Engineering Change Management Systemfor Lincoln Foodservice Products

By Duane YoderBy Duane Yoder

October 12, 2006October 12, 2006

MSE 7000MSE 7000

Professor Steve DusseauProfessor Steve Dusseau

Background Information

• Educational backgroundEducational background• BS PhysicsBS Physics• BS Electrical EngineeringBS Electrical Engineering

• Work ExperiencesWork Experiences• Four years of engineering for Gen Tel of IndianaFour years of engineering for Gen Tel of Indiana• Twenty-three years of engineering experience in a Twenty-three years of engineering experience in a

manufacturing company (Lincoln FP)manufacturing company (Lincoln FP)• Seventeen years in engineering managementSeventeen years in engineering management

Why this project of Change Management?

• My current role on the QAD MFG/PRO My current role on the QAD MFG/PRO ERP implementation team is the PCC ERP implementation team is the PCC Module and Item records Module and Item records

• I currently manage the CAD administration I currently manage the CAD administration and PDMLink implementation and PDMLink implementation

• It is one of the hottest issues at LincolnIt is one of the hottest issues at Lincoln• The ECO process needs to become LeanThe ECO process needs to become Lean

Product Lifecycle Management

• Every product goes through a lifecycleEvery product goes through a lifecycle• The primary phases of a lifecycle areThe primary phases of a lifecycle are

• ConceptConcept• DesignDesign• ReleaseRelease

• Between each phase is a gateBetween each phase is a gate• Concept ApprovalConcept Approval• Design ApprovalDesign Approval

Lifecycle Attributes and Operations

Concept Development

ReleaseDetail Design

Concept A

pproval

Design A

pproval

Phase Attributes•Roles•Access Rules

Gate Attributes•Criteria for Promotion

Gate-Specific Operations•Promote•Deny

Phase-Specific Operations•Submit•Demote

Basic Lifecycle Affects and Effects

Concept Development

ReleaseDetail Design

Concept A

pproval

Design A

pproval

Submit

Promote

Demote

PromoteDeny

Typical Engineering Change Process

What is an Engineering Change?

What is an Engineering Change?

• Change to the Product Structure (BOM)Change to the Product Structure (BOM)• Adding or deleting a partAdding or deleting a part• Changing the quantity of parts in an assemblyChanging the quantity of parts in an assembly

• Change to the Part ItselfChange to the Part Itself• Change of specificationsChange of specifications• Change of approved sourceChange of approved source

• Change of Routing (Steps of Assembly)Change of Routing (Steps of Assembly)• Change of processes or sequencesChange of processes or sequences

What does an Engineering Change Do?

• Changes one or more of the four “F”sChanges one or more of the four “F”s• FormForm• FitFit• FunctionFunction• FeeFee

• The communication of the change is called The communication of the change is called an ECO, PCO, or ECNan ECO, PCO, or ECN

What must the ECO Do?

• Tell Tell whatwhat to change to change• Show Show howhow to make the change to make the change• Tell Tell whenwhen to make the change (effectivity) to make the change (effectivity)• Tell Tell whowho makes the change (define tasks) makes the change (define tasks)• Show Show wherewhere the change is at (documentation) the change is at (documentation)• Tell Tell whywhy the change is made (reasons) the change is made (reasons)

Where is the biggest gap in the Process?

• Effectivity of ChangeEffectivity of Change• Engineering uses revision lettersEngineering uses revision letters• Operations and Manufacturing use datesOperations and Manufacturing use dates

• DoDo not use before, do not use afternot use before, do not use after

• Other methodsOther methods• Use to depletionUse to depletion• Serial numberSerial number• Customer NumberCustomer Number• Lot NumberLot Number

Where is Effectivity Managed at Lincoln?

• Engineering - CAD PDMLink DatabaseEngineering - CAD PDMLink Database• Documentation revision control Check-in and CheckoutDocumentation revision control Check-in and Checkout• Promote and DemotePromote and Demote

• Operations and Manufacturing - MFG/PRO Operations and Manufacturing - MFG/PRO ERP DatabaseERP Database• Implementation by datesImplementation by dates

• Balance inventoryBalance inventory• Meet customer demandsMeet customer demands

One Database or Two?

• Engineering - PDMLink Engineering - PDMLink • Supports more than just engineering documentationSupports more than just engineering documentation• Change management meets CMII requirementsChange management meets CMII requirements• Configurable workflow and roles for matrix organizationConfigurable workflow and roles for matrix organization• Managed locallyManaged locally

• Operations/Manufacturing - MFG/PROOperations/Manufacturing - MFG/PRO• Operations based for date effectivityOperations based for date effectivity• Strong support of operations and businessStrong support of operations and business

The Impact of the Gap

• Engineering documentation remains in queue Engineering documentation remains in queue while new changes are being implemented.while new changes are being implemented.

• Fit becomes an issue when new changes are Fit becomes an issue when new changes are implemented before previous changes are in implemented before previous changes are in production.production.

• Historical Engineering records BOMs do not Historical Engineering records BOMs do not synchronize with production by dates.synchronize with production by dates.

PDMLink

PCC

The Solution - PDMLink for ECO Process

PCC for the EPR PCO Implementation

Bridge the Gap between PDMLink & PCC

Oracle Progressive

ImportProcess

PDMLinkMFG/PROPCC Module

Exported File

As Designed As Manufactured

To be automated at a later date

MFG/PRO and PCC

• The incorporation and implementation of The incorporation and implementation of changes meet operation needschanges meet operation needs

• Historical records of “As Manufactured” Historical records of “As Manufactured” with revision history is always availablewith revision history is always available

• Full ERP functionality is maintained with Full ERP functionality is maintained with Corporate OfficeCorporate Office

The Plan

Conclusion:

• Where one database is preferred the ability Where one database is preferred the ability to take advantage of the benefits of both is to take advantage of the benefits of both is the next best solution.the next best solution.

• Work towards automation and data sharing Work towards automation and data sharing between the Oracle and Progressive between the Oracle and Progressive databases.databases.

• Design the workflow of PDMLink to follow Design the workflow of PDMLink to follow Lean principles.Lean principles.

Questions & Answers

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References:

• Windchill PDMLink Users GuideWindchill PDMLink Users Guide• Donald N Frank, Configuration Mangement in Aerospace and DefenseDonald N Frank, Configuration Mangement in Aerospace and Defense• Microsoft Corporation Microsoft Corporation