Configuration. Management for. Senior Managers. Essential Product Configuration. and Lifecycle Management

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1 Configuration Management for Senior Managers Essential Product Configuration and Lifecycle Management for Manufacturing Frank B. Watts ELSEVIER AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Butlcrworth-Hcincmann is an imprint of F.lsevicr

2 Contents List of Figures Preface Policies and Critical Practices xi xiii xvii 1 Introduction 1 2 Why CM 5 The Dirty Half Dozen 5 Process Speed 6 Throw It over the Wall 6 Quality Control for Engineering 7 Summary 8 3 CM System, Where to Start 9 Process Measurements 9 Distributed CM 10 Organization 11 Chain of Command 12 CM Manager 12 ISO Standards and Certification 13 DOD/Military Standards 13 Best of the Best Practices 15 Standards Responsibility 15 People Required 16 Function Name 17 Responsibilities 17 Reengineer or Continuous Improvement 19 Plan to Improve 20 Summary 21 4 CM and Software 23 Software's Current Condition 23 Modern Trend 24 Process Redesign before Software 24 CM's Roll in Software 25 What CM Should Control and Not 25 Software (SW) and Firmware (FW) Control 26 Summary 27

3 vi Contents 5 Standard Foundation Blocks 29 Standards Writing 29 General Standards 30 Acronyms and Definitions 31 Part Numbers Significant or Not 32 Class Coding 33 Interchangeability and the Part Number 34 Interchangeability/Part Number/Rev Change 35 Item/Document Numbering 36 Interchangeability Discussed 37 Interchangeability Defined 38 Ideal Part/Document Number 39 Assignment of Part Number and Revision Level 40 Revision Levels 41 Revision Control 41 Part Marking : 41 Cognizant Engineer 42 Approved Manufacturers List 42 Deviations 43 Spare Parts 45 Publications 46 Nameplate/Serial Number/Labels 46 Transmissions to Customers 47 Summary 47 6 Signatures on CM Documenta 49 Involvement versus Signature 49 One Author and One Acceptor 50 Signing the BOM or Parts List 51 Just in Time 51 Who Obtains Signatures? 52 Quality Assurance Role 52 Technical Release 52 Signature Alternatives 54 Summary 54 7 Process Improvement 55 Process Speed Gase History 56 Gase Study Change Process Reengineering 57 Process Time Expectations 58 Teams 58 Change Boards 59 Forms 60 Customer Orders 60 Backlogs/Work in Process 63

4 Contents vii Age Reports 64 Summary 64 8 Release Process 67 Engineering and Company Phases 67 Phases of Release 68 Release in Lead Time 69 Lead Time Release Performance 71 Team in Release 71 Signatures on Releases 73 Release Phase Chart 73 Rules for Release 74 Product Specification Release 75 Contract/Planning Phase 76 Design and Development Phase 76 Pilot Phase 77 Production Phase 78 Obsolete 79 Software Release 79 Release Process Standards 80 Release Metrics 80 Release Process Quality 82 Release Process Flow 83 Release Time and Volume Measurement 85 Summary 86 9 Bill of Material Process 87 Design Data 87 New Product BOM 88 Product Cost 89 PLMand ERP 89 One BOM Entry 90 Operations BOM Data 92 Engineering-Friendly Parts List 93 BOM Content 93 Structuring the BOM 95 Evolve the BOM 95 Just-in-Time BOM 97 Structuring Firmware and Software 97 Features and Options 98 The Perfect BOM 98 BOM Work Flow 99 BOM Standards 100 BOM Metrics 100 Summary 102

5 viii Contents 10 Request for Change Process 103 Separate Request Process 103 Does Your Request Process Work? 104 Cost Reduction and Improvements 104 Screening Requests 105 Request Review Team 108 Request Work Flow 109 Request Standards 109 Request Metrics 110 Failure Reporting 110 Summary Change Cost/Payback 115 Cost of Change 115 Real Cost Reductions 116 Design and Development Costs 118 Operations and Field Service Costs 118 Part Costs 118 Cost Policy 118 Responsibility for Estimating Cost 119 Cost Work Flow 119 Cost Estimating Standards 120 Summary Change Management 123 Managing Changes 123 Fast Change 124 Get-Arounds 124 Change Team 125 Redline Markups for Change 125 One-One-One-One Rule 126 Urgency/Class/Type 127 Software Changes 128 Manufacturing, Quality, and Service Documents 128 Impacts of Change 130 Technical Signatures on Changes 130 Change Package 131 Technical Release: Point of No Return 132 Rev Level 133 Updating the Master Documents 133 Queuing Changes to the Master 135 Effectivity 135 Effectivity Volatility 136 Tracing Changes 136 Who and How to Trace 137

6 Contents ix Old Design Parts 137 Closing the Change 138 Obsolete 138 Change Standards 139 Change Work Flow 139 Change Metrics 140 Case Study 142 Change Quality Metrics 146 Summary Field Change Process 149 Safety Recalls 149 Changes to Retrofit or Not 149 Classification of Field Change 150 Field Change Order 150 Field Instruction Writing 151 Field Change Flow 151 Field Change Metrics 152 Field Change Standards 152 Summary Take It to the Bank Benefits 157 Critical to Success 158 Index 161

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