McDonnell Douglas has radically changed its approach to new product development under an internal project called Design, Manufacturing and Producibility Simulation (DMAPS). The new process has four steps: concept baseline, concept layout, assembly layout and build-to-package; each of which relies on three dimensional master solid models and a variety of advanced simulation and modeling tools. The result is a disciplined process that eliminates non-value added activity and provides all Integrated Product and Process Team (IP2T) members with the tools needed to effectively perform assigned tasks.McDonnell Douglas applied the new approach to a redesign of the T-45A Horizontal Stabilator. This project demonstrated that three dimensional master modeling can eliminate two dimensional drawings and enable physical mockups to be replaced by computergenerated virtual prototypes. The project also demonstrated the use of several advanced simulation tools for the product design, the assembly tooling, and the manufacturing processes. Those tools enabled the IP2T to assess impacts to manufacturing accurately and provide an electronic build plan for the shop.Relative to similar production development projects, McDonnell Douglas achieved a 40% reduction in the product development cycle time and expended 50% fewer labor hours. The higher quality build-to-package is expected to eliminate at least 80% of the engineering and tooling rework. The electronic build plan will accelerate operator learning and improve quality.