Watts Engineering Documentation Control Handbook

Configuration Management and Product Lifecycle Management
4. Auflage 2011
ISBN: 978-1-4557-7861-4
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 400 Seiten

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

Frank Watts has over forty-eight years of industrial and consultation experience as a design engineer, industrial engineer, manufacturing engineer, systems analyst, project manager, and in management. He founded his own specialist configuration management company to provide specific expertise in product release, change control, bills of material and other engineering documentation control issues.Formally a director of engineering services, a director of operations and a director of manufacturing engineering, Watts has worked for Caterpillar, Collins Radio, Control Data, Storage Technology, UFE and Archive. He has guided the development of engineering change control processes at numerous companies and made significant contributions towards improving new product release processes, installing MRP/ERP systems and new numbering systems, as well as helping companies attain a single BOM database and guided reengineering of CM processes. He is an NDIA Certified Configuration and Data Manager, author of several magazine articles and author of the Engineering Documentation Control Handbook and CM Metrics.

Autoren/Hrsg.

Watts, Frank B.

Inhaltsverzeichnis

1;Front Cover;1
2;Engineering Documentation Control Handbook: Configuration Management and Product Lifecycle Management;4
3;Copyright;5
4;Contents;6
5;Preface;14
6;Chapter 1 - Introduction;20
6.1;What is Configuration Management;23
6.2;Between Engineering and Manufacturing;24
6.3;Configuration Management Ladder;26
6.4;Configuration Management Discipline;27
6.5;Configuration Management System;27
6.6;History of Configuration Management;28
6.7;Organization of Configuration Management;29
6.8;Document Control Function Responsibilities;31
6.9;Configuration Management Function Responsibilities;31
6.10;Distributed Configuration Management;33
6.11;Manager’s Job;33
6.12;Manager of Configuration Management;33
6.13;Organization Within Configuration Management;35
6.14;Configuration Management—What is It?;35
6.15;Summary;38
7;Chapter 2 - Product Documentation;40
7.1;Document Formats and Standards;40
7.2;Body of a Part Drawing;46
7.3;Body of the Assembly Drawing;49
7.4;Controlled Engineering Parts List;54
7.5;Units of Measure;54
7.6;Specification Control and Source Control Drawings;55
7.7;AML – QVL – AVL;55
7.8;General Specifications;58
7.9;Process Design Specifications;62
7.10;Document Groups and Control;63
7.11;Distributed Document Control/CM;66
7.12;Files, Master Docs, and Revision Control;67
8;Chapter 3 - Identification Numbers;70
8.1;Product Numbers and Model Numbers;71
8.2;Part Number Cycle;71
8.3;Version Numbers;73
8.4;Traceability;74
8.5;Serial Numbers;74
8.6;Part Numbers;75
8.7;Classification Coding;76
8.8;Naming Convention;77
8.9;Preferred and Alternate Parts;77
8.10;Significant vs Non-Significant Part Number;77
8.11;Recommended Part Number;78
8.12;Sketch Numbers;80
8.13;Part Number Assignment;81
8.14;Changing the Part Numbering System;82
8.15;Revision Numbers and Letters;83
8.16;Revision Levels;85
8.17;Page Revision Levels;86
8.18;Change Identification Number;86
8.19;What Gets a Part Number;87
8.20;Item Marking;88
8.21;Labels and Stickers;89
9;Chapter 4 - Interchangeability and Service Parts;92
9.1;Interchangeability Defined;92
9.2;Compatible;94
9.3;Interchangeable Always Applicable?;94
9.4;Service Parts and Assemblies;95
9.5;Interchangeable in All Applications;97
9.6;Interchangeability Examples;97
9.7;Interchangeability Test;101
9.8;Part Number Change Logic;101
9.9;Form and Function;104
9.10;Field Units;105
9.11;PCB Interchangeability/“Bug Fixes”;106
9.12;Interchangeability in Doubt;109
10;Chapter 5 - Bill of Material;112
10.1;BOM Data Responsibility;113
10.2;Data Dictionary;114
10.3;Item Master File;115
10.4;Design Engineering Data;115
10.5;Parent–Component Relationship;117
10.6;Marked-Up Parts List;117
10.7;Manufacturing Data;119
10.8;System Item Codes;119
10.9;Field Support Data;120
10.10;BOM Data Element Criteria;121
10.11;Structuring the BOM;129
10.12;Phantom Coding Solution;132
10.13;Common BOM Structure Problem;133
10.14;Unstructure the BOM;134
10.15;Structure and Pictorial Assembly Drawings;136
10.16;Structuring for Multiple Plant Build;137
10.17;Structuring to Stock an Item;137
10.18;Structuring to Buy an Item;137
10.19;Structuring to Ship Between Buildings/JIT/DFT;138
10.20;Structuring Firmware/Application Software;139
10.21;Structuring the Standard Assembly;140
10.22;One Product Structure;140
10.23;Structure Right the First Time;141
10.24;BOM Evolution;141
10.25;Design for Modularity;143
10.26;Modular Parts List;144
10.27;Modular BOM Benefits;145
10.28;Modular Forecasting and Scheduling;146
10.29;Order-Related BOM;147
10.30;Customer-Configured BOM;147
10.31;The Perfect BOM;147
10.32;Referenced Documents in the BOM;148
10.33;Configurator Software;149
11;Chapter 6 - Teams and Other Foundation Blocks;152
11.1;Cross-Functional Teams;153
11.2;Team Make Up;154
11.3;Team Responsibility;155
11.4;Team Meetings;155
11.5;Team Action List;157
11.6;Team Success;158
11.7;Team Measurement;159
11.8;Design Responsibility;159
11.9;Cognizant Engineer List;161
11.10;Other Function Engineers;162
11.11;Signature Responsibility;163
11.12;Delegated Design;163
11.13;Change Control Boards;164
11.14;Production Process Documentation;169
11.15;Fabricated Part Processing;169
11.16;Assembly Instructions;170
11.17;Process Document Control;171
11.18;Process Control Summary;172
11.19;Sales Document Control;173
11.20;Quality Document Control;173
11.21;Publications;173
11.22;On Time Publications;174
11.23;Lot Control;175
11.24;Shelf Life;176
11.25;Down-Level Drawings;177
11.26;Non-Conforming Material;178
11.27;Field Support;178
11.28;Field Change Order and Kit;179
11.29;Software (SW) and Firmware (FW) Control;180
11.30;ISO/QS/AS;182
12;Chapter 7 - Document Release and Product Lifecycle;184
12.1;Lifecycle Release Phases;185
12.2;Documents Tied to the Release Phase;187
12.3;The Revision Block;188
12.4;Lifecycle Phase Issues;188
12.5;Baseline–Lifecycle Phase Relationships;189
12.6;CM and the Release Process;190
12.7;Product Definition Phase;193
12.8;Product Development Phase;194
12.9;Product Pilot Phase;195
12.10;Product Production Phase;197
12.11;Product Phase Out;197
12.12;Management of the Release Process;198
12.13;Release Status Codes;199
12.14;Release Form and Signatures;199
12.15;Release Checklist;201
12.16;Closing the Gap in Pilot;202
12.17;Catch-22;203
12.18;Lifecycle Release Process;203
12.19;Lifecycle Process Tasks;203
12.20;Lifecycle Release Flow Diagram;205
12.21;Measure the Lifecycle Process Time;207
12.22;Release Process Visibility;208
13;Chapter 8 - Change Requests;210
13.1;Field Failures;211
13.2;Reliability and Other Test Data;212
13.3;Material Review Boards (MRB);212
13.4;Production Problems;213
13.5;Can Anyone Originate a Change?;213
13.6;Request for Change;214
13.7;Request Form Instruction;214
13.8;Avoid Temptation;217
13.9;Request Process Design;218
13.10;Request Flow/Procedure;218
13.11;Request Process Measurement;220
13.12;Request Action Items List;220
13.13;Summary;221
14;Chapter 9 - Change Lifecycle Cost;222
14.1;Cost Estimating a Change;223
14.2;Design and Development Cost;223
14.3;Manufacturing and Field Costs;223
14.4;Materials and Parts Costs;223
14.5;Cost Policy;224
14.6;Who Estimates Change Cost;224
14.7;Change Cost Payback;225
14.8;Which Requests/Changes to Estimate;226
14.9;Change Cost Form;226
14.10;Dollar Approvals;229
14.11;Charge-Back of Costs;230
14.12;Estimates Without Delay;230
15;Chapter 10 - Change Management;232
15.1;Why Change?;234
15.2;Change Types;235
15.3;Deviations, Waivers, Off-Specs, etc.;236
15.4;Change Urgency;238
15.5;Class of Change;241
15.6;Fixes in a Change;242
15.7;Software Changes;243
15.8;What Goes into the ECO Package;244
15.9;Distribution of the ECO;246
15.10;Depiction of Adds and Deletes;247
15.11;Flag Notes;249
15.12;Mark Up Standard;249
15.13;Same As Except;251
15.14;Change Revision Drafting;252
15.15;Queuing Changes;253
15.16;Advanced Document Change Notice;253
15.17;Who Signs What;255
15.18;Empower the Change Team;257
15.19;Change Impacts;257
15.20;Mark Ups in Production;258
15.21;Effectivity;258
15.22;Effectivity Responsibility;261
15.23;The Effectivity Pipeline;263
15.24;Disposition of Old Design Parts;264
15.25;Effectivity Planning;265
15.26;Effectivity and the Parts List;266
15.27;Effectivity/Make to Order;268
15.28;Effectivity/Batch Manufacturing;268
15.29;Sequencing Parts List Changes;268
15.30;Sequencing Changes to Part Design;269
15.31;Tracking the Change;271
15.32;Status Accounting or Traceability Reports;272
15.33;Change Modeling and Testing;273
15.34;ECO Package Revisions;274
15.35;Change Forms;274
15.36;ECO Online;276
15.37;Form Instruction – ECO;276
15.38;Facts Database;282
15.39;Cultural Change;282
16;Chapter 11 - Fast Change;284
16.1;Why is Process Speed Important?;284
16.2;Bone Pile Reduction and Other Benefits;286
16.3;Measure the Change Process Time;287
16.4;Publish Change Time Measurement;287
16.5;Change Process Points to Measure;289
16.6;Change Process Phases;291
16.7;Revision of Master Documents;291
16.8;Set Change Throughput Goals;293
16.9;Measure Volume and Reduce Backlog;294
16.10;Managing for Fast Change;296
16.11;Significance of Change Speed;298
17;Chapter 12 - Process Improvement/Work Flow Diagrams;300
17.1;Trolls;301
17.2;Establish Key Process Metrics and Publish Them;305
17.3;Design Change Process Improvements;305
17.4;Missionary Team Leader;306
17.5;Steps to Reinvent a Process;306
17.6;Continuous Improvement or Reinvent;308
17.7;Fast Change Work Flow;309
17.8;Change Work Flow Diagram;311
17.9;Engineering Work Flow;311
17.10;Point of No Return – Technical Release;313
17.11;Change Checklist;314
17.12;CM Change Work Flow;315
17.13;Manufacturing (Implementation) Work Flow;317
17.14;Quality Factor;319
17.15;A Case Study;320
17.16;Continuous Improvement;323
17.17;CM Implementation Critical Success Factors;324
17.18;System Redesign is Not Easy;325
18;Chapter 13 - Process Standards and Audits;326
18.1;CM Policy;328
18.2;Writing and Formatting Standards;329
18.3;Best Practice for a Standard;332
18.4;Subjects to Standardize;333
18.5;Procedures;334
18.6;Procedure in a Flow Diagram;337
18.7;Standards Manual;337
18.8;Training;338
18.9;Auditing the CM Processes;338
18.10;Audit Plan;339
18.11;Audit Frequency;340
18.12;Audit Follow Up;340
18.13;Train Without a Whistle;343
19;Chapter 14 - EDC and the Supply Chain;344
19.1;Supply Chain is Broken;345
19.2;Purchase Order – CM Boilerplate;348
19.3;ECO Sent to Supplier;349
19.4;Supply Chain Analysis;349
19.5;Supplier’s Relationship with the Customer;350
19.6;Supplier BOM;350
19.7;Purchased Proprietary Assembly Changes;351
19.8;Customer Review and Approval of Changes;351
19.9;Change Approval Default Clause;352
20;Chapter 15 - Benchmarking;354
20.1;Benchmarking Pitfall;355
20.2;How to Benchmark;355
20.3;Benchmarking Survey;356
20.4;Automotive Suppliers – Summary of Results;356
20.5;Survey – 58 University Seminar Attendees;362
20.6;Benchmark Report;364
20.7;Interpretation of Surveys;365
21;Chapter 16 - Product Manufacturing Software;366
21.1;Current Software;366
21.2;Develop Your Own Software?;368
21.3;Software Purchased and Tailored;368
21.4;Purchasing Software;369
21.5;CM’s Role in Software Choices;370
21.6;Software Trend;370
21.7;Validation;371
21.8;Software Question for This Century;371
21.9;Manufacturing Company Software (MCS);372
21.10;CM Strategy Summarized;374
21.11;Education and Training;375
22;Reference and Reading List;378
23;Index;380