Overview
The ERPlite Engineering Change Order (ECO) module facilitates Engineering Change Control. This tutorial will demonstrate the ECO module by processing a sample change to the multilevel BOM for the product ASY0008 shown below: ERPlite facilitates the creation and updating of multilevel BOM's.
by storing the documentation in a relational database and linking the changes to the Bill of Materials (BOM).
Example: Product management have had several requests for a new Monitor for the ASY0008 system. Based on a marketing study they have requested a monitor that is 50% less expensive and has a contrast adjustment control. The following Engineering Change Request was generated to request a response from the Engineering department:
(Main Menu -> BOM -> SubMenu -> ECO).
The ECO form is multipurpose: Engineering Change Requests, Orders and Deviations. A deviation is simply a limited ECO and will not be discussed further in this tutorial. The tutorial will follow the monitor change request through to completed Engineering Change Order.
Engineering Change Process
Engineering procures samples of competitive monitors and determines that the Samsung Model M1235 comes closest to meeting the requirement. The M1235 costs 33% less than the current monitor, but falls short of the requested 50% reduction. Discussions with marketing indicate that the 1235 will be acceptable.
The Project Engineer creates the item master for the new monitor (CMP0002).
Since the function of the parent item is changed by this new monitor, ASY0008 is reved up to ASY0008A via the ItemMaster.
The BOM is created for the ASY0008A assembly:
Engineering then proceeds to edit the Engineering Change Order before submitting it for approval.
Now, the ECO is edited to show CMP0001 being replaced by CMP0002(and ASY0008 by ASY0008A). Any number of changed, added or deleted components can be listed. Blanks are left where there is no old or new component.
Note that the old and new part numbers are not typed in, they are selected from a pull down menu:
This tight coupling of the data in the ECO with the BOM database dramatically reduces opportunities for human error in implementing ECO's. The part number is picked from a list of approved parts, not just written into the ECO.
Next, the engineer identifies items impacted by the change:
Regulatory approvals, hardware, procedures, manuals.
Then, recommendations are made re disposition inventory: parts on order, stores, WIP, finished goods and customer owned. Decision to track the shipped monitors by destination is recommended. This tracking facilitates customer service support.
Finally, the changed drawings are listed along with a hyperlink to their online location. By double clicking on the hyperlink, the document can be reviewed by any reviewer's PC (assuming there is an intranet). Viewers are available for most documents from the supplier of the document creation software (Microsoft for Word and Excel, Autocad for CAD drawings etc).
Finally, the required signoffs are listed along with the effectivity date:
The signoffs can be electronic if valid in your companies standard operating procedures. Many companies find that signoff confirmation via email is sufficient. However, if ink signoffs are required then the ECO can be printed, once consensus exists, and routed for signoff.
In preparation for release of the ECO to manufacturing, the project engineer verifies the current BOM (ASY0008) that includes the parts changed by the ECO. As soon as the ECO is pending, the "obsoleted" column shows the ECO number(EC50007). This forewarns manufacturing that this BOM is under review.
Perusal of the new revision BOM (ASY0008A), shows the current status and the ECO (EC50007)that documents and authorizes the changes.
With EC50007 released, manufacturing is now authorized to implement as of the effectivity date and other instructions in the document.
The electronic copy of the ECO then is made available to manufacturing for implementation. Since the electronic version is guaranteed to be the most up to date version, there is a dramatic reduction in errors resulting from someone having a printed, out of date copy.