Engineering Change Order

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1 Engineering Change Order

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3 Copyright Chapter 1 - Copyright Horizons International, Inc. All rights reserved. Information in this document is subject to change without notice. The software described in this document is furnished under a license agreement or nondisclosure agreement. The software may be used or copied only in accordance with the terms of those agreements. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior written permission of Horizons International, Inc. Horizons International, Inc. P.O. Box 2056 La Mesa, CA U.S.A. Version Crystal Reports One of the reporting tools Horizons applications uses is Crystal Reports. With the report viewer in an application that interfaces with SQL, it is free of charge. If the reporting tool is accessed through a server the licensing hinges on where the report processing is occuring. If running in an environment where the application is on an individual machine accessing an SQL server, then there is no licensing cost for Crystal Reports. However, if it is used in a remote terminal server or Citrix environment, and is installed on a network, Crystal Reports Standard per NAMED user must be purchased. Horizons is not responsible for any misuse of licensing procedures. 1

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5 Table of Contents Chapter 1: Introduction Introduction...2 Glossary...3 Chapter 2: Overview Overview of Engineering Change Orders...6 ECO Terminology...7 Changes to Horizons Manufacturing Suite BOM Maintenance...8 Chapter 3: Using ECO Using ECO...10 PROCEDURES FOR ECO...11 Daily Processing Procedures Engineering Change Orders window...16 ECO Select window...20 ECO Maintenance window...22 Adding a sub item...24 Editing a sub item...24 Procedures for Processing Engineering Change Orders...26 ECO Approvals window...27 Process Changes...28 Automatic Process-ing of ECOs...29 Historical BOMs...30 Chapter 4: ECO Setup ECO Setup...34 i

6 Where And When the New ECO and REV Numbers Will Appear...38 Chapter 5: ECO Hardware Dispositions ECO Hardware Dispositions...42 Chapter 6: ECO Approval User Setup ECO Approval User Setup...46 Chapter 7: HMS Notes Setup HMS Note Setup...50 Chapter 8: Engineering Change Orders Engineering Change Orders...54 Buttons at the Top...54 Fields...55 ECO Select...60 Buttons at the Top...60 Header Fields...61 Scrolling Region...63 ECO Priority Lookup...67 Chapter 9: ECO Lookup ECO Lookup...70 Header Fields...70 Scrolling Region...71 Buttons at the Bottom...72 Chapter 10: ECO Maintenance ECO Maintenance...76 ii

7 Fields To The Right Of Treeview...78 Scrolling Region Below Treeview...84 Scrolling Region At The Bottom Of The Screen...85 ECO Item Lookup...87 Additional ECO Information...90 Buttons at the Top...90 Header Region...91 Cpnt Fields...92 Component WorkCenters...96 Buttons at the Top...96 Fields Scrolling Region Buttons at the Bottom ECO Finished Good Defaults Buttons at the Top Fields ECO Rev Lookup Header Fields Scrolling Region Chapter 11: Approvals ECO Approval Buttons At The Top Header Region Scrolling Region Chapter 12: Process Changes Process ECO Changes Chapter 13: Manual Rev Adjust ECO Manual Rev Adjustment Header Fields Scrolling Region iii

8 Chapter 14: ECO Reports ECO Reports Chapter 15: Remove ECO History Remove ECO History Index

9 Chapter 1: Introduction Chapter 1: Introduction 1

10 Chapter 1: Introduction Introduction Welcome to the Horizons Manufacturing Suite (formerly known as Horizons Light Manufacturing), a software program designed to automate both discrete and process manufacturers tracking mechanisms. This suite of applications seamlessly integrates with Microsoft Business Solutions Great Plains Edition or Standard Edition. NOTE: This manual is a living document that will be updated as additional functionality and code releases become available. Layout HMS Maintenance BOM Maintenance

11 Chapter 1: Introduction This manual follows several conventions to make it easier to read. Field names are in bold print, and window names are italicized. For example, the Save button on the BOM Maintenance window. Furthermore, each window is typically broken up into 4 sections: 1. The Buttons at the Top. 2. The Header Fields pertains to Parent items. Header Fields must be saved by saving the entire window. 3. The Scrolling Region pertains to component items. The scrolling fields save when Tabbing from line to line, leaving the Scrolling Region for the Header Fields, or leaving the window. 4. The Buttons at the Bottom. Cascaded menu items are indicated by pipes. For example, the path to the BOM Maintenance window is HMS Maintenance BOM Maintenance. 3

12 Chapter 1: Introduction Glossary BOM Bill of Materials. This is the recipe that the Work Order follows to build the Finished Good, or Subassembly (Parent). Component The items that make up the Parent. NOTE: A Sub-Assembly is a component of the Parent Item. ECO Engineering Change Orders component. ECO allows unlimited revisions of all Bill of Materials, future, current and historical. This includes selecting historical revisions for a current Work Order that has been set up to use existing stock. Finished Good The end result of a manufacturing process. HMS Horizons Manufacturing Suite. This suite was previously known as Horizons Light Manufacturing. You might still see references in the software to Horizons Light Manufacturing or HLM, particularly with reference to specific palette options and window names. MRP The Material Requirements Planning component. Based on demand, the system advises production and purchase needs of Components and Parent Items. There is the capability to order Labor and Overhead. MPS Master Production Schedule component. A high level view of overall production by Work Order, Sales Order, or Forecasts. Multiple Bins If Multi Bin is activated under Setup Inventory Inventory Control, then mark the Enable Multiple Bins checkbox. For more information see the Multiple Bins chapter in the Bill of Materials and Production Entry Manual. Parent Item The Parent Item refers to Finished Goods, Sub-Assemblies, and Reverse manufactured goods. 4

13 Chapter 1: Introduction Router The Router Component. Router allows the ability to setup Operations, Cost Centers and Work Centers, and organize them into steps for each Bill of Materials. Then the routing sequence can be printed out on a traveler report. Shop Floor Control Shop Floor Control component. Shop Floor Control includes the Router component, and adds the ability to schedule Work Orders, enter time, and issue stock automatically through the Production Traveler Processing window. Capacity can be seen on the color coded SFC Capacity by Work Center window. The planner is color coded, and when there is a capacity overage the cell will show up as red. The HMS Work Order Status window provides details about each Router Step, Operation, and Work Center function, as well as the actual Status of the order. The Production Traveler Processing window offers a method of tracking the processing of quantities and time spent on each step in production. S/L Serial/Lot numbers. The Serial/Lot component allows full tracking from the customer that bought the Finished Good to the component Lot used in making the Finished Good, and the Vendor from whom it was purchased. Sub-Assembly A Parent Item that is used in a Bill of Materials as a component to build another Finished Good. For example, if a bicycle is the Finished Good, the seat might be a Sub-Assembly. The seat has its own Bill of Materials and can be produced at the same time as the whole bicycle, or separately. WIP The Work In Process component. WIP allows the transfer of materials from one location to another, and final adjustments to component line items can be made before posting production. WO A Work Order or build that is the order to manufacture the Parent Item. 5

14 Chapter 1: Introduction 6

15 Chapter 2: Overview

16 Chapter 2 - Overview Overview of Engineering Change Orders Engineering Change Orders (ECO), makes it possible to create and track changes to components and Bills of Materials. Revisions with effective dates are entered by item and applied to Bills of Materials. The records can have a Priority set which is for user information only and does not affect when a Revision is implemented. Drawing ID and Drawing Sequence Number can be entered and any documents (drawings or text) from programs outside of Dynamics can be attached for future reference. Unlimited Notes are available for each Engineering Change Order or Item and Revision Number. The Effective date is the determining factor as to when a Revision is put into effect. When a new production Work Order is entered for an item or then Process Changes routine is run then the program will check to see if a new revision needs to be processed. If there is one then all component changes will be made to the Bill of Material. Components that are removed or added will be logged in the Component Change Log regardless of the setting of the Logging option in HLM Setup. In addition any errors encountered during the Revision update will be logged. When Horizons Manufacturing Suite, (HMS), has been in use and Bills of Materials are entered, then the program will automatically create a list of the current revisions in the ECO tables when the ECO module is first entered. The revision will be designated as!a unless revisions have been entered in HLM Item Maintenance or Dynamics Item Maintenance using the HLM Alternate window. 6

17 ECO Terminology Chapter 2 - Overview When ever the term Base Item or ECO Item is used in this manual, it refers to the parent, component or new item that has been selected at Parent / Cpnt or Replace With fields in the Engineering Change Orders window. A Parent based ECO is one that has a Finished Good in the Parent/Cpnt field on the Engineering Change Orders window. A Component based ECO is one that has either a component or subassembly in the Parent/Cpnt field on the Engineering Change Orders window. Whenever the term Sub Item or Affected Item is used, it refers to the item(s) selected in ECO Select or ECO Maintenance screens to be attached to the ECO Item. Implement means to execute the ECO, at or after it s effective date, to become the active BOM in BOM Maintenance and to be used for future Production Work Orders. The old BOM is now in ECO History. The following are the items found on the ECO Palette ( HMS Maintenance ECO Maintenance). 7

18 Chapter 2 - Overview Changes to Horizons Manufacturing Suite BOM Maintenance Due to the longer length of the Revision numbers with the Engineering Change Orders module, longer fields have been added to Horizons Manufacturing Suite s BOM Maintenance screen. This, in turn, has squeezed the ECO number out the main BOM Maintenance screen. The ECO number for the Parent can be found under the FG Defaults button off the BOM Maintenance screen. The ECO number for the components can be found under the Accounts button off the BOM Maintenance screen scrolling window header when the component is highlighted in the scrolling window. 8

19 Chapter 3: Using ECO

20 Chapter 3 - Using ECO Using ECO The ECO Module is designed to allow users to manage and track changes to Bills of Materials without having to setup new, active Bill of Materials or Parent Inventory Items. Engineering Change Orders are documents that describe the changes to an assembly. This can be a replacement, deletion, addition of parts or a change to an existing part. 10

21 PROCEDURES FOR ECO Chapter 3 - Using ECO Whenever the term Base Item or ECO Item is used in this manual, it refers to the parent, component or new item that has been selected at Parent / Cpnt or Replace With fields in the Engineering Change Orders window. A Parent based ECO is one that has a Finished Good in the Parent/ Cpnt field on the Engineering Change Orders window. Setup Procedures Addressing the ECO Main Setup Prior to producing a new change order, setup for your procedures needs to be done in the ECO Setup window. This window is where options can be selected to instruct the system on how to handle change orders. Hardware Dispositions To setup hardware dispositions open the ECO Disposition Setup window by clicking Hardware Dispositions on the HMS ECO palette. In this window new dispositions can be added to the list if needed. The ECO Disposition Setup window is used to setup user-defined headings to indicate the disposition of items on the old Bill of Materials. This list is accessed during processing, in ECO Maintenance, through the Detail button to the right of the Treeview. The Detail button opens the Additional ECO Information window for items being changed. These Disposition ID s are accessed under the magnifying glasses listed under Hardware Disposition in the lower, right corner. For more information, see Chapter 4: Hardware Dispositions. The dispositions currently appear on the ECO Impact report. The first six dispositions are on the report header by default. Up to 15 may be placed on the report using the report Legends in the Dynamics Report Writer. Setup User Approvals Engineering Change Orders may be approved before they can be processed to take effect. At least one unrequired user approval should be set up. The ECO Approval User Setup window is used to define which users are allowed to approve Engineering Change Orders as well as which users are REQUIRED to approve Engineering Change Orders so that they may be implemented. When a user approval is required the Req. checkbox needs to be marked. For more information see Chapter 11: Approvals. 11

22 Chapter 3 - Using ECO Daily Processing Procedures There are 2 different scenarios that can be utilized when implementing a new change order. 1. When a component ECO Item is being replaced with another component on all parents the Engineering Change Order window, and the ECO Select window are used. The Engineering Change Orders window is used to initiate change orders. By default, the system will automatically apply a Rev Number during the creation of the change order, however, the user may choose to remove it. The initial setup of a change order must be performed here. The ECO may then be edited in the ECO Select and ECO Maintenance windows. The ECO Select window allows the user, during the initial setup of an ECO, to specify items that will be affected along with the type of change(s) to be made. The information in this window is stored in a temporary table and is deleted when the window is closed. In order for any changes made here to have an affect, you must click the Process button. This will cause the changes to show up in the ECO Maintenance window, where further modifications may be made. With this type of ECO, the replacing component / subassembly item will have the new ECO and REV numbers, on the active BOM in BOM Maintenance. The parents affected by the change will have only the new REV number, unless the option Apply This ECO # To All Affected Items is marked in the Engineering Change Orders window before the ECO is saved. The following steps need to be followed to initiate an Engineering Change Order to replace one component with another one. 1) Open the Engineering Change Orders window. The next change order number will default in the ECO Number field. Tab through the fields making selections as needed. 2) In the Parent/Cpnt field enter the component that you want to replace. 3) In the Replace With field input the component that will be used to replace the Parent/Cpnt item. 4) The Rev. field is populated automatically, but the field can be modified if necessary. 5) The Effective Date is populated automatically, but can be changed if necessary. 6) Consider the check boxes, and other options on the window and make selections accordingly. 12

23 Chapter 3 - Using ECO 7) A click on the Select button at the top of the window to open the ECO Select window where all items that will be impacted with the change will appear in the scrolling area of the window. 8) Mark the Chg. checkbox, and then click the Process button at the top of the screen to complete initiating the change order. The system asks if the user wants to open the ECO Maintenance window. This is an optional choice. In ECO Maintenance window changes can be seen in the Treeview, and additional information about the change can be accessed by clicking buttons to the right of the Treeview. For example: highlighting a component in the treeview, and then clicking the Detail button will open the the Additional ECO Information window. If a Parent Item is highlighted and Parent is the choice on the pop-up window, then the ECO Finished Good Defaults window will open. For more information see Chapter 10: ECO Maintenance. 2. The second scenario occurs when the Parent ECO Item has several components changed. 1) Open the Engineering Change Orders window. The next change order number will default in the ECO Number field. Tab through the fields making selections as needed. 2) Enter a Parent Item in the Parent/Cpnt field. 3) Then click on the Select button to open the ECO Select window. A list of components that are attached to the parent item are listed in the scrolling area. Components can be deleted, and item quantities can be changed in this window. To add components to the parent item go to the ECO Maintenance window. 4) When changes have been made click on the Process button at the top of the window, and following the prompts open the ECO Maintenance window. 5) In the ECO Maintenance window the changes made in the ECO Select window can be viewed in the Treeview. A new component can be added to the Bill of Materials by highlighting the Parent Item in the tree, and clicking the Select Item button, and then making a selection from the pop-up window. A window will open that will allow the addition of new components to the Parent Item. When an item has been selected, the Redisplay icon at the upper left corner just above the treeview will need to be clicked, so the new item can appear 13

24 Chapter 3 - Using ECO in the treeview area. Components can also be deleted by highlighting a component, and clicking on the Delete button. 6) Highlighting a component, and then clicking the Detail button will open the Additional ECO Information window which gives further information about the component, and where further editing to the new component can be done. Activating Changes 1. Activating changes can be done in 3 ways. 1) Processing can be done in the Process ECO Changes window according to the Check From This Date field which is linked with the Effective Date field for each revision in the Engineering Change Order window. When selections are made click on the Process button to complete the operation. 2) Immediate manual processing can be done in the ECO Approval window. Once all of the approval users have been selected, and a revision has been entered in the ECO Number field, click on the Execute Now to complete processing. 3) Processing revisions can also be automatically done through the Production Entry window when the revision Effective Date is the same as the User Date in the upper lefthand corner of the Great Plains Toolbar. NOTE:To view revision history select the History radio on the ECO Maintenance window. The revision hisory will populate the treeview area. 14

25 Chapter 3 - Using ECO 15

26 Chapter 3 - Using ECO Engineering Change Orders window HMS Maintenance ECO Maintenance Engineering Change Orders 1. Choose or enter an ECO Number. This number will automatically increment from ECO Setup, but can be overridden. To apply the users next change to an existing ECO number, overwrite the incrementing number and type in the existing number. (Do not try to lookup and select the existing ECO number, or the user will be selecting the entire ECO record rather than just the number.). 2. Choose or enter a Priority. This is an information only field that will print on reports. 3. Enter a Description. The Description entered here will automatically appear in the white text box below in this screen. This is designed to save time. The text in the ECO Comment box is easily accessible from many screens, including when viewing historical ECO s. The Description is not as easily accessible, although through zooming, it can be seen in history. 4. Choose or enter the Parent/Cpnt. 16

27 Chapter 3 - Using ECO There are several ways an ECO can be used. Enter a component, subassembly component, subassembly parent, end item parent or a new, unused item, depending on the changes to be made. The possible changes that can be made are: a. Changes to a component / subassembly item that exists on a Bill of Materials (BOM) i. When the component will have a change made to it on all BOMs where it exists. When an ECO where the component is being changed on multiple BOMs, is implemented, the component / subassembly item will have the new ECO and REV numbers, on the active BOM in BOM Maintenance and Item Maintenance. The sub items, or parents affected by the change, will have neither the new ECO or REV numbers, unless the option Apply This ECO To All Affected Items is marked in this screen before the ECO is saved. ii. When the component will be deleted on multiple BOMs or everywhere it exists. When an ECO where the component is being deleted on multiple BOMs is implemented, the component / subassembly item will be gone, and the affected parents will have new REV number only. The ECO number will only be seen in ECO History for the old BOM and not in BOM Maintenance, unless the option Apply This ECO To All Affected Items is marked in this screen before the ECO is saved. iii. When the component will be replaced on multiple BOMs or everywhere it exists. When an ECO where the component is being replaced on multiple BOMs is implemented, the replacing component / subassembly item will have the new ECO and REV numbers on the active BOM in BOM Maintenance. The parents affected by the change will have only the new REV number, unless the option Apply This ECO To All Affected Items is marked in this screen before the ECO is saved. b. Changes to a new item that does not exist as a component / subassembly on BOMs i. When the component will be added to multiple BOMs. When an ECO where the component is being added to multiple BOMs is implemented, the new component / subassembly item being added will have the new ECO and REV numbers, on the active BOM in BOM Maintenance and Item Maintenance. The parents affected by the change will have the new REV number only, unless the option Apply This ECO To All Affected Items is marked in this screen before the ECO is saved. c. Changes to a subassembly parent item or finished good parent 17

28 Chapter 3 - Using ECO i. When the parent will have several changes made to it s BOM For example, one component is replaced by an updated new component, and the scrap% must change on a second component due to the replacing item. When implemented the parent ECO item, only, will have the new ECO and REV numbers in the active BOM in BOM Maintenance and Item Maintenance. This is the case whether the sub item components are being added, deleted, replaced or changed. The affected components will not have the new ECO number unless the option Apply This ECO To All Affected Items is marked in this screen before the ECO is saved. 5. Choose or enter the Replace With item. Enter a new, unused item at Replace With if an existing BOM component / subassembly component was entered at Parent / Cpnt above, and the goal is replace the above item with this item on one or many BOMs. 6. The REV Number will increment automatically unless the user marks the option in ECO Setup to Disable Revision Sequence Check If this option is marked, the program will verify that a revision entered is after the last entered revision. If the REV Number is not in order, an error message will appear when the ECO is saved. 7. The Effective Date will default to today s date. The Effective Date must be unique for each Parent/Cpnt item per ECO. This means that two ECOs cannot be set up with the same Parent/Cpnt item and the same Effective Date. An error message will appear when the ECO is saved, if they are not unique. 8. Enter a Drawing ID and Drawing Seq. #, if desired. These fields will print on reports but are memo fields only 9. Enter a Change Request #, if desired. This field will also print on reports. 10. If you are using the ECO for development purposes you may check the Prototype field. This will keep the ECO from being implemented, even if it is past the Effective Date 11. If the user would like the sub or affected items selected in ECO Select or ECO Maintenance to have the new ECO number, mark the Apply This ECO To All Affected Items option. See step number 4 above for more details on how this affects where the ECO # will populate. Normally the users do not want to mark this option as the ECO system populates the proper screens with the REV and ECO #, as needed. Only under special circumstances would this option need to be marked. 12. When the user is ready to add sub-items that the ECO will affect, three methods can be used: a. Checking the Auto-Add All Parent Items check box. 18

29 Chapter 3 - Using ECO b. If the Parent/Cpnt item above is a component or subassembly in existing BOMs, and the change will affect all existing parents, the user can add all parents automatically by checking the Auto-Add All Parent Items checkbox before saving the record. When the record is saved the parent items will be added as the sub-items of the ECO and can then be viewed by opening ECO Maintenance (click on the button called ECO Maint at the top of the screen.). c. Through the ECO Maint. Button. Sub items can also be added manually by saving the ECO and accessing ECO Maintenance. The ECO Maint. button will do both. d. By clicking the Select button. 19

30 Chapter 3 - Using ECO ECO Select window If you do not want to select all parents, but want to pick and choose, click on the Select button to open ECO Select where the sub-items can be selected. HMS Maintenance ECO Maintenance Engineering Change Orders Select button When accessing the ECO Select screen, there are several possible scenarios: 1. When working with a component ECO Item that exists on BOMs: a. The Parent checkbox is automatically marked (the Cpnts checkbox will be inactive unless the ECO Item is a subassembly). b. The parent items to the component ECO Item, which were entered in the Parent/ Cpnt field in Eng. Change Orders, will list with the existing Quantity, U of M and Scrap %. c. If you mark the All Items checkbox, the Quantity will be 0 and the U of M will be the base U of M. Items to be applied to this ECO can be marked. 2. When working with a new, unused component ECO Item: a. The All Items checkbox will need to be marked to list all available parents to which the new component could be added. 20

31 Chapter 3 - Using ECO b. The Quantity and Scrap % will default as zero 3. When working with an end item parent ECO Item: a. The Cpnts checkbox is automatically marked and Parents checkbox is inactive. b. The components (and subassembly components) to the parent ECO Item, entered in the Parent / Cpnt field in Eng. Change Orders, will list with the existing Quantity, U of M and Scrap %. 4. When working with a subassembly ECO Item: a. The Parent checkbox is automatically marked and parents to the subassembly will list. b. The Cpnts checkbox will also be active so that the subassembly s components may be selected. Keeping the above scenarios in mind, there are several other steps that may be performed within the ECO Select window: 5. You may access the BOM to which the ECO item belongs if the item is a subassembly parent or end item parent via the M button. 6. The C button provides access to a where used inquiry called Component Inquiry, regardless what type of item the ECO Item is. 7. Quantity, U of M and/or Scrap % can be entered. Entering a value in one of these fields will mark the record. When entering a quantity, the user will be asked if they want to roll this quantity down to all marked records. This will save time when entering a change to a component in several parents, for example. 8. Add, Chg, Delete and Add to Parent can also be marked in preparation for ECO Maintenance. It is easier to make these changes and settings in ECO Select, than in ECO Maintenance. 9. Click the View Marked button to see only the marked records to be added to ECO Maintenance. 10. When ready, click the Process button to add all marked items to the ECO. The user is asked if they want to open ECO Maintenance when the process is finished. 21

32 Chapter 3 - Using ECO ECO Maintenance window ECO Maintenance allows the user to view and edit current and historical ECOs and BOMs. Once ECO are saved in Eng. Change Orders, they will appear in the ECO Maintenance tree view. This window may also be used to add the sub items w which will be affected by the ECO, rather than using the ECO Select window. HMS Maintenance ECO Maintenance ECO Maintenance The ECO Maintenance window may be used in two ways: As an inquiry screen As an editing tool When using the ECO Maintenance window as an inquiry screen: 1. The top, left drop down menu determines the type of information displayed in the white tree view box below. The possible choices are: a. Engineering Changes shows only the Engineering Changes which have been entered in the ECO system. b. Finished Goods shows the list of finished goods by Bill of Material in the tree view window c. Subassemblies shows only the sub-assemblies from the Bill of Materials. If there are sub items that have been selected for an ECO, there will be a + (plus sign) to the left of the ECO #. 22

33 Chapter 3 - Using ECO i. Click the plus sign to see a list of the sub items that will be affected by the change. ii. Highlight each sub item and view the fields to the right of the white tree view box to see what changes will be happening. iii. Click on the Detail button on the right, to see details such as quantity changes, etc. ECO Maintenance defaults to the Engineering Changes view, upon opening the screen. 2. The Show radio buttons are used in conjunction with the View drop down to determine what type of data is showing in the tree view. a. The Planned radio button relates only to the Engineering Changes choice in the View drop down menu. ECO Maintenance defaults to the Planned radio button upon opening. b. The In Use and History radio buttons relate to all three drop downs choices: i. In Use shows the current BOMs. ii. History will show all historical BOMs that are the result of ECO changes being implemented. Any time an ECO is processed, a copy of the BOM, before and after, is made or updated. 3. When the Finished Goods drop down option is selected along with the History radio button, the user can view Historical BOMs for only end item parent numbers. These BOMs are sorted by the parent number with the REV number listed. The plus sign, to the left of the Item Number, can be clicked to see the components as they were at that time. Click on the Detail button on the right to see details such as quantity changes, etc. 4. When the Subassemblies drop down option is selected along with the History radio button, the user can view Historical BOMs for only subassembly items and sort by the Subassembly number with the REV number listed. The plus sign to the left of the Item Number can be clicked to see the components as they were at that time. Click on the Detail button on the right, to see details such as quantity changes, etc. 5. When the Engineering Changes drop down option is selected along with the History, the user can view all Historical BOMs by ECO number with the REV number and ECO Item listed. The plus sign to the left of the Item Number can be clicked to see the sub items that were affected with that ECO. Click on the Detail button on the right, to see details such as quantity changes, etc. 6. The Parent Items window, in the picture of ECO Maintenance above - just below the tree view, shows either the parents of the item highlighted in the tree view, or all the past Revisions of that item. Click on the button at the 23

34 Chapter 3 - Using ECO lower, right corner of the Parent Items window to make the toggle change. In the picture of ECO Maintenance above, this button says Revisions. When clicked it changes to Parent Items and the heading of the window changes to Item Revisions. Click on the button again, and it changes back. When using ECO Maintenance as an editing tool: When working with Planned ECOs, the user can add or edit directly in the ECO Maintenance window, provided the ECO has been saved in the Engineering Change Orders window Adding a sub item 1. First select the ECO in the white tree view box. 2. Then the click the Select Items button to add the required items. 3. Once the item has been selected using the Select Items button, you may either: a. Mark the new sub item for deleting by clicking the Delete checkbox b. Click the Detail button to make changes. 4. Once all is correct for the new item, click the Save button. Editing a sub item For sub items added previously, the user can edit each ECO s sub-items. 1. First open the ECO in the tree view by clicking on the Plus Sign to the left of the ECO Number. 2. Highlight one of the sub items that list. 3. Click on the Detail button on the right. This will either open the Additional ECO Information or ECO Finished Good Defaults windows, depending on the type of item highlighted in the tree view. In these windows the BOM Setup fields can be changed for the new BOM. 4. Once changes are complete, click the Save button. If changes were made in the ECO Select screen, the user will be able to see them in the Details button and further edit them if desired. NOTE:the following steps may be completed when either adding or editing a sub item. 5. When the ECO sub-item is a parent item, as in a replace type ECO, a New Parent Rev will be automatically entered. This will be the next Rev for that item. It is necessary for each Parent change to have a new revision or else a historical BOM of the previous component structure will not be kept in the ECO history it will be overwritten by the new change. This field is active and can be edited, if desired. 6. If desired, you may enter Manufacturers Parts numbers in the Manufacturers Part Number window at the bottom of the screen. 24

35 Chapter 3 - Using ECO This window is used to enter Manufacturers Parts by Revision Number for each item that is highlighted in the ECO Tree window. These parts do not have an effective date of their own. When a user looks up MPN s for an existing item in the standard MPN window in BOM Maintenance, on the active BOM, they will see these entries, made through the ECO Maintenance screen, as well. The controlling factor here is whether the item being edited in ECO, has been added to the BOM yet. If it has not, the parts entries are not valid until the item is a part of a BOM when the ECO is implemented to become the active BOM. 7. You may use the E button next to the Browse Buttons, at the top left of the screen, to zoom to the Engineering Change Orders window and display the record highlighted in the ECO Maintenance tree view. 25

36 Chapter 3 - Using ECO Procedures for Processing Engineering Change Orders Once the above steps for creating and editing the ECO have been completed, the ECO must be implemented. ECOs may be processed three ways: 1. By hand, individually using the Approvals screen. 2. By hand, individually or as a group using the Process Changes screen. 3. Automatically using Production Work Orders as the ECO s Effective date come due. 26

37 ECO Approvals window Chapter 3 - Using ECO HMS Maintenance ECO Maintenance Approvals The Approvals window is provided to allow all designated users the ability to comment on and approve an ECO. The users are set up in the Approval User Setup window. Each user can be Required to approve before the ECO can be processed, and they can be assigned a Department for reporting purposes. 1. Lookup the ECO to approve via the lookup icon at the ECO Number field. Once ECO Lookup is open, mark the Unapproved Only and Unprocessed Only checkboxes as needed to filter the ECOs listed. 2. To view details such as notes and item setup open ECO Maintenance via the ECO Maint. button at the top of the screen. 3. Review the changes which the ECO will be making. a. The ECO Item appears with a red P for Primary in the scrolling window in the bottom half of the ECO Approvals screen. b. The Revision numbers will list as the numbers that will be used when the ECO is implemented. c. The new Cpnt Quantity should be listed correctly based on changes made in the Details button in ECO Maintenance. 27

38 Chapter 3 - Using ECO d. The Add and Delete comments and checks should be correct based on the changes made in ECO Maintenance. 4. The ECO system tracks which user is logged into Dynamics or eenterprise. All the approving user has to do is click the Approve (or Un-Approve) button. 5. Once approved, a date will appear next to that user s name in the Approval List. In this way, management can tell who has approved and who hasn t. 6. Each user may enter their own comments about the ECO. To see a particular users comments, highlight that user in the Approvers List. 7. Once all required approvers have approved, the system will allow the Approved For Production box to be checked. This will then reflect in ECO Maintenance and on reports for that ECO. 8. The ECO can be processed immediately in this window by clicking on the Execute Now button. The Approved For Production box must be checked first. The Effective Date will be changed to today s date. 9. Once the ECO is processed, the Processed date will fill in with today s date. In this way viewers can tell if an ECO has been made active in BOM Maintenance. Process Changes HMS Maintenance ECO Maintenance Process Changes Once the Approved For Production box is available to be marked for an ECO in ECO Approvals, it can also be processed in the Process Changes window. This window will process any ECOs where the Effective Date is today or earlier. When looking up at From Item and To Item, be sure to mark the Unapproved Only and Unprocessed Only checkboxes as needed to filter the ECOs listed. 28

39 Chapter 3 - Using ECO Automatic Processing of ECOs If neither the ECO Approvals nor the Process Changes screens are used, ECOs will automatically be processed when a Work Order is entered for a Parent Item where the parent or one of its components has an ECO with an effective date of today. 29

40 Chapter 3 - Using ECO Historical BOMs Creating Production from Historical BOMs Should it be necessary, it is possible to use a Historical BOM in Production Entry. A Historical BOM is one that has been superseded by a BOM that was changed via an Engineering Change Order. This is accomplished from within the Production Entry screen by entering the Revision Number for the Finished Good on the Work Order at the Rev field in the upper right corner of the screen. You may also enter Rev numbers for any Subassemblies (in the Production Subassembly Options window use the blue S prompt to access). The components will be compiled from the ECO history BOM if all the data is complete in ECO Maintenance. If there are any records missing there may be an error after Calculating the work order stating that some items were removed. The user will need to first run check links on the BOM Components tables and then check the historical ECO and make changes if necessary. Editing Historical BOMs Historical BOMs can be edited by marking the option in ECO Setup called Edit Existing ECO BOMs. This will open up most fields in ECO Maintenance to editing. NOTE:The users must be careful when making changes to make sure they do not upset relationships between tables. The user should make a backup of their HLM tables before doing any editing. 1. Simply bring up the Historical BOM by marking the History radio button at the top right of ECO Maintenance. 2. Choose either Finished Goods or Subassemblies in the drop down at the top left. 3. Once found, open it in the tree view via the Plus Sign, highlight the affected component sub item, and click Detail to modify. This will open the Additional ECO Information window if it is a subassembly, and the ECO Finished Goods Default window if the item is a Parent Item. 4. Subassemblies can be edited in the Additional ECO Information window. The fields at the bottom of the window correspond with the original BOM fields in BOM Maintenance. If the item is a Parent options can be changed in the ECO Finished Goods Default window. 5. If a component is missing, highlight the ECO Item (the item with the + next to it) and click Select Item to lookup and add the item. Then click Detail to enter the necessary information for the item that is being added Note that this process is basically the same as editing a Planned ECO as outlined above. 30

41 Chapter 3 - Using ECO Changes to In Use BOMs Any changes made to a current Bill of Materials in BOM Maintenance, will update the BOM in ECO. When an ECO is processed a copy of the new BOM, as well as the old, is made in ECO. 31

42 Chapter 3 - Using ECO 32

43 Chapter 4: ECO Setup

44 Chapter 4 - ECO Setup ECO Setup The ECO Setup window provides the initial setup for the ECO module. HMS Maintenance ECO Maintenance ECO Setup OK The OK button closes the ECO Setup window. Next ECO number The Next ECO Number field is a six to twelve character alphanumeric field which is used to set the starting point for ECO numbers. The system will automatically increment the ECO number during processing, starting with the number entered here. However, this number may be manually overridden when creating a change order. It is important to note that the ECO Number may consist of letters, numbers or both. When numbers are being used, they should be placed at the END of the format to ensure that they will increment properly. Additionally, ECO numbers must be able to handle a change of the number of digits. For example, an ECO number beginning with 12 will be considered to be greater than one beginning with 100. Place zeros in front of the number to keep this from happening. For example, use 0012 and 0100 in the above example to maintain proper order 34

45 Chapter 4 - ECO Setup Revision Number Format Because the ECO number is alphanumeric, the Revision Number Format field is used to tell the system which format is being used so that it will increment the numbers properly. There are three possible choices: Letters will only allow letters. This format will increment automatically. Numbers will only allow numbers. This format will increment automatically. Both Letters & Numbers will allow a mix. When using Letters & Numbers be sure the number portion is at the end of the format. Otherwise the number will not increment. Revision numbers will increment automatically only when an ECO is entered with the same item as a previous ECO. An ECO with a different Parent/Cpnt item number will not cause the Revision number to increment. Initial Rev Number The Initial Rev Number field is used to tell the system the number to begin incrementing from. Depending on the selection for Revision Number Format above, this field may be numeric only, alpha only or alpha-numeric. In processing, this default number can be overridden. As with ECO Numbers, Revisions beginning with numbers must be able to handle a change of the number of digits. For example, a Revision number beginning with 12 will be considered to be greater than one beginning with 100. Place zeros in front of the number to keep this from happening. For example, use 0012 and 0100 in the above example to maintain proper order. The next Revision number increments by number or letter from the greatest one, in alphanumeric order, found in the system. It looks in the Engineering Change Orders window (HLM_ECOs table), ECO Finished Good history, the ECO Master (at both the Item Revision field and the New Parent Revision, since Sub-Assemblies may have Revisions in both fields), and HMS Item Maintenance. Once the system has looked at all of these locations, it chooses the Rev number that is highest in alphabetical order and increments from that number. NOTE:ECO Setup allows the user to select the basic Revision Number format, but the incrementing does not depend on this. The last Revision found will be checked to see if it ends in a number or a letter and the appropriate incrementing method will be used on that basis. If a Revision ends in a number, the number must be capable of being incremented. If the ending number after the last letter is all nines, the number will start over at 1. The user should set up the Rev Number format so that it will accommodate more than the largest number of changes that will ever be made. If the Revision ends in a letter, the Revision number will only be incremented if the it is all letters (no numbers or periods). If it ends in a letter and is not all letters then a blank Revision number will be returned. 35

46 Chapter 4 - ECO Setup If a format includes periods and ends in a number then only the part of the Rev after the last period will be incremented. The user must update any other segments. Remove Delete Cpnts From Router Setup When HMS Router is registered, marking this checkbox will remove items that are marked to delete during an ECO change of revision, from the Item List assigned to Router Steps. # Of Items To Show In Treeview At One Time For those companies with complex, multi-level Bills of Materials, this option can help by allowing you to set how many items you will see at once in the Treeview in ECO Maintenance, thereby reducing the time it takes to populate the Treeview window. Disable Revision Sequence Check When an Effective Date or Rev Number is entered in the Engineering Change Order window or the ECO Approval window, the system will automatically check the sequencing of Revisions compared to the Effective Date. Marking Disable Revision Sequence Check causes the system to not perform this check. Mark this checkbox if you do not care whether the Effective Dates are out of order from the Revision numbers. NOTE:In order for the Sequence Check to be successful, the Revision Numbers must be in alphanumeric order. Edit Existing ECO Boms A checkmark in Edit Existing ECO BoMs allows the user to edit existing ECO BOMs in ECO Maintenance, even after the ECO has been approved. Any fields relating to the ECO BOM can then be altered, including adding or deleting items, changing Rev Numbers, ECO Numbers or Effective Dates. An entire BOM can be copied and then altered to create history or records that need to be in the system. Auto-Approve BOMs When ECO Processed When the Require Approval to Use Finish Good in Production option is selected in HMS Setup, Bills of Material must be marked as approved in the Finished Goods Approval window (accessed through HMS Transactions BOM Approval) in order to be used in Production Entry. If this feature is in use, marking the Auto-Approve BOMs When ECO Processed field causes the new Bill of Material that is created when an ECO is processed, to be automatically marked as approved in Finished Goods Approval. This makes the new BOM immediately available for use in Production Entry. 36

47 Chapter 4 - ECO Setup NOTE:When the HMS Setup option Require Approval to Use Finish Good in Production is not marked, selecting Auto-Approve BOMs When ECO Processed does not mark the BOM for approval in Finished Goods Approval, since no approval is required. # of BOMs per FG Item to retain in ECO History The # of BOMs per FG Item to retain in ECO History field allows the user to limit the number of historical Bills of Material that the system retains in the database. The system can be set to hold up to 99,999,999,999,999 historical BOMs per Finished Good item. This is used primarily in systems where a large number of Engineering changes are made, causing disk space to become an issue. A zero in this field indicates that the system is to retain ALL historical BOMs. When a number greater than zero appears in this field and an ECO containing a Parent Item is processed, the system performs the following steps: 1. Check to see if there are any historical BOMs for the Parent Item(s) affected. 2. If there are, the system will determine how many historical BOMs there are for that Parent Item. 3. If there are more than the number listed here, the system will delete any historical BOMs in excess of this number and so that only the number of BOMs listed here remain. Note that which specific BOMs are going to be retained is determined by the Revision number associated with them. The system keeps the BOMs whose Revision number is highest in alphanumeric order. 37

48 Where And When the New ECO and REV Numbers Will Appear There are several possible scenarios when discussing where and when the ECO and Revision numbers appear: Component ECO where the component is being changed on multiple BOMs When this type of ECO is implemented, the component / subassembly item will have the new ECO and REV numbers on the active BOM in BOM Maintenance and in HMS Item Maintenance. The sub items, or parents affected by the change, will have neither the new ECO or REV numbers, unless the option Apply This ECO # To All Affected Items is marked in Engineering Change Orders before the ECO is saved. Component ECO where the component is being deleted on multiple BOMs When this type of ECO is implemented, the component / subassembly item will be gone, and the affected parents will have new REV number only. The ECO number will only be seen in ECO History for the old Bill Of Material and NOT in BOM Maintenance, unless the option Apply This ECO # To All Affected Items is marked Engineering Change Orders before the ECO is saved. Component ECO where the component is being replaced on multiple BOMs With this type of ECO, the replacing component / subassembly item will have the new ECO and REV numbers, on the active BOM in BOM Maintenance. The parents affected by the change will have only the new REV number, unless the option Apply This ECO # To All Affected Items is marked in the Engineering Change Orders window before the ECO is saved. Component ECO where the component is being added to multiple BOMs With this type of ECO, the new component / subassembly item being added will have the new ECO and REV numbers on the active BOM in BOM Maintenance and HMS Item Maintenance. The parents affected by the change will have the new REV number only, unless the option Apply This ECO # To All Affected Items is marked in the Engineering Change Order window before the ECO is saved. Parent Item ECO With this type of ECO, only the Parent Item will have the new ECO and REV numbers in the active BOM in BOM Maintenance and HMS Item Maintenance. This is the case whether the sub item components are being added, deleted,

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