Engineering documentation control handbook configuration management and product lifecycle management

Engineering Documentation Control Handbook Engineering DOCUMENTATION CONTROL HANDBOOK CONFIGURATION MANAGEMENT AND PRODUCT LIFECYCLE MANAGEMENT FOURTH EDITION FRANK B WATTS Amsterdam • Boston • Heidel.

Engineering DOCUMENTATION CONTROL HANDBOOK CONFIGURATION MANAGEMENT AND PRODUCT LIFECYCLE MANAGEMENT FOURTH EDITION FRANK B WAT TS Amsterdam • Boston • Heidelberg • London New York • Oxford • Paris • San Diego San Francisco • Singapore • Sydney • Tokyo William Andrew is an imprint of Elsevier William Andrew is an imprint of Elsevier The Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GB, UK 225 Wyman Street, Waltham, MA 02451, USA First edition 1993 Second edition 2000 Third edition 2008 Fourth edition 2012 Copyright Ó 2012 Elsevier Inc All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the Publisher Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangement with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein) Notices Knowledge and best practice in this field are constantly changing As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Control Number: 2011936727 ISBN: 978-1-4557-7860-7 For information on all William Andrew publications visit our website at www.elsevierdirect.com Printed and bound in the United States 12 13 14 15 10 PREFACE The wide acceptance of this book has been very gratifying This work seems to have taken on a life of its own The third edition publisher wrote: “Your book over the last year has resulted in the most ‘Buy This Book’ links of our entire catalog It is very well received by the Googleites.” Sales have exceeded 11,000 at the time of writing of this fourth edition Why? While management fads come and go, buzzword programs abound, software acronyms and software applications ebb and flow, the critical importance and the basics of engineering documentation control remain the same The author thinks of himself as “the Vince Lombardi of document control.” Basic blocking and tackling! In that sense, the fourth edition has not changed the principles but has been significantly rewritten and edited A new chapter on product manufacturing systems has been added All with the intent of improved explanations, emphasizing product lifecycle management, and Configuration Management (CM) as engineering’s quality control function Whether you think of this subject as Engineering Documentation Control (EDC) or CM, or Product Lifecycle Management (PLM) it needs to be recognized as a key business strategy The wall or gap between engineering and the rest of the world has existed too long in many companies The “throw it over the wall” syndrome can be overcome It is prevalent in new product releases, bills of material, change requests, and change processes as well as in related software packages Simple, make-sense, fast, accurate, efficient, measured, and well-understood Engineering Documentation Control/Configuration and Product Lifecycle Management can tear down that wall – bridge that gap The title of this book indicates that Engineering Documentation Control – Configuration Management and Product Lifecycle Management are equivalent terms But are they really? Many people feel that EDC is a subset of CM Some think of EDC as what they are currently doing and CM as what they ought to be doing PLM is a term used primarily by software applications for engineering – but it certainly implies a cycle that transcends engineering into manufacturing and to the customer Much of the truth in this discussion is in “the eyes of the beholder.” Historically, the CM term was largely invented by the Defense Industry and the Department of Defense (DOD) The term had been used and xiii j xiv Preface abused so extensively by our product manufacturing world that it had taken on a parochial and a very complex meaning Commercial businesses began “taking back” the CM term in a simplified form Many defense product manufacturers are moving toward commercial practices – simplified Configuration Management – a healthy trend In the meantime, the software configuration management folks have largely usurped the CM term for application to the development and production of software tools If you “Google” the CM term, you will largely find software tools for controlling software tools The author is thus all the more pleased to have consistently used the Engineering Documentation Control term This work will use all of these terms selectively Can CM in a Defense Industry context be made simple? A study published in National Defense magazine, September 1992, by George Krikorian, PE, summarizes the conditions at that time “The results revealed that the cost of a product when selling to DOD increases from five percent to one hundred percent as compared to the same or similar product cost to a commercial (non-DOD) enterprise.” One of the significant reasons given was MIL-SPECS and Standards Configuration Management standards make up a significant portion of the total DOD Specs and Standards There has been some significant reform in the DOD, however, so the hope for military contractors and taxpayers is improving Meanwhile, some in the commercial segment are erroneously moving toward more complex CM The Automotive and Aeronautical segments have written their own versions of ISO standards adding a layer of bureaucracy that is making our autos and air transport expensive, adding little value or safety to the products The FDA continues to make their requirements excessive by controlling products in the same manner they control drugs The ISO standards have evolved but not necessarily for the better While claiming to be more general and less specific, the page count has, nevertheless, increased significantly The primary goal of this book is to keep CM simple The basics of bestin-class Configuration Management will be presented from the ground up, for application in either a “commercial” or “military” kind of business The typical CM approach is to acquire and read all the applicable commercial and Military Specs, Standards, and Directives, and then design the system around them Rather, every product manufacturing business should develop a simple, make-sense, fast, accurate, efficient, measured, and well-understood process approach to Engineering Documentation Preface xv Control/Configuration Management/Product Lifecycle Management and then examine the DOD, MIL, DOE, FDA, ISO/QS/AS, and all other applicable agency standards After careful examination of those standards, add to or modify that approach to satisfy the customer/agency specifications, as and if necessary Since the first edition of this book, many companies have become ISO/ AS/QS-certified Write down what you and what you have written, it is said Companies have also come to realize that certification only gets their CM practices minimally documented and followed A significant majority of ISO requirements and problems involve the CM discipline, but there is no built-in assurance in the ISO certification that the processes are efficient, measured, productive, or that they outperform the competition Thus, writing down what you and doing what is written may be a form of insanity – which is defined as doing the same thing over and over again, and expecting different results Subsequent revisions of ISO requirements have emphasized process improvement The emphasis of this book is not on ISO requirements The emphasis is on helping people help their companies toward exceptional CM practices and processes The quick release of new product documentation, minimal structuring of a single bill of material database, the ability to request changes, and to change the documentation and product quickly, accurately, and at least cost are critical to a company’s profitability Thus, the development and implementation of a simple, make-sense, fast, accurate, efficient, measured, and well-understood CM system is an important business strategy Simply put, it sets the stage for innovation in engineering and operations The basic principles of world-class EDC/CM are applicable, regardless of the kind of manufacturing or the kind of customer Toward achieving this make-sense approach, the following will be the guiding principles of this book: • Develop a generic approach that is good for commercial or agencyregulated companies Many of the existing texts on this subject address DOD Specifications and Standards This work takes a generic approach • Take the acronyms out wherever possible! The goal here will be to only use those acronyms which are universal in the manufacturing business and to explain each where it is first used • Use the English language, defining terms as we go, as opposed to using, for example, over 20 pages of glossary found in one text • Take the jargon, mystique, double-talk, fads, and unnecessary complexity out of Configuration Management xvi Preface • Systematically approach the discipline by using an example product – an electronic ignition, application software programmed, front-end loader with a variety of features and options Develop the design documentation for this product, structure the bills of material with operations people, release it from engineering to manufacturing, request changes, change it, and close the loop by knowing when each change was made and what is in each product as needed • Develop principles that are sound for any size company, while recognizing the nuances that may be present in small, large, multinational, make-to-print, make-to-stock, make-to-order, or design-to-order for discrete product manufacturing • Develop principles which are sound for any type of product, while recognizing differences in products that vary from needles to nuclear ships, and production rates that vary from quantities per second to years per quantity one • Emphasize early costing of the product and changes, a generally ignored aspect of CM practice • Show how redundant bills of material can be eliminated, how to simplify the bill of material structuring, and how to evolve bills in lead time to produce the product • Develop generic CM processes in the form of flow diagrams and standards to use as a guide in the development of your own processes Assure that the horse (documentation) comes before the cart (the product) • Establish methods for achieving fast processing of releases, requests, and changes The emphasis will be on speed – a long-overlooked criterion and very costly oversight • Outline methods for analyzing an existing system and implementing a new system Outline methods that can be used, whether reinventing the system and/or using continuous improvement techniques • Explore methods for standardizing the processes and auditing them • Outline the importance of EDC/CM in the supply chain, note how the chain can be broken and address the issues facing the Original Equipment Manufacturer (OEM) and the supplier • Share benchmarking surveys and analysis with the readers • Identify the most serious, most often made, mistakes in the discipline • Distinguish between Engineering Documentation Control, Configuration Management, and Product Lifecycle Management Preface xvii • Develop a few key metrics for all the processes – speed, quality, and volume Many more measures of merit are in the author’s CM Metrics book • Develop EDC/CM/PLM rules and give reasons for the rules Realize that almost all rules have exceptions Realize that all the rules need not be followed in your company, but violation of very many will lead to chaos • Demonstrate why the CM function is essentially the quality control function for engineering Such goals can be accomplished without sacrificing product quality In fact, the quality of documentation releases and changes as well as the quality of the product must increase as new or improved Engineering Documentation Control is implemented Good CM alone will not achieve best-in-class Total Quality Manufacturing (TQM); however, best-in-class TQM cannot be achieved without best-in-class Configuration Management This will be accomplished while improving quality, not hurrying up to it wrong! Engineering Documentation Control is a significant business strategy and an absolute foundation block for: TQM, JIT (Just In Time), crossfunctional teams (concurrent engineering), engineering/manufacturing/ supply chain software systems, lean manufacturing, meeting domestic or international standards, and efficient manufacturing In fact, it must be a significant company strategy if best-in-class or world-class manufacturing is to be achieved One reviewer of this book titled his review, “Setting the Stage for Innovation.” Time for innovation in design and manufacturing can be realized, with the current work force, by first making the EDC/CM processes simple, make-sense, fast, accurate, efficient, measured, and well understood My thanks to the universities who have sponsored my seminar Also to the over 3500 folks who have attended – I learn something in each seminar My many customers also deserve hearty thanks since I learn something from each of them Last, but not least, thanks to the third edition reviewers, their compliments and ideas for improvement Frank B Watts, BSME, CCDM ec3corp@rkymtnhi.com www.ecm5tools.com Winter Park, Colorado CHAPTER Introduction Contents 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 ManagementdWhat is It? Summary 8 10 12 12 14 14 14 16 16 19 Why we need engineering documentation at all? Why control that documentation? The mere use of the word “control” puts most engineers into a very defensive mode Are we trying to stifle the engineer’s creativity? What is there to “manage” about the configuration of a product? Let us first identify the basic “raw materials” of product manufacturing – the very essence of product manufacturing There are four primary elements: • Money – for the start-up/profits • Tools (machine, mold, software, etc.) • People (and the processes and measurements they choose) • A product embodied in design drawings and specs So why is it a surprise for some to hear that the management of those design documents is a critical discipline? Think about it Without design documents, you not have a producible product Without control of design documents with make-sense processes and measurements, you have chaos Why architects make drawings and specifications for a home or plant? Do they this for their own pleasure or for a trade magazine or show? Isn’t the documentation done so the customers get what they want? Aren’t the Engineering Documentation Control Handbook ISBN 978-1-4557-7860-7, Doi:10.1016/B978-1-4557-7860-7.00001-6 Ó 2012 Elsevier Inc All rights reserved j Engineering Documentation Control Handbook documents for the builder who has to build the house and for the eventual owner who will have to maintain it? Try building or maintaining a product without adequate drawings and specs, it becomes especially difficult and error-prone when changes are being made Try controlling the cost without controlling the changes Still, most businesses operate to some extent without proper, timely, or adequate control of their documentation The symptoms are usually everywhere Let us take a look at the symptoms Manufacturing says: • I don’t understand what I’m supposed to build • What criteria we test to? • Where is the change I need to: Reduce costs Avoid making scrap Avoid making parts that will have to be reworked? • Will this change increase the “bone pile” of down-level material? • Why I have these bad parts on the dock? Sales says: • You mean the product isn’t ready for the market window • Where is that promised new feature? • Why didn’t we deliver a product with the options the customer asked for? Customer says: • I didn’t get what I ordered • Where is the fix you promised me? • Where is that new feature or option? Dealer/Field Service says: • Shouldn’t my publications match my product? • Where is the fix for this nagging product, firmware, or software problem? • Our customer is angry – can’t we move faster? Repair says: • I could fix it easier if I knew what is in this product • What changes should be and shouldn’t be incorporated upon repair? Quality says: • Is this cost included in our Cost of Quality? • Should we treat ourselves, our suppliers, or our customers this way? • How can we meet our customer’s standards? • We can’t meet international and US standards Employee says: • I asked them to something about this a long time ago Introduction Do any of these symptoms sound familiar? The cure is: simple, make-sense, fast, accurate, measured, efficient and well-understood Engineering Documentation Control/Configuration Management (EDC/CM) standards and processes Good design documentation and its control is the solution for the root cause of these symptoms Thus, Configuration Management is the medicine that cures the root causes CM, kept simple, results in many benefits to the company What are the benefits of a fast, accurate, and well-understood CM system? Let us take a look at the potential benefits of a carefully planned CM strategy Benefits: • Helps to get new products to the market faster and reduce delivery time for a customized product • Happier customers because they see the new option, change, or feature they had requested, much quicker • The customers get what they ordered with fewer missed delivery commitments • Reduces the “bone piles” of down-level material • Gets real cost reductions implemented quicker • Reduces the manufacturing rework and scrap costs significantly • Improves bill of material (BOM) accuracy and saves the corresponding material waste and correction time, resulting in corresponding improvement in product quality and inventory accuracy • Eliminates multiple BOMs and saves the costs of maintaining the bills, not to mention eliminating the risks associated with multiple bills • Evolution of the BOM in lead time to produce the product quicker • Reduces field maintenance, retrofit, and repair cost • Know exactly what items are non-interchangeable in each product • Improves the understanding and communication between design engineering and the rest of the world • Clarifies the responsibilities and thus eliminates finger pointing • Saves wear and tear on CM managers, master schedulers, and all types of engineers • Complies with applicable customer or agency standards • Sorts out changes that are not needed or aren’t cost-effective • Saves many dollars a year in paper and copying costs alone • Significant reduction in the cost of quality • Allows the company to qualify as a best-in-class producer • Sets the stage for innovation in engineering and manufacturing Index down-level drawings, 158 down-level prints, 164 Drawing Room Manual (DRM), 234 drawings, 31, 32f bills of material, 106, 117–118, 119 body of, 27–35 change management, 232, 232f cognizant engineer lists, 143 Configuration Management, 296, 296f, 297 general specifications, 40 part numbers system changing, 63 product delivery processes, 175 product documentation, 30, 36 product manufacturing software, 354 product pilot phases, 177 supply chains, 326, 331, 332–333 Title Block, 25 DRM see Drawing Room Manual dwells, 312 E ECAD systems, 31, 105–106 ECN (Engineering Change Notice), 237 ECO see Engineering Change Orders ECP see Engineering Change Proposals ECR numbers: Technical Release, 295 Effectivity Pipeline change management, 244–245 EIA (Electronics Industry Association), 10 electric start assembly, 125 electronic ignition front-end loaders, 19, 19f Electronics Industry Association (EIA), 10 emergency change management, 220, 220t Employees, empowerment in change management, 238 end item part numbers, 43, 55 end product levels: interchangeability, 86 service parts, 86 end product part numbers, 40–41 end product serial numbers, 157 engineering-centric software, 347 Engineering Change Notice (ECN), 237 367 Engineering Change Orders (ECO): adds, 228 bills of material, 98 change effectivity, 241 change forms, 256, 256f change impacts, 239 change process audit, 323 change requests, 194 change urgency, 219, 220 deletes, 228 distribution, 227–228 document release, 181 effectivity, 242–244, 246 fast change processes, 271, 272, 275, 277–278 field change orders, 160, 162f fixes in change, 223 flag notes, 230 form instruction, 257–263 identification numbers, 67 interchangeability, 86 make to order effectivity, 249 manufacturing workflow, 298 mark up standards, 231 modeling change management, 255 old design part disposition, 245 on-line, 257 package contents, 225–227 package revisions, 255 part design sequencing changes, 250 parts list change sequencing, 249 parts lists effectivity, 248 process standards, 317 production mark ups, 239, 240f purpose, 257 quality factors, 300 Revision Block, 26 same as except documents, 232–233 service parts, 86 signatures, 237 software changes, 224 Status Accounting, 253 supply chains, 326, 330 team empowerment, 238 team firmware/software control, 163 team publications, 154–155 Technical Release, 294 368 Index Engineering Change Orders (ECO): (Continued) testing change management, 255 traceability reports, 253 tracking change, 252 Engineering Change Proposals (ECP), 237 engineering-defined product development phases, 283 engineering documents, 18 Engineering fast change processes, 272, 273, 274 Engineering Service data, 96 Engineering Services, 95 Engineering Services Directors, 334 engineering workflow, 292–294 engineers: supply chains, 326 Engineer-to-Order environments, 56 entry Technicians, 16 ERP systems, 100, 101f, 113–114, 347, 349, 353 Executive Vice President, 301–302 F fabrication: instructions, 150 part processing, 150–151 family tree drawings, 106 fast change processes, 220, 221f, 265–279 backlog reduction, 275–277 benefits, 267–268 bone piles, 267–268 importance of speed, 265–267 managing for, 277–279 master document revision, 272–274 phases, 272 points to measure, 270–272 publishing time measurements, 268–270 set change throughput goals, 274–275 significance of speed, 279 time measurements, 268–270 volume measurements, 275–277 work flow, 290–291 FCO see Field Change Orders FDA: assembly instructions, 152 change management, 226 part numbers assignment, 69 product documentation, 46 team process control, 153 feature modular BOMs, 124–125, 125f FELs see front-end loaders field change forms, 161, 162f Field Change Orders (FCO), 86, 160–161 Field Changes: trolls, 285 Field Engineers, 76–77, 116, 144 field failures: change requests, 192–193 supply chains, 328 field replaceable items, 115–116 Field Service data, 96 Field Service organizations, 95, 193 Field Service representatives, 237 Field Services, field support data, 101 Field Support Engineers, 113 Field Support issues, 192 field support teams, 159–160 field units, 86–87 Find Numbers (FN), 33, 34f, 195, 196f firmware (FW), 120–121, 161–163 flag notes, 230 flat bills of material, 106 flow diagrams, 281–306 change requests, 199–201 document release, 186–188 process standards, 311–312, 313, 318 FN (Find Numbers), 34f, 195, 196f follow-up audits, 321 formatting process standards, 310–313 form numbers, 318–319 forms: benchmarking, 340–341 blanket release documents, 171, 185 change lifecycle costs, 207–210 change management, 255–263, 256f change requests, 195–197 deviation, 217, 218f, 340 document release, 180–182 field change, 161, 162f release processes, 180–182 Request for Change, 195–197, 255–257 foundation blocks see teams Index from-to drafting descriptive change depiction methods, 228–229 front-end loaders (FELs), 51 assembly parts lists, 33, 34f bills of material, 97, 98–99, 109, 110, 111, 115, 115f, 119, 119f, 124 change management, 99f, 248 cognizant engineer lists, 142 design pictorial drawings, 31, 32f electronic ignition types, 19, 19f interchangeability examples, 79 model identification numbers, 52 part drawings, 27, 28f part number cycles, 52 parts, 119, 119f process design specifications, 43 product identification numbers, 52 purchased items, 119, 119f release phase documents, 169 service parts, 77 specification control drawings, 37, 39f team measurement, 140, 141f functional non-interchangeability, 53 function engineers, 143–144 FW (firmware), 120–121, 161–163 G “garage shop” development, 135 Garwood, R D., 135 gas start assembly, 125 Golden Rule: bills of material, 131 change lifecycle costs, 212 change management, 236 change requests, 202 fast change, 279 files, 49 interchangeability, 82, 91 master documents, 49 part number change logic, 85 product manufacturing software, 349, 352, 357 recommended part numbers, 61 release process management, 179 release process visibility, 189 revision control, 49 369 trolls, 286 graphics, 354 see also drawings grouping documents, 44, 45f Guideline: bill of material, 109, 110, 116, 121–122, 130 product documentation, 43 H hand carried urgency classes, 222 hand carry changes, 274, 278 hand carry personnel, 219 hard copy distribution cost savings, 227–228, 228f hard copy ECO distribution, 227–228 hard copy masters, 44, 49 hard copy revision modes, 23 hardware systems, 54 headings: action items lists, 139, 201–202 high-end companies: assembly instructions, 151 change management, 250 high-end manufacturers: bills of material, 117 high-tech products: process design specifications, 43 holds, 312 I ideal part numbers, 59–61 identification numbers, 51–72 alternate part, 58 changing of, 67–68 classification coding, 57–58 items marking, 69–70 labels, 70–72 letters, 64–66 model numbers, 52 naming conventions, 58 non-significant part numbers, 58–59 page revision levels, 67 part numbers, 52–54, 56–57, 62–64, 68–69 preferred part, 58 product numbers, 52 recommended part numbers, 59–61 370 Index identification numbers (Continued) revision levels, 66–67 revision numbers, 64–66 serial numbers, 55–56 significant part numbers, 58–59 sketch numbers, 61–62 stickers, 70–72 traceability, 55 version numbers, 54 IE see Industrial Engineers IEEE see Institute of Electrical and Electronic Engineers Imperial systems, 27–28 implementation: benchmarking, 340 critical success factors, 305–306 fast change processes, 272, 273–274 see also manufacturing implementation workflow, 298–299 Implemented/Close measure points, 272 Improvement Teams, 286, 290, 308 incorporation drafting, 273 Industrial Engineers (IE): bills of material, 111, 117 change lifecycle costs, 206 change management, 246 Configuration Management change workflow, 297 delegated design, 144–145 fast change processes, 268–269 product manufacturing software, 354 team responsibility, 136 Information Technology Software, 347 see also product manufacturing software in-house changes, 332 injection molding companies, 349–350 “in/out date” columns, 35 Input To the System document release process tasks, 186 “in series” business, Institute of Electrical and Electronic Engineers (IEEE), 10 interchangeability: application, 75–76, 78 change management, 222, 247, 251 compatibility, 75 Configuration Management, 9, 16 definition, 73–75 doubts, 90–91 examples, 78–82 field units, 86–87 form, 85–86 function, 85–86 letters, 64, 66 printed circuit boards, 87–90 revision identification numbers, 64, 66 service parts, 73–91 specification control drawings, 38 supply chains, 327 tests, 82 trolls, 284 internal audits, 319–320 internal customers, 25 International Standards Organization (ISO), 163–164 change management, 214, 226 Configuration Management, 7, 10, 320 fast change processes, 265 process standards, 309 product manufacturing software, 356 trolls, 282 Inventory Control Society (APICS), 10 item-by-item prerelease, 175–176 item master files, 96 item numbers see part numbers items marking, 69–70 J job-enriched methods, 16 Just-In-Time (JIT), 102, 115, 118, 119, 277, 348–349 K Kaizen principles, 308–309 key process metrics, 286 L labels, 70–72 large business units, 12 large multi-plant companies, 11 leadership, 138, 138f, 287 Lean Manufacturing disciplines, 118 learned Technicians, 16 letters in identification numbers, 64–66 Index Lifecycle Management, 8–9 lifecycle release processes, 166–168, 184–188 line-down change processes, 220, 221f Loader Companies: assembly drawings, 31 bills of material, 94, 97 change lifecycle costs, 211 change management, 227, 236–237, 240, 244, 251, 253–254, 256, 256f, 257 change requests, 195, 199, 200f, 201 change work-flow diagrams, 292 definition release phases, 174 document release forms and signatures, 181 document signatures, 28–29 down-level drawings, 158 ECO form instruction, 257 engineering workflow, 292, 293f fast change processes, 271 interchangeability application, 76 labels, 70–71 letters, 64 life cycle release phases, 166, 166f, 167 manufacturing workflow, 299 part identification numbers, 56–57 process standards, 314 product phase out, 178 release phase documents, 169 revision identification numbers, 64 source control drawings, 36 specification control drawings, 36 stickers, 70–71 version identification numbers, 54 log/revision blocks, 227 lot control, 156–157 lot-oriented companies, 249 low-end companies, 151 low-end manufacturers, 117 M make-to-order companies: bills of material, 109–110 change management, 249, 250 change work-flow diagrams, 292 down-level drawings, 158 371 product documentation, 41–42 serial identification numbers, 56 make-to-print companies: change work-flow diagrams, 292 Configuration Management release processes, 172 identification numbers, 52 life cycle release phases, 167 product documentation, 43 make-to-stock companies: change work-flow diagrams, 292 product documentation, 40–41 management by exception, 179 management champions, 287 Management Steering Committees, 287 Managers, 14–16 manual parts list mark-ups, 98–99 manual process ECO distribution, 227–228 Manufacturing, bills of material, 100 change lifecycle costs, 211 change management, 243 Configuration Management change workflow, 296, 296f control numbers, 157 phase flow, 298, 298f team production processes, 150 technical document categorization, 44, 45f workflow, 298–299 Manufacturing Change Order (MCO): team process control, 153 manufacturing company software (MCS), 353–355 Manufacturing Document Control groups, 69 Manufacturing Engineers (ME): action items lists, 139 bills of material, 117 change management, 219–220, 237, 239, 240f, 246 delegated design, 145 document signatures, 29–30 Imperial systems, 27–28 Metric system, 27–28 signature responsibility, 144 372 Index Manufacturing Engineers (ME): (Continued) Title Block, 25 Manufacturing fast change processes, 272, 274–275 manufacturing representatives, 237 manufacturing software systems: bills of material, 98–99, 102, 113–114 interchangeability, 78 revision levels, 66–67 see also product manufacturing software manufacturing un-bundle documents, 227, 227f marked print change depiction methods, 228–229 Marketing, 52 market windows, 123 mark ups: bills of material, 98–100 change depiction methods, 229 change management, 230–232, 231f, 232f, 239, 240f process standards, 317 Mass Customization, 130 master design documents, 271–272 master digital file copies, 44 master documents, 48–49, 272–274 Master Schedulers, 53–54 material costs, 243 material drop points, 112 Material Review Boards (MRB), 159, 193 Material Spec, 33–34 ME see Manufacturing Engineers Mean Time between Failure (MTBF), 215 Mean Time to Repair (MTTR), 215 medium-sized companies, 353 Metric system, 27–28 Microfilm Back Up File Complete document release process tasks, 186 military companies, 266 military-regulations, 5–6 see also Department of Defense minimally significant part numbers, 59–61 missionary team leaders, 287 mitigated lifecycle costs, 207 model identification numbers, 52 Modeling and Testing Complete document release process tasks, 185 modifiers: tracking change, 252 Modular Feature and Option Design, 124 modular parts lists, 125–126 modular shopping list matrices, 125, 126f mold tool numbers, 27 Motor Mount Assembly, 121 motor plants, 119 motor tests, 111, 113f MRB see Material Review Boards MRP systems: bills of material, 100, 101f process standards, 317 product manufacturing software, 347, 349, 352 MTBF see Mean Time between Failure MTTR see Mean Time to Repair multi-plant companies, 11 multi-plant manufacturing modes, 106 multiple BOM data inputs, 103, 104f, 114, 284, 347–348 multiple plant build, 118 multiple-use notes, 30 N naming conventions, 57, 58 National Defense Industry Association (NDIA), 356 New Document(s) Complete document release process tasks, 185 NIS (number issued) document release status codes, 180 non-conforming material review boards, 193 non-conforming team material, 159 non-interchangeability: change management, 247, 248, 252 definition, 74, 75 examples, 82 form, 85 function, 85 items marking, 70 letters, 66 part number change logic, 83–84 part number cycles, 53 Index purchased proprietary assembly changes, 332 revision identification numbers, 66 serial identification numbers, 56 trolls, 284 version identification numbers, 54 non-significant part numbers, 58–59, 60 no pictorial documents, 162–163 normally fast change, 220 O obsolescence processes, obsolete documents, 178 Obsolete events, 166f, 167, 169 OEMs: supply chains, 328 off the shelf items, 331 off-specs, 217–218 old-new drafting descriptive change depiction methods, 228–229 one BOM databases, 105–107, 328 one-item parts lists, 40–41 one problem at a time communications, 193 one product structures, 121–122 one-time costs, 210 on-line ECO change management, 257 online signatures, 30 on time publications, 155–156 operations-centric software, 347 Opportunity Cost Analysis, 210 option modular BOMs, 124–125, 125f Order Entry Departments, 52–53 Order Entry Modules, 349–350 order-related BOMs, 128 Original Product Used-On, 23 O-rings, 157 outside audits, 319–320 overlay abilities, 229, 356 P packaging: bills of material, 109–110 page-matrix methods, 67 page revision levels, 67 paper-dependent systems, 44 paperless systems, 17 parent–component relationships, 98 part numbers, 56–57 373 alternate types, 58 assignment, 62–63, 68–69 bills of material, 108, 119, 120 change logic, 82–85 identification numbers, 52–54, 63 Make-to-Order product specifications, 42 Make-to-Print product specifications, 43 Make-to-Stock product specifications, 40–41 non-significant part numbers, 58–59 preferred types, 58 recommended, 59–61 significant part numbers, 58–59 supply chains, 326 system changing, 63–64 trolls, 282, 284 parts design sequencing changes, 250–251 parts drawings, 27–30, 28f, 354 parts lists: bills of material, 94, 98–100, 102–103, 105–106 change management, 231, 231f, 247–250 Controlled Engineering Parts List, 33, 34f, 35, 354 Make-to-Stock product specifications, 40–41 product documentation, 24, 31, 33–36, 40–41 product manufacturing software, 354 Title Block, 24 see also parent–component relationships pay back periods, 206–207, 210 PC see Production Control PCB see printed circuit boards phantom coding, 113–114 phantom designation of assembly, 114 phase charts, 170–171, 171f phase out release phases, 166f, 167 pick and try replacement processes, 244 pictorial drawings see drawings piggyback, cuts and adds, 88 pilot change management phases, 236–237 Pilot Production: development release phases, 175 374 Index pilot release phases, 166f, 167, 169, 175, 176–178, 183 planner-buyer combined responsibility, 243 planning bills, 184 play-script procedures, 317, 312 PO see purchase orders policy see Configuration Management preferred part identification numbers, 58 Preliminary Design Reviews, 174–175 PRE (pre-release/pilot) document release status codes, 180 Prerelease events, 166f, 167 primary customers/users see acceptors printed circuit boards (PCB): bills of material, 111, 113f, 115, 115f, 120, 125–126 bug fixes, 87–90 interchangeability, 87–90 labels, 71 process design specifications, 43 recommended part identification numbers, 61 stickers, 71 prints, 239, 240f procedure see Configuration Management process consumable items, 34–35 process design specifications, 43–44 process document control, 152–153 Process Engineers, 152 process improvement, 281–306 continuous improvement, 289–290, 304–305 design change, 286–287 key process metrics, 286 missionary team leaders, 287 re-invention steps, 287–290 system redesign, 306 trolls, 282–286 process routing, 150 Process Specification, 150 process standards, 307–324 applicability, 310 authorization, 313 best practice, 313 descriptive, 317 example standards, 315 flow diagrams, 318 formatting process standards, 310–313 play-script procedures, 317 policy, 310–311 practice, 310–311 primary responsibility, 312 procedure, 311–312, 315–317 purpose, 310 Standard Definitions, 313 standards manual, 318–319 subjects to standardize, 314–315 training, 319 writing process standards, 310–313 process team documentation, 150 process-time graphs for fast change, 269, 269f product applications software, product costs, 243 Product Data Management (PDM), 347 product definition phases, 174–175 product development phases, 175–176 product documentation, 21–49 Approved Manufacturers Lists, 36–39 Approved Vendor Lists, 36–39 assembly drawings, 30–35 assembly parts lists, 33–35 Configuration Management, 47–48 control, 44–47 controlled engineering parts lists, 35 data management, 48–49 distributed document control, 47–48 document signatures, 28–30 document size, 44 drawing notes, 30 files, 48–49 formats, 21–27 general specifications, 39–43 groups, 44–47 Imperial systems, 27–28 Make-to-Order product specifications, 41–42 Make-to-Print product specifications, 43 Make-to-Stock product specifications, 40–41 master documents, 48–49 Index Metric system, 27–28 online signatures, 30 part drawings, 27–30 process design specifications, 43–44 proprietary note, 44 Qualified Vendor Lists, 36–39 Revision Block, 22, 22f, 25–27 revision control, 48–49 source control drawings, 36 specification control drawings, 36 standards, 21–27 terminology, 22, 22f Title Block, 22–25, 22f Units of Measure, 35–36 product identification numbers, 52 Production Baselines, 177 Production Control (PC): change management, 241, 243, 245–246, 252 Configuration Management, 297 fast change processes, 272 manufacturing workflow, 299 Production Floor Implementation operations, 297 production line approaches, 16 production mark ups, 239 see also mark ups Production Phase needs, 331 production process documentation, 150 production release phases, 166f, 167, 169, 177, 178, 183 Product Lifecycle Management (PLM), 347, 353 product lifecycles, 165–189, 347, 353 Product Line Rationalization, 130–131 product manufacturing companies, 54 product manufacturing software, 347–357 Configuration Management, 350, 351–352, 353–354, 355–356 current software, 347–349 development, 349 education, 356–357 manufacturing company software, 353–355 375 purchase, 349–350 question, 352–353 tailoring, 349–350 training, 356–357 trends, 351–352 validation, 352 product nameplates: source control drawings, 37, 38f Product numbers: part number cycles, 53 see also part numbers product part number cycles, 52, 53f product phase out, 178–179 product pilot phases, 176–178 product production phases, 178 Product Release: Configuration Management system, 8–9 Product Specification: assembly parts lists, 33–34 at Revision, 174–175 Baseline, 174–175 document release, 166 Make-to-Order, 41–42 Make-to-Print, 43 Make-to-Stock, 40–41 product development phases, 175 product documentation, 40–43 supply chains, 332 Product Spec Release, 166f, 167, 169 program locks, 35 programmable front-end loaders, 19, 19f progressive in time revision level changes, 249–250 Project Engineers: action items lists, 139 change requests, 193 cognizant engineer lists, 142 delegated design, 144 team design responsibility, 141 team meetings, 138, 138f proprietary notes, 44 Publications Departments: bills of material, 117 product manufacturing software, 354 teams, 154–155 publishing time measurements, 268–270 376 Index purchased proprietary assembly changes, 332 Purchase Orders (PO), 43, 329, 332 Q QC see Quality Control factors QPL functions: bills of material, 120 QS standards, 163–164 Qualification Test Reviews, 177 Qualified Vendor Lists (QVL), 36–39 Quality Assurance (QA): change management, 237 change requests, 192 CM audits, 320 Configuration Management, 11 product documentation, 45 Quality Control (QC) factors, 2, 154, 300, 304, 356 quality factors, 300–301 Quality of Service Audit, 320 quality tests, 182 Quality and Workmanship manuals, 144–145 queues, 312 queuing: change management, 234 QVL see Qualified Vendor Lists R radio, 144–145 Recognize Problem events, 341 recommended part numbers, 59–61 Redesign Complete events, 341 red line abilities, 98–99 redline abilities: change management, 229 product manufacturing software, 356 trolls, 285 redundancy, 105, 117, 331 Reengineering the Corporation (Hammer and Champy), 352 Reengineering processes, 305 Re-Engineering Your Business (Morris and Brandon), 352 Ref-doc: Quantity-Unit of Measure fields, 120 referenced documents, 129–130 Reinventing processes, 287–290 reject/accept tests, 182 release processes: audit, 321–322 benchmark changes, 339–340 benchmarking, 344 Configuration Management, 17 Configuration Management change workflow, 296, 296f identification numbers, 54 improvement, 290 revision levels, 168, 168f trolls, 283 typical types, 166, 166f visibility, 189 see also document release Release Product Spec document release process tasks, 185 Release software code changes, 224 Release to Manufacturing, 296, 296f, 298 Release to Production, 297 reliability test data, 193 REL (released/production)document release status codes, 180 Repairs, Request for Change forms, 195–197, 255–257 request processes: audit, 323 benchmarking, 340, 345 Configuration Management, 17 improvement, 290 responsible engineers see cognizant engineers retrofit decisions: interchangeability, 90–91 trolls, 285 Return to Supplier categories, 246 rev fixated sequencing configurations, 249 Review Design Concepts, 184 Review Model, Tests, and Documents document release process tasks, 185 Revision Block: document release, 169, 170f product documentation, 22–23, 22f, 25–27 Index revision control: team document control, 153 revision-date-controlled standards, 318–319 revision drafting: change management, 233–234 revision identification numbers, 64–66 revision levels: assembly parts lists, 33, 34f AS standards, 164 bills of material, 99 change management, 230, 251 identification numbers, 66–67 importance, 64, 65f interchangeability, 90–91 ISO, 164 QS standards, 164 release phase documents, 168, 168f release processes, 168, 168f revisions: change management, 255 rev level documents, 327 route sheets, 150 routine change management, 220, 220t Rule: action items list headings, 139 alternate parts, 58 Approved Manufacturers List, 37 Approved Vendor Lists, 37 assemblies, 77 assembly drawings, 31 assembly parts list, 35 baseline-lifecycle phase relationships, 170–171 bills of material, 108, 117, 118, 126–127 change control boards, 146–149 change lifecycle costs, 205–207, 211 change management, 215–217, 219, 221–223, 225, 229, 237, 241, 243, 245–247, 250 change requests, 192, 194, 198 cognizant engineer lists, 142 cross-functional teams, 134 delegated design, 145 design change process improvements, 286 document groups and control, 45–46 document signatures, 29 document sizes, 44 377 down-level drawings, 158 end item part numbers, 86 engineering workflow, 293 fast change, 267–269 fast change workflow, 291 field failures, 192 field units, 87 firmware control, 161 Imperial system, 27 interchangeability, 78, 81, 90 items marking, 69 labels, 71 letters, 64, 66 lifecycle process tasks, 185 lifecycle process time, 188 lifecycle release flow diagrams, 188 lifecycle release phases, 167 Make-to-Order product specifications, 42 Make-to-Stock product specifications, 40 Metric system, 27 part number change logic, 84 part number cycles, 54 part numbers, 57, 68, 69 preferred parts, 58 process document control, 152, 153 process standards, 308, 309 product definition phases, 175 product development phases, 176 production problems, 194 product phase out, 179 product pilot phases, 177, 183 publications, 154, 155 Qualified Vendor List, 37 quality factors, 301 recommended part numbers, 60, 61 release checklists, 182 release forms, 182 release phase documents, 169 Revision Block, 26 revision levels, 66 revision numbers, 64, 66 serial numbers, 56 service parts, 77 signatures, 182 software control, 161 stickers, 71 378 Index Rule: (Continued) supply chains, 333 team meetings, 137 team responsibility, 136 technical release, 295 on time publications, 155 Title Block, 23 Used-on databases, 78 rule of tens, 135, 283, 328 S SAE see Society of Automotive Engineers Sales, 2, 52–53 sales documents, 45, 154 Sales Orders: Make-to-Order product specifications, 41–42 part number cycles, 52–53 same as except marked documents, 232–233 same items see interchangeability Sample standards, 315, 316f sanity tests, 319–320, 336 SCDs see Specification Control Drawings scratch stickers, 253 self-audits, 319–320 seminar attendee benchmarking surveys, 343–346 serial numbers (SN), 55–56, 157, 253 Service departments, 354 service parts: assemblies, 76–78 bills of material, 121 field units, 86–87 form, 85–86 function, 85–86 interchangeability, 73–91 product manufacturing software, 354 trolls, 283–284 service un-bundle documents, 227, 227f shallow BOMs, 140 shelf life: teams, 157 shipping: bills of material, 119 shopping lists, 125, 126f, 130 signatures: Change Control Boards, 145–150 change management, 236–238 document release, 180–182 engineering workflow, 293 product documentation, 28–30 Revision Block, 26 team responsibility, 144 Title Block, 25 significant part numbers, 57–60 sign-off tables, 296–297 Simultaneous Engineering Teams, 134–135 single BOM databases, 353 single level BOMs, 119, 119f single sideband airborne radio, 144–145 sketch identification numbers, 61–62 small business units, 12, 17 small companies: bills of material, 95 Configuration Management, 18 product documentation, 46 product manufacturing software, 353 team process control, 154 SN see serial numbers Society of Automotive Engineers (SAE), 10 software (SW) control, 161–163 software systems: bills of material, 94, 97–99, 102, 106, 113–114, 120–121, 130–131 change management, 224–225 classification coding, 57 Configuration Management, 8, 10 document release status codes, 180 engineering, interchangeability, 78 letters, 66 manufacturing, revision identification numbers, 66 revision levels, 66–67 supply chains, 325 version identification numbers, 54 see also Computer-Aided-Design/ Drafting; product manufacturing software solid model CAD, 33 source control drawings, 36, 37, 38f Spare-Parts Lists, 33–34 Index specialty software, 349–350 Specification Control Drawings (SCDs): cognizant engineer lists, 143 general specifications, 40 part numbers system changing, 63 product documentation, 36, 37, 39f supply chains, 332–333 spin-off products: change requests, 200 Configuration Management, 173 Make-to-Stock product specifications, 41 Standard Operating Procedure (SOP), 307–308 standards: AS, 163–164 mark up, 230–232 QS, 163–164 see also ISO; process standards Standards Institute: American National, 10 Start Project document release process tasks, 184 start-up companies, 18 start-up costs, 210 Status Accounting: change management, 246–247, 253–254 Configuration Management, status codes, 180 steering committees, 287, 301–302 stickers, 70–72 stocking items, 118 structure assembly drawings, 117–118 subject matter experts, 308 submarine valve manufacturers, 109–110 super-fast change processes, 220, 221f supplier items, 340 supply chains, 325–334 analyses, 330–331 bills of material, 112, 119 BOMs, 331–332 breaking, 325, 326–329 change approval default clauses, 333–334 CM boilerplates, 329 customer approval/review, 332–333 customer relationships, 331 ECO, 330 purchased proprietary assembly changes, 332 379 purchase orders, 329 Support documents, 44, 45f Support and Process document release process tasks, 186 Sustaining Engineers, 144, 206–207 SW see software control System Integration Specification, 40 system item codes, 100–101 system overview training sessions, 319 Systems Updated measure points, 271 T Tabs: definition, 60–61 teacher Technicians, 16 teams, 133–164 action lists, 138–139 assembly instructions, 151–152 AS standards, 163–164 Change Control Boards, 145–150 change management, 238 cognizant engineer lists, 142–143 cross-functional teams, 134–135 delegated design, 144–145 design responsibility, 140–142 down-level drawings, 158 fabricated part processing, 150–151 fast change processes, 269, 269f field change orders, 160–161 field support, 159–160 firmware control, 161–163 function engineers, 143–144 headings, 139 ISO, 163–164 kit, 160–161 lot control, 156–157 make up, 135–136 measurement, 140 meetings, 136–138 non-conforming material, 159 performance measurements, 140, 141f process control summary, 153–154 process document control, 152–153 process improvement, 287 process standards, 308, 311–312 production process documentation, 150 product manufacturing software, 355 380 Index teams (Continued) publications, 154–156 QS standards, 163–164 quality document control, 154 responsibility, 136 sales document control, 154 shelf life, 157 signature responsibility, 144 software control, 161–163 success, 139–140 on time publications, 155–156 Technical Release, 271, 294–295 technical signatures, 293 Technicians, 16 telecommunications, 219–220 ‘tens rule’, 135, 283, 328 Test Specifications: Make-to-Order product specifications, 41–42 process design specifications, 43 supply chains, 332–333 throwaway products, 161 “throw it over the wall syndrome”, 4–5 time to market, 355–356 time and volume measurement reports, 269, 269f, 302, 303f tipping points, 286 Title Blocks: product documentation, 22–25, 22f recommended part identification numbers, 60f, 61 top-level part numbers, 53, 58–59, 60 traceability: change management, 247, 253–254 identification numbers, 55 Tracing, 246 see also Status Accounting Tracking: change management, 246, 252–253 Configuration Management, purchased proprietary assembly changes, 332 see also Status Accounting trading systems, 350–352 transparent databases, 97 traveler records, 56 trolls, 282–286 U umbrella process Control, 46 un-bundle manufacturing and service documents, 227, 227f unique part numbers, 42 unique service assemblies, 115, 115f Units of Measure, 35–36, 328 university see seminar attendee benchmarking surveys Update of Drawings, 296, 296f, 297 up front cross-sectional teams, 355 urgent change management, 220, 220t Used-On data, 130 assemblies, 78 bills of material, 97, 130 interchangeability, 78 product documentation, 23, 24 Used-on databases, 78 V value engineering analyses, 206 valve manufacturers, 109–110 vanilla loaders, 125 Vehicle Identification Numbers (VIN), 54 version identifiers, 54, 252 versions numbers, 55 Version software code changes, 224 Vice President (VP) positions: Configuration Manufacturing, 11 fast change processes, 276 steering committees, 301–302 VIN (Vehicle Identification Numbers), 54 volume measurements, 275–277 VP see Vice President positions W waivers, 217–218 warranty, 332 was-is drafting descriptive change depiction methods see from-to drafting descriptive change depiction methods was-now drafting descriptive change depiction methods see from-to drafting descriptive change depiction methods Index weldment design, 145 Where Used data, 24 see also Used-On data white-wash processes, 321 Whiz-Bang Numbers, 52 Wight, Oliver, 219 work flow diagrams, 281–306 Workmanship and Quality manuals, 144–145 workstations, 117, 277 World Class BOM processes, 108 writing process standards, 310–313 381 ... emphasizing product lifecycle management, and Configuration Management (CM) as engineering? ??s quality control function Whether you think of this subject as Engineering Documentation Control (EDC) or... structuring, and control of the BOM (the “BOM process? ?); (iii) the requesting of engineering changes (the “request process? ?); and (iv) the making of engineering changes (the “change process? ?) So what... accurate, measured, efficient and well-understood Engineering Documentation Control/ Configuration Management (EDC/CM) standards and processes Good design documentation and its control is the solution