In this new edition of his widely-used Handbook, Frank Watts, widely recognized for his significant contributions to engineering change control processes, provides a thoroughly practical guide to the implementation and improvement of Engineering Documentation Control (EDC), Product Lifecycle Management and Product Configuration Management (CM). Successful and error-free implementation of EDC/CM is critical to world-class manufacturing. Huge amounts of time are wasted in most product manufacturing environments over EDC/CM issues such as interchangeability, document release and change control - resulting in faults, product release delays and overspends.
The book is packed with specific methods that can be applied quickly and accurately to almost any industry and any product to control documentation, request changes to the product, implement changes and develop bills of material.
The result is a powerful communications bridge between the engineering function and ?the rest of the world? that makes rapid changes in products and documentation possible. With the help of the simple techniques in the handbook, companies can gain and hold their competitive advantages in a world that demands flexibility and quick reflexes - and has no sympathy for delays.
The new edition sets EDC/CM in the context of Product Lifecycle Management (PLM), providing guidance on choosing, purchasing and implementing PLM software systems. Watts guides the reader to harness these tools and techniques for business objectives including Process Improvement and time-to-market.
- Solid, pragmatic ideas for real product and process cost reduction. According to one reviewer: ?most books focus on the basics without examining all facets of each process area or functional area. This may be good for quickly learning, but it will only take the reader so far. Mr. Watts imparts the same information, but invites the reader to think and to consider strengths and weaknesses of processes and procedures. The copious examples, illustrations and breadth of topics covered make this book 'the' reference on EDC and CM.?
- Strategic emphasis shows how processes may be integrated and tears down the ?wall? between Engineering and Operations
- Thorough description of Product Lifecycle Management software tools
In this new edition of his widely-used Handbook, Frank Watts, widely recognized for his significant contributions to engineering change control processes, provides a thoroughly practical guide to the implementation and improvement of Engineering Documentation Control (EDC), Product Lifecycle Management and Product Configuration Management (CM). Successful and error-free implementation of EDC/CM is critical to world-class manufacturing. Huge amounts of time are wasted in most product manufacturing environments over EDC/CM issues such as interchangeability, document release and change control - resulting in faults, product release delays and overspends. The book is packed with specific methods that can be applied quickly and accurately to almost any industry and any product to control documentation, request changes to the product, implement changes and develop bills of material. The result is a powerful communications bridge between the engineering function and 'the rest of the world' that makes rapid changes in products and documentation possible. With the help of the simple techniques in the handbook, companies can gain and hold their competitive advantages in a world that demands flexibility and quick reflexes - and has no sympathy for delays. The new edition sets EDC/CM in the context of Product Lifecycle Management (PLM), providing guidance on choosing, purchasing and implementing PLM software systems. Watts guides the reader to harness these tools and techniques for business objectives including Process Improvement and time-to-market. Solid, pragmatic ideas for real product and process cost reduction. According to one reviewer: 'most books focus on the basics without examining all facets of each process area or functional area. This may be good for quickly learning, but it will only take the reader so far. Mr. Watts imparts the same information, but invites the reader to think and to consider strengths and weaknesses of processes and procedures. The copious examples, illustrations and breadth of topics covered make this book "e;the"e; reference on EDC and CM.' Strategic emphasis shows how processes may be integrated and tears down the 'wall' between Engineering and Operations Thorough description of Product Lifecycle Management software tools
Front Cover 1
Engineering Documentation Control Handbook: Configuration Management and Product Lifecycle Management 4
Copyright 5
Contents 6
Preface 14
Chapter 1 - Introduction 20
What is Configuration Management 23
Between Engineering and Manufacturing 24
Configuration Management Ladder 26
Configuration Management Discipline 27
Configuration Management System 27
History of Configuration Management 28
Organization of Configuration Management 29
Document Control Function Responsibilities 31
Configuration Management Function Responsibilities 31
Distributed Configuration Management 33
Manager’s Job 33
Manager of Configuration Management 33
Organization Within Configuration Management 35
Configuration Management—What is It? 35
Summary 38
Chapter 2 - Product Documentation 40
Document Formats and Standards 40
Body of a Part Drawing 46
Body of the Assembly Drawing 49
Controlled Engineering Parts List 54
Units of Measure 54
Specification Control and Source Control Drawings 55
AML – QVL – AVL 55
General Specifications 58
Process Design Specifications 62
Document Groups and Control 63
Distributed Document Control/CM 66
Files, Master Docs, and Revision Control 67
Chapter 3 - Identification Numbers 70
Product Numbers and Model Numbers 71
Part Number Cycle 71
Version Numbers 73
Traceability 74
Serial Numbers 74
Part Numbers 75
Classification Coding 76
Naming Convention 77
Preferred and Alternate Parts 77
Significant vs Non-Significant Part Number 77
Recommended Part Number 78
Sketch Numbers 80
Part Number Assignment 81
Changing the Part Numbering System 82
Revision Numbers and Letters 83
Revision Levels 85
Page Revision Levels 86
Change Identification Number 86
What Gets a Part Number 87
Item Marking 88
Labels and Stickers 89
Chapter 4 - Interchangeability and Service Parts 92
Interchangeability Defined 92
Compatible 94
Interchangeable Always Applicable? 94
Service Parts and Assemblies 95
Interchangeable in All Applications 97
Interchangeability Examples 97
Interchangeability Test 101
Part Number Change Logic 101
Form and Function 104
Field Units 105
PCB Interchangeability/“Bug Fixes” 106
Interchangeability in Doubt 109
Chapter 5 - Bill of Material 112
BOM Data Responsibility 113
Data Dictionary 114
Item Master File 115
Design Engineering Data 115
Parent–Component Relationship 117
Marked-Up Parts List 117
Manufacturing Data 119
System Item Codes 119
Field Support Data 120
BOM Data Element Criteria 121
Structuring the BOM 129
Phantom Coding Solution 132
Common BOM Structure Problem 133
Unstructure the BOM 134
Structure and Pictorial Assembly Drawings 136
Structuring for Multiple Plant Build 137
Structuring to Stock an Item 137
Structuring to Buy an Item 137
Structuring to Ship Between Buildings/JIT/DFT 138
Structuring Firmware/Application Software 139
Structuring the Standard Assembly 140
One Product Structure 140
Structure Right the First Time 141
BOM Evolution 141
Design for Modularity 143
Modular Parts List 144
Modular BOM Benefits 145
Modular Forecasting and Scheduling 146
Order-Related BOM 147
Customer-Configured BOM 147
The Perfect BOM 147
Referenced Documents in the BOM 148
Configurator Software 149
Chapter 6 - Teams and Other Foundation Blocks 152
Cross-Functional Teams 153
Team Make Up 154
Team Responsibility 155
Team Meetings 155
Team Action List 157
Team Success 158
Team Measurement 159
Design Responsibility 159
Cognizant Engineer List 161
Other Function Engineers 162
Signature Responsibility 163
Delegated Design 163
Change Control Boards 164
Production Process Documentation 169
Fabricated Part Processing 169
Assembly Instructions 170
Process Document Control 171
Process Control Summary 172
Sales Document Control 173
Quality Document Control 173
Publications 173
On Time Publications 174
Lot Control 175
Shelf Life 176
Down-Level Drawings 177
Non-Conforming Material 178
Field Support 178
Field Change Order and Kit 179
Software (SW) and Firmware (FW) Control 180
ISO/QS/AS 182
Chapter 7 - Document Release and Product Lifecycle 184
Lifecycle Release Phases 185
Documents Tied to the Release Phase 187
The Revision Block 188
Lifecycle Phase Issues 188
Baseline–Lifecycle Phase Relationships 189
CM and the Release Process 190
Product Definition Phase 193
Product Development Phase 194
Product Pilot Phase 195
Product Production Phase 197
Product Phase Out 197
Management of the Release Process 198
Release Status Codes 199
Release Form and Signatures 199
Release Checklist 201
Closing the Gap in Pilot 202
Catch-22 203
Lifecycle Release Process 203
Lifecycle Process Tasks 203
Lifecycle Release Flow Diagram 205
Measure the Lifecycle Process Time 207
Release Process Visibility 208
Chapter 8 - Change Requests 210
Field Failures 211
Reliability and Other Test Data 212
Material Review Boards (MRB) 212
Production Problems 213
Can Anyone Originate a Change? 213
Request for Change 214
Request Form Instruction 214
Avoid Temptation 217
Request Process Design 218
Request Flow/Procedure 218
Request Process Measurement 220
Request Action Items List 220
Summary 221
Chapter 9 - Change Lifecycle Cost 222
Cost Estimating a Change 223
Design and Development Cost 223
Manufacturing and Field Costs 223
Materials and Parts Costs 223
Cost Policy 224
Who Estimates Change Cost 224
Change Cost Payback 225
Which Requests/Changes to Estimate 226
Change Cost Form 226
Dollar Approvals 229
Charge-Back of Costs 230
Estimates Without Delay 230
Chapter 10 - Change Management 232
Why Change? 234
Change Types 235
Deviations, Waivers, Off-Specs, etc. 236
Change Urgency 238
Class of Change 241
Fixes in a Change 242
Software Changes 243
What Goes into the ECO Package 244
Distribution of the ECO 246
Depiction of Adds and Deletes 247
Flag Notes 249
Mark Up Standard 249
Same As Except 251
Change Revision Drafting 252
Queuing Changes 253
Advanced Document Change Notice 253
Who Signs What 255
Empower the Change Team 257
Change Impacts 257
Mark Ups in Production 258
Effectivity 258
Effectivity Responsibility 261
The Effectivity Pipeline 263
Disposition of Old Design Parts 264
Effectivity Planning 265
Effectivity and the Parts List 266
Effectivity/Make to Order 268
Effectivity/Batch Manufacturing 268
Sequencing Parts List Changes 268
Sequencing Changes to Part Design 269
Tracking the Change 271
Status Accounting or Traceability Reports 272
Change Modeling and Testing 273
ECO Package Revisions 274
Change Forms 274
ECO Online 276
Form Instruction – ECO 276
Facts Database 282
Cultural Change 282
Chapter 11 - Fast Change 284
Why is Process Speed Important? 284
Bone Pile Reduction and Other Benefits 286
Measure the Change Process Time 287
Publish Change Time Measurement 287
Change Process Points to Measure 289
Change Process Phases 291
Revision of Master Documents 291
Set Change Throughput Goals 293
Measure Volume and Reduce Backlog 294
Managing for Fast Change 296
Significance of Change Speed 298
Chapter 12 - Process Improvement/Work Flow Diagrams 300
Trolls 301
Establish Key Process Metrics and Publish Them 305
Design Change Process Improvements 305
Missionary Team Leader 306
Steps to Reinvent a Process 306
Continuous Improvement or Reinvent 308
Fast Change Work Flow 309
Change Work Flow Diagram 311
Engineering Work Flow 311
Point of No Return – Technical Release 313
Change Checklist 314
CM Change Work Flow 315
Manufacturing (Implementation) Work Flow 317
Quality Factor 319
A Case Study 320
Continuous Improvement 323
CM Implementation Critical Success Factors 324
System Redesign is Not Easy 325
Chapter 13 - Process Standards and Audits 326
CM Policy 328
Writing and Formatting Standards 329
Best Practice for a Standard 332
Subjects to Standardize 333
Procedures 334
Procedure in a Flow Diagram 337
Standards Manual 337
Training 338
Auditing the CM Processes 338
Audit Plan 339
Audit Frequency 340
Audit Follow Up 340
Train Without a Whistle 343
Chapter 14 - EDC and the Supply Chain 344
Supply Chain is Broken 345
Purchase Order – CM Boilerplate 348
ECO Sent to Supplier 349
Supply Chain Analysis 349
Supplier’s Relationship with the Customer 350
Supplier BOM 350
Purchased Proprietary Assembly Changes 351
Customer Review and Approval of Changes 351
Change Approval Default Clause 352
Chapter 15 - Benchmarking 354
Benchmarking Pitfall 355
How to Benchmark 355
Benchmarking Survey 356
Automotive Suppliers – Summary of Results 356
Survey – 58 University Seminar Attendees 362
Benchmark Report 364
Interpretation of Surveys 365
Chapter 16 - Product Manufacturing Software 366
Current Software 366
Develop Your Own Software? 368
Software Purchased and Tailored 368
Purchasing Software 369
CM’s Role in Software Choices 370
Software Trend 370
Validation 371
Software Question for This Century 371
Manufacturing Company Software (MCS) 372
CM Strategy Summarized 374
Education and Training 375
Reference and Reading List 378
Index 380
| Erscheint lt. Verlag | 11.10.2011 |
|---|---|
| Sprache | englisch |
| Themenwelt | Technik ► Maschinenbau |
| Wirtschaft ► Betriebswirtschaft / Management ► Logistik / Produktion | |
| ISBN-10 | 1-4557-7861-3 / 1455778613 |
| ISBN-13 | 978-1-4557-7861-4 / 9781455778614 |
| Haben Sie eine Frage zum Produkt? |
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