printing), robotics, and artificial intelligence to accelerate production.
• Supply chain optimization: Developing strategies to identify and secure critical materials and components.
• Workforce development: Training programs to equip workers with the skills needed for rapid upscaling.
• Government-industry partnerships: Fostering collaboration between the public and private sectors to share resources and expertise.

The Path Forward: Innovation and Collaboration

DARPA’s RFI is not just a call for technical solutions; it’s a call for innovative thinking that challenges conventional approaches to manufacturing. The agency is interested in solutions that can be applied across both the defense and commercial sectors, leveraging the full breadth of the U.S. and global manufacturing capabilities.

DARPA’s Industrial Mobilization for Crisis Manufacturing initiative is a critical step towards building a more resilient and adaptable nation. By investing in innovative solutions, the U.S. can better prepare for future crises and protect its citizens.