Engineering DOCUMENTATION CONTROL HANDBOOK

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1 Engineering DOCUMENTATION CONTROL HANDBOOK CONFIGURATION MANAGEMENT AND PRODUCT LIFECYCLE MANAGEMENT FOURTH EDITION FRANK B. WATTS Amsterdam Boston Heidelberg London New York Oxford Paris San Diego San Francisco Singapore Sydney Tokyo William Andrew is an imprint of Elsevier

2 Preface xiii 1. Introduction 1 What is Configuration Management 4 Between Engineering and Manufacturing 5 Configuration Management Ladder 7 Configuration Management Discipline 8 Configuration Management System 8 History of Configuration Management 9 Organization of Configuration Management 10 Document Control Function Responsibilities 12 Configuration Management Function Responsibilities 12 Distributed Configuration Management 14 Manager's Job. 14 Manager of Configuration Management 14 Organization Within Configuration Management 16 Configuration Management What is It? 16 Summary r Product Documentation 21 Document Formats and Standards 21 Body of a Part Drawing 27 Body of the Assembly Drawing 30 Controlled Engineering Parts List / 35 Units of Measure 35 Specification Control and Source Control Drawings 36 AML - QVL - AVL 36 General Specifications 39 Process Design Specifications 43 Document Groups and Control 44 Distributed Document Control/CM 47 Files, Master Docs, and Revision Control Identification Numbers 51 Product Numbers and Model Numbers 52 Part Number Cycle 52

3 vi Contents Version Numbers 54 Traceability 55 Serial Numbers 55 Part Numbers 56 Classification Coding 57 Naming Convention 58 Preferred and Alternate Parts 58 Significant vs Non-Significant Part Number 58 Recommended Part Number 59 Sketch Numbers 61 Part Number Assignment 62 Changing the Part Numbering System 63 Revision Numbers and Letters 64 Revision Levels 66 Page Revision Levels 67 Change Identification Number 67 What Gets a Part Number 68 Item Marking 69 Labels and Stickers Interchangeability and Service Parts 73 Interchangeability Defined 73 Compatible 75 Interchangeable Always Applicable? 75 Service Parts and Assemblies 76 Interchangeable in All Applications 78 Interchangeability Examples, 78 Interchangeability Test 82 Part Number Change Logic 82 Form and Function 85 Field Units 86 PCB lnterchangeability/"bug Fixes" 87 Interchangeability in Doubt Bill of Material 93 BOM Data Responsibility 94 Data Dictionary 95 Item Master File 96 Design Engineering Data 96 Parent-Component Relationship 98

4 Contents vii Marked-Up Parts List 98 Manufacturing Data 100 System Item Codes 100 Field Support Data 101 BOM Data Element Criteria 102 Structuring the BOM 110 Phantom Coding Solution 113 Common BOM Structure Problem 114 Unstructure the BOM 115 Structure and Pictorial Assembly Drawings 117 Structuring for Multiple Plant Build 118 Structuring to Stock an Item 118 Structuring to Buy an Item 118 Structuring to Ship Between Buildings/JIT/DFT 119 Structuring Firmware/Application Software 120 Structuring the Standard Assembly 121 One Product Structure 121 Structure Right the First Time 122 BOM Evolution 122 Design for Modularity 124 Modular Parts List 125 Modular BOM Benefits 126 Modular Forecasting and Scheduling 127 Order-Related BOM. 128 Customer-Configured BOM 128 The Perfect BOM 128 Referenced Documents in the BOM t 129 Configurator Software Teams and Other Foundation Blocks 133 Cross-Functional Teams 134 Team Make Up 135 Team Responsibility 136 Team Meetings 136 Team Action List 138 Team Success 139 Team Measurement _ 140 Design Responsibility 140 Cognizant Engineer List 142 Other Function Engineers 143

5 viii Contents Signature Responsibility 144 Delegated Design 144 Change Control Boards 145 Production Process Documentation 150 Fabricated Part Processing 150 Assembly Instructions 151 Process Document Control 152 Process Control Summary 153 Sales Document Control 154 Quality Document Control 154 Publications 154 On Time Publications 155 Lot Control 156 Shelf Life 157 Down-Level Drawings 158 Non-Conforming Material 159 Field Support 159 Field Change Order and Kit 160 Software (SW) and Firmware (FW) Control 161 ISO/QS/AS Document Release and Product Lifecycle 165 Lifecycle Release Phases ' 166 Documents Tied to the Release Phase 168 The Revision Block 169 Lifecycle Phase Issues 169 Baseline-Lifecycle Phase Relationships 170 CM and the Release Process 171 Product Definition Phase 174 Product Development Phase 175 Product Pilot Phase 176 Product Production Phase 178 Product Phase Out 178 Management of the Release Process 179 Release Status Codes 180 Release Form and Signatures 180 Release Checklist. 182 Closing the Gap in Pilot 183 Catch Lifecycle Release Process 184

6 Contents ix Lifecycle Process Tasks 184 Lifecycle Release Flow Diagram 186 Measure the Lifecycle Process Time 188 Release Process Visibility Change Requests 191 Field Failures 192 Reliability and Other Test Data 193 Material Review Boards (MRB) 193 Production Problems 194 Can Anyone Originate a Change? 194 Request for Change 195 Request Form Instruction 195 Avoid Temptation 198 Request Process Design 199 Request Flow/Procedure * 199 Request Process Measurement 201 Request Action Items List 201 Summary Change Lifecycle Cost 203 Cost Estimating a Change 204 Design and Development Cost 204 Manufacturing and Field Costs 204 Materials and Parts Costs 204 Cost Policy 205 Who Estimates Change Cost, 205 Change Cost Payback 206 Which Requests/Changes to Estimate 207 Change Cost Form 207 Dollar Approvals 210 Charge-Back of Costs 211 Estimates Without Delay Change Management 213 Why Change? 215 Change Types 216 Deviations, Waivers, Off-Specs, etc. 217 Change Urgency 219 Class of Change 222

7 x Contents Fixes in a Change 223 Software Changes 224 What Goes into the ECO Package 225 Distribution of the ECO 227 Depiction of Adds and Deletes 228 Flag Notes 230 Mark Up Standard 230 Same As Except 232 Change Revision Drafting «233 Queuing Changes 234 Advanced Document Change Notice 234 Who Signs What 236 Empower the Change Team 238 Change Impacts 238 Mark Ups in Production 239 Effectivity 239 Effectivity Responsibility 242 The Effectivity Pipeline 244 Disposition of Old Design Parts 245 Effectivity Planning 246 Effectivity and the Parts List 247 Effectivity/Make to Order 249 Effectivity/Batch Manufacturing ' 249 Sequencing Parts List Changes 249 Sequencing Changes to Part Design 250 Tracking the Change 252 Status Accounting or Traceability Reports 253 Change Modeling and Testing 254 ECO Package Revisions 255 Change Forms 255 ECO Online 257 Form Instruction - ECO 257 Facts Database 263 Cultural Change Fast Change 265 Why is Process Speed Important? 265 Bone Pile Reduction and Other Benefits 267 Measure the Change Process Time 268 Publish Change Time Measurement 268

8 Contents xi Change Process Points to Measure 270 Change Process Phases 272 Revision of Master Documents 272 Set Change Throughput Goals 274 Measure Volume and Reduce Backlog 275 Managing for Fast Change 277 Significance of Change Speed 279 a 12. Process Improvement/Work Flow Diagrams 281 Trolls 282 Establish Key Process Metrics and Publish Them 286 Design Change Process Improvements 286 Missionary Team Leader 287 Steps to Reinvent a Process 287 Continuous Improvement or Reinvent 289 Fast Change Work Flow 290 Change Work Flow Diagram 292 Engineering Work Flow 292 Point of No Return - Technical Release 294 Change Checklist 295 CM Change Work Flow 296 Manufacturing (Implementation) Work Flow 298 Quality Factor N A Case Study 301 Continuous Improvement 304 CM Implementation Critical Success Factors 305 System Redesign is Not Easy Process Standards and Audits 307 CM Policy 309 Writing and Formatting Standards 310 Best Practice for a Standard 313 Subjects to Standardize 314 Procedures 315 Procedure in a Flow Diagram 318 Standards Manual 318 Training 319 Auditing the CM Processes 319 Audit Plan 320 Audit Frequency

9 xii Contents Audit Follow Up 321 Train Without a Whistle EDC and the Supply Chain 325 Supply Chain is Broken 326 Purchase Order - CM Boilerplate 329 ECO Sent to Supplier 330 Supply Chain Analysis 330 Supplier's Relationship with the Customer 331 Supplier BOM 331 Purchased Proprietary Assembly Changes 332 Customer Review and Approval of Changes 332 Change Approval Default Clause Benchmarking 335 Benchmarking Pitfall 336 How to Benchmark, 336 Benchmarking Survey Automotive Suppliers - Summary of Results 337 Survey - 58 University Seminar Attendees 343 Benchmark Report, 345 Interpretation of Surveys Product Manufacturing Software 347 Current Software 347 Develop Your Own Software? 349 Software Purchased and Tailored 349 Purchasing Software 350 CM's Role in Software Choices 351 Software Trend 351 Validation 352 Software Question for This Century 352 Manufacturing Company Software (MCS) 353 CM Strategy Summarized 355 Education and Training 356 Reference and Reading List 359 Index 361

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