Engineering Documentation Control Handbook - Configuration Management and Product Lifecycle Management

Front Cover

Engineering Documentation Control Handbook: Configuration Management and Product Lifecycle Management

Copyright

Contents

Preface

Chapter 1 - Introduction

What is Configuration Management

Between Engineering and Manufacturing

Configuration Management Ladder

Configuration Management Discipline

Configuration Management System

History of Configuration Management

Organization of Configuration Management

Document Control Function Responsibilities

Configuration Management Function Responsibilities

Distributed Configuration Management

Manager’s Job

Manager of Configuration Management

Organization Within Configuration Management

Configuration Management—What is It?

Summary

Chapter 2 - Product Documentation

Document Formats and Standards

Body of a Part Drawing

Body of the Assembly Drawing

Controlled Engineering Parts List

Units of Measure

Specification Control and Source Control Drawings

AML – QVL – AVL

General Specifications

Process Design Specifications

Document Groups and Control

Distributed Document Control/CM

Files, Master Docs, and Revision Control

Chapter 3 - Identification Numbers

Product Numbers and Model Numbers

Part Number Cycle

Version Numbers

Traceability

Serial Numbers

Part Numbers

Classification Coding

Naming Convention

Preferred and Alternate Parts

Significant vs Non-Significant Part Number

Recommended Part Number

Sketch Numbers

Part Number Assignment

Changing the Part Numbering System

Revision Numbers and Letters

Revision Levels

Page Revision Levels

Change Identification Number

What Gets a Part Number

Item Marking

Labels and Stickers

Chapter 4 - Interchangeability and Service Parts

Interchangeability Defined

Compatible

Interchangeable Always Applicable?

Service Parts and Assemblies

Interchangeable in All Applications

Interchangeability Examples

Interchangeability Test

Part Number Change Logic

Form and Function

Field Units

PCB Interchangeability/“Bug Fixes”

Interchangeability in Doubt

Chapter 5 - Bill of Material

BOM Data Responsibility

Data Dictionary

Item Master File

Design Engineering Data

Parent–Component Relationship

Marked-Up Parts List

Manufacturing Data

System Item Codes

Field Support Data

BOM Data Element Criteria

Structuring the BOM

Phantom Coding Solution

Common BOM Structure Problem

Unstructure the BOM

Structure and Pictorial Assembly Drawings

Structuring for Multiple Plant Build

Structuring to Stock an Item

Structuring to Buy an Item

Structuring to Ship Between Buildings/JIT/DFT

Structuring Firmware/Application Software

Structuring the Standard Assembly

One Product Structure

Structure Right the First Time

BOM Evolution

Design for Modularity

Modular Parts List

Modular BOM Benefits

Modular Forecasting and Scheduling

Order-Related BOM

Customer-Configured BOM

The Perfect BOM

Referenced Documents in the BOM

Configurator Software

Chapter 6 - Teams and Other Foundation Blocks

Cross-Functional Teams

Team Make Up

Team Responsibility

Team Meetings

Team Action List

Team Success

Team Measurement

Design Responsibility

Cognizant Engineer List

Other Function Engineers

Signature Responsibility

Delegated Design

Change Control Boards

Production Process Documentation

Fabricated Part Processing

Assembly Instructions

Process Document Control

Process Control Summary

Sales Document Control

Quality Document Control

Publications

On Time Publications

Lot Control

Shelf Life

Down-Level Drawings

Non-Conforming Material

Field Support

Field Change Order and Kit

Software (SW) and Firmware (FW) Control

ISO/QS/AS

Chapter 7 - Document Release and Product Lifecycle

Lifecycle Release Phases

Documents Tied to the Release Phase

The Revision Block

Lifecycle Phase Issues

Baseline–Lifecycle Phase Relationships

CM and the Release Process

Product Definition Phase

Product Development Phase

Product Pilot Phase

Product Production Phase

Product Phase Out

Management of the Release Process

Release Status Codes

Release Form and Signatures

Release Checklist

Closing the Gap in Pilot

Catch-22

Lifecycle Release Process

Lifecycle Process Tasks

Lifecycle Release Flow Diagram

Measure the Lifecycle Process Time

Release Process Visibility

Chapter 8 - Change Requests

Field Failures

Reliability and Other Test Data

Material Review Boards (MRB)

Production Problems

Can Anyone Originate a Change?

Request for Change

Request Form Instruction

Avoid Temptation

Request Process Design

Request Flow/Procedure

Request Process Measurement

Request Action Items List

Summary

Chapter 9 - Change Lifecycle Cost

Cost Estimating a Change

Design and Development Cost

Manufacturing and Field Costs

Materials and Parts Costs

Cost Policy

Who Estimates Change Cost

Change Cost Payback

Which Requests/Changes to Estimate

Change Cost Form

Dollar Approvals

Charge-Back of Costs

Estimates Without Delay

Chapter 10 - Change Management

Why Change?

Change Types

Deviations, Waivers, Off-Specs, etc.

Change Urgency

Class of Change

Fixes in a Change

Software Changes

What Goes into the ECO Package

Distribution of the ECO

Depiction of Adds and Deletes

Flag Notes

Mark Up Standard

Same As Except

Change Revision Drafting

Queuing Changes

Advanced Document Change Notice

Who Signs What

Empower the Change Team

Change Impacts

Mark Ups in Production

Effectivity

Effectivity Responsibility

The Effectivity Pipeline

Disposition of Old Design Parts

Effectivity Planning

Effectivity and the Parts List

Effectivity/Make to Order

Effectivity/Batch Manufacturing

Sequencing Parts List Changes

Sequencing Changes to Part Design

Tracking the Change

Status Accounting or Traceability Reports

Change Modeling and Testing

ECO Package Revisions

Change Forms

ECO Online

Form Instruction – ECO

Facts Database

Cultural Change

Chapter 11 - Fast Change

Why is Process Speed Important?

Bone Pile Reduction and Other Benefits

Measure the Change Process Time

Publish Change Time Measurement

Change Process Points to Measure

Change Process Phases

Revision of Master Documents

Set Change Throughput Goals

Measure Volume and Reduce Backlog

Managing for Fast Change

Significance of Change Speed

Chapter 12 - Process Improvement/Work Flow Diagrams

Trolls

Establish Key Process Metrics and Publish Them

Design Change Process Improvements

Missionary Team Leader

Steps to Reinvent a Process

Continuous Improvement or Reinvent

Fast Change Work Flow

Change Work Flow Diagram

Engineering Work Flow

Point of No Return – Technical Release

Change Checklist

CM Change Work Flow

Manufacturing (Implementation) Work Flow

Quality Factor

A Case Study

Continuous Improvement

CM Implementation Critical Success Factors

System Redesign is Not Easy

Chapter 13 - Process Standards and Audits

CM Policy

Writing and Formatting Standards

Best Practice for a Standard

Subjects to Standardize

Procedures

Procedure in a Flow Diagram

Standards Manual

Training

Auditing the CM Processes

Audit Plan

Audit Frequency

Audit Follow Up

Train Without a Whistle

Chapter 14 - EDC and the Supply Chain

Supply Chain is Broken

Purchase Order – CM Boilerplate

ECO Sent to Supplier

Supply Chain Analysis

Supplier’s Relationship with the Customer

Supplier BOM

Purchased Proprietary Assembly Changes

Customer Review and Approval of Changes

Change Approval Default Clause

Chapter 15 - Benchmarking

Benchmarking Pitfall

How to Benchmark

Benchmarking Survey

Automotive Suppliers – Summary of Results

Survey – 58 University Seminar Attendees

Benchmark Report

Interpretation of Surveys

Chapter 16 - Product Manufacturing Software

Current Software

Develop Your Own Software?

Software Purchased and Tailored

Purchasing Software

CM’s Role in Software Choices

Software Trend

Validation

Software Question for This Century

Manufacturing Company Software (MCS)

CM Strategy Summarized

Education and Training

Reference and Reading List

Index