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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.