BOM管理與工變管理
大葉大學產品資訊管理課程
課程第六週
[回顧]E-BOM名詞解釋
E-BOM
Part Master
Component
Assembly
Assembly structure
Alternative Part
Substitutes Part
View
BOM Expansion
Supplier
CPC
CM
Product structure
management
[回顧]What is a BOM?
The bill of materials (BOM) is the
framework to capture and organize
product data.
Read the Article from
[回顧]What is a BOM?
The BOM is a list of each part needed to
create a finished product . In real-world
usage,however, the BOM is a complex
collection of individual pieces of information
and the relationships between them.
The BOM is also a vendor list that specifies
how huge sums of money are spent.
[回顧]What is a BOM?
A Product Structure is a division of parts
into assemblies and components
creating a hierarchical relationship
Assm1
A
1
uses
isFor
Assm2
A
1
Comp1
A
1
Assm1
A
1
supBy
弘光實業
[回顧]What is a BOM?
料號
結構資訊
料號
組成或構成描述資
訊
實體零件的描述資
訊
設定變化的基準
結構有效性
日期有效性
批量有效性
[回顧]What is a BOM?
Engineering BOM Capture and Management
Bicycle
Seat
Seat
Post
Steering
System
Frame
Drive
System
Decal
Handle
Bar
Front
Wheel
Fork Chain Crank Pedal
日期有效性
[生效日期:2002/10/10]
[失效日期:2002/12/10]
[回顧]What is a BOM?
料號
結構資訊
料號
組成或構成描述資
訊
實體零件的描述資
訊
[回顧]What is a BOM?
P-A
結構資訊
P-B
結構資訊
P-B’
結構資訊
P-D
日期有效性
[生效日期:2002/10/10]
[失效日期:2002/12/10]
日期有效性
[生效日期:2002/12/10]
[失效日期:2003/1/10]
日期有效性
[生效日期:2002/11/3]
[失效日期:2003/1/10]
圖示有效性的操作
展開設定
以目前的日期
進行展開
[回顧]What is a BOM? 圖示有效性的操作
P-A
結構資訊
P-B
結構資訊
P-B’
結構資訊
P-D
日期有效性
[生效日期:2002/10/10]
[失效日期:2002/12/10]
日期有效性
[生效日期:2002/12/10]
[失效日期:2003/1/10]
日期有效性
[生效日期:2002/11/3]
[失效日期:2003/1/10]
P-A
P-B
日期有效性
If [now=2002/12/7] Then
[回顧Part & Supplier?
弘光實業
Assm1
A
1
supBy
Start Point of
CPC
CowBoy
supBy
Part Master & Supplier
[回顧]Part & Supplier?
弘光實業
CowBoy
Assm-A
A
1
Assm-A
B
1
拹同研發
[回顧]Part & Supplier?(CPC)
弘光實業
P-A
P-B
P-C
P-D
A實業
B實業
C實業
Information sharing/transportation
Document management
Project management
Change management
All across the Enterprise
boundary
BOM active show
工變管理
Show the flash movie…
工變管理
工變管理的緣起
同義名詞
工變定義
工變的重要性
工變執行方式
ECM範疇
ECM系統效益
工變管理的緣起
Changes to a product occur frequently
in high tech engineering environments,
where initial product designs are often
continuously evolving prototypes, and in
environments facing technological
advances, changes in consumer
demand, and fluctuations in the
availability of components and raw
materials.
工變管理的緣起
Whenever a company creates a product, it
has to be defined and its definition will need
to be kept up to date as changes take place.
Changes to technical products are
unavoidable and an essential part of every
overall product development process.
Effective change management ensures that
technical requirements are clearly defined,
documented and controlled throughout the
product life cycle.
同義名詞
EC - engineering change
ECB - engineering change board
ECC - engineering change control
ECN - engineering change notification,
engineering change notice
ECO - engineering change order
ECP - engineering change
proposal,engineering change package
ECR - engineering change request
工變定義
Engineering change control refers to the
process of controlling how an item is
built. It is controlled by a function that
assures that the process of product
evolution is done smoothly and with
proper authorization.
工變定義
Engineering change management refers
to the process of assigning numbers to
the various changes in a product.
工變定義
Our engineering change process
provides flexibility without compromising
careful control of the manufacturing
process. It's centered on the
engineering change notice (ECN). An
ECN must be entered, approved,
implemented and tracked for all
changes. ECNs may be implemented
immediately, or at a future date.‘
工變定義
All companies have to make changes to
existing products and to products under
development to meet customer requirements.
Engineering changes allow us to manage
these changes efficiently without interrupting
production of existing products. They allow
product and process information such as
models, drawings, BOMs and NC programs
to be updated and activated according to a
user defined schedule.‘
工變定義
Engineering change - an orderly
process for evolving the design of a
product.
爲何會有工變
Customers always have problems and new
requirements
Design engineers want to improve
functionality
Purchasing finds new suppliers
Marketing and sales want lots of new and
modified products
Production implements continuous
improvement
爲何會有工變
Installation staff give input on what is really
important in the field
Customer service collects application
problems and expects quick fixes
Manufacturing engineering wants to reduce
costs
Regulatory authorities constantly change the
rules
Regulatory authorities管理單位(政府機關)
工變的重要性
Engineering changes have to be
implemented with minimum effort and
cost while providing maximum benefits
and quality. Changes have to be made
as fast as possible because our
customers want upgraded product as
soon as possible.‘
工變的重要性
Effective Engineering Change Management
eliminates problems that arise from people not
using the latest version of a document
eliminates problems caused by unauthorized
changes to documents by forcing users through a
formal change procedure
eliminates risk by ensuring appropriate people
know of changes from receiving up to date and
complete information
gives full traceability of all documentation and
relationships'
工變的重要性
Respond to customer needs faster than
competitors [競爭力的來源]
Improve time to market
Be sure you are working with the latest
information [對工程人員來說]
Manage complex and compound documents
and drawings
Be sure the team's information is up to date
and easy to find
工變的重要性
Keep up to date with changing
specifications and requirements [對客戶
而言]
Share accurate, up to date information
with a geographically dispersed team[目
前最需要達成的]
Manage all information including off-line
and paper documents
工變的重要性
Do change impact analysis as far down
as tooling and manufacturing process
costs [透過程序的執行直達最底層]
Inform off-site team members instantly
of changes [Notification]
Communicate effectively and accurately
with downstream users
工變的重要性
Communicate last minute changes to team
members
Link changes to databases for instant
updating
Preview the impact of engineering changes
Drive down review and approval cycle times
Monitor change approval and implementation
progress
Know the status of all change orders
工變的重要性
Reduce change cycle time
Track a large volume of changes
Manage and control product revisions
Manage 'as designed' versus 'as changed'
Find out about the history of past changes
Find out about planned engineering changes
工變執行方式
Three steps:
Draw a line through the old information and
write in the new information. Date and sign.
Record the effective date for the change in
the change book.
On the effective date remove the old
documents from production and replace
them with the modified documents.
較不重要的變更處理方式
追求時效
工變執行方式
Four steps:
Clarify the problem and the proposed
change
Search for solutions
Select the best solution
Implement the change
工變執行方式
Five steps:
Establish ECR
Analyze ECR
Approve / release ECP/ECO Plan
Execute ECO
Track ECO
一般常見的EC方式
工變執行方式
Seven steps:
Review change, and establish its impact on
data
Estimate the project and financial
implications
Approve execution of change
Change data at the highest level,
progressively increasing the level of detail
工變執行方式
Seven steps:
Identify all affected released documents
and transmitted data files that require
modification
Schedule and perform the change to all
derived data
Release the changes
工變執行方式
Nine steps:
Prepare change proposal
Approve change proposal
Authorize impact analysis prepare impact
analysis
Authorize change order
Prepare change order
Perform signoffs
Approve change order
工變執行方式
Nineteen steps:
Fill in the ECR form
Send the ECR to the technical services
department
Assign a number to the ECR
Send the ECR to the appropriate department
Review problem, identify causes, evaluate
solutions, propose effective date
Send ECR to the technical documentation group
工變執行方式
Ensure that the latest revision of all documentation
is available
Make an ECR package
Send a copy of the ECR package to each
engineering change board (ECB) member
Review the proposed change and investigate
impact
Schedule an ECB meeting
Review all aspects of the ECR
Agree effective date
工變執行方式
Sign the ECR
Send the ECO to the technical
documentation group
Update documentation
Make copies
Distribute copies
File ECO
變更範疇
Just solve my problem
Change the document
Respond quickly to marketing
Look after the changes in this
customer's requirements
Solve all our problems
小
大
ECM系統效益
We'll reduce the cycle time for
engineering changes
We can reduce the costs of change
management
We'll get the benefits of electronic
change information flow
ECM系統效益
We'll get better status information on our
changes
We'll be able to make sure the best
change process is followed
We'll improve engineering change
resource utilization and co-ordination
ECM系統效益
We'll have an audit trail of engineering
change activities
The ECM system will bring engineers on
different sites together to work on
changes
We'll be able to make better change
management plans
ECM系統效益
We'll get more reliable estimates of
change costs and times
An ECM system will make changes
easier to manage
We'll be able to run changes in parallel
and get them done quicker
We'll be more responsive to change
So Many Parts to the ECM
Jigsaw
External organizations want changes
but can't always make them happen
Internal organizations sometimes want
changes, sometimes don't
They all get involved in the EC process
Jigsaw拼圖玩具
So Many Parts to the ECM
Jigsaw
Many computer systems are somehow
related to the EC process
Products and processes, and their
descriptions, are the main focus of ECM,
and their volume is very high
And everyone needs to know and follow
the rules of ECM
External organizations want
changes but can't always
make them happen
Customers and potential customers
Dealers and Distributors
Logistics organizations
Suppliers and Vendors
Regulatory Authorities
這些都是驅動EC的重要角色
Internal Organizations
Sometimes Want Changes,
Sometimes Don't
Design engineering
Purchasing department
Marketing and sales
Manufacturing engineering
Software engineering
Internal Organizations
Sometimes Want Changes,
Sometimes Don't
Manufacturing
Installation organization
Customer service
Standardization organization
Technical services
They all get involved in the
EC process
EC Submitter, Proposer, Initiator
EC Analyst, Evaluator
EC Board member, ECB Chair
Functional organizations
Product Teams
Many Computer Systems
Are Somehow Related to the
EC Process
Order processing requires accurate
updates of product codes and release
status
Planning has to phase out old versions
while phasing in new releases
Many Computer Systems
Are Somehow Related to the
EC Process
Development has to document all
changes consistently
Manufacturing needs accurate and
timely information about all changes
past, present and planned
Customer Service has to communicate
product improvements to customers
Products and Processes, and Their
Descriptions, Are the Main Focus of
ECM, and Their Volume Is Very High
Products, main assemblies and sub-
assemblies
Components and parts
Raw materials
Processes and sub-processes
Product information
Process information
And Everyone Needs to
Know and Follow the Rules
of ECM
Document, Implement, Inform, Check
But some people don't know or don't
follow the rules
Typical Activities in ECM
Requests come in daily from all the players
Screening all requests is an absolute must for
filtering symptoms from root causes
Evaluating the requests can take quite a time
if the information systems are not integrated
Decide what to do to optimize the return-on-
engineering-change
Order the selected changes to be made by
the various functions
Typical Activities in ECM
Actuate the changes
Track the changes through the process
Notify the changes by documenting all
activities and the resulting
consequences
Manage the changes from a supervisory
function
Typical Problems With All
These Activities
Let's start with the worst case: unhappy
customers
Unhappy managers are another, but mainly
internal, problem
Engineers get unhappy with an ECM system
that doesn't work
Time runs out
Costs go up
Quality goes down
Engineers get unhappy with an
ECM system that doesn't work
This overloads them and patches
consume a lot of their energy
As a consequence, innovation and new
product design suffer
A corresponding part of their time is
wasted
Future trends in ECM will
make it even more complex
More locations will be involved
More participants in the process will make it
even more complicated
Key customers will request more and quicker
engineering changes
More market pressure will result in more
change requests and less time to perform
engineering changes
Companies will be swamped by mountains of
Engineering Changes
But with successful ECM
you'll get lots of benefits
Customer satisfaction increases
constantly because the customers start
perceiving that their input somehow
ends up in new or improved products
Happy managers have time for value
adding activities
Effective engineers can focus on
innovation
But with successful ECM
you'll get lots of benefits
Cost reductions become effective much
earlier
Quality improvements become effective
much earlier
Time savings allow all corporate
functions to focus on what really matters
And they all lived happily ever after
Identifying an effective ECM
solution
Plan and establish the ECM Project
Understand the current situation of ECM
Project the future situation of ECM
Map the way forward
Prepare and deliver a successful
presentation to management
Plan and Establish the ECM
Project
Start the project doing the most
important things first
Select the project leader and build the
core team
Map the major project activities, design
a feasible plan and prepare a realistic
budget
Plan and Establish the ECM
Project
Identify major project risks and think
about how to overcome them
counteracting resistance to change
Document the results achieved so far
Organize and internally publish the
project kickoff meeting
Understand the current
situation of ECM
Identify critical products and processes
Identify involved people, organizations and
key roles
Assess the currently used information and
information systems
Collect major problems and quantify related
costs and lost market opportunities
Help management define objectives for the
future ECM process
Project the Future Situation
of ECM
Identify the benefits of quick,
effective ECM for strategic products
and services
Describe future information and
information systems
Project the Future Situation
of ECM
Show that existing problems will be
overcome
Assume that the major problems of
ECM are solved and the new ECM
system is operational.
Project the reduced costs and the
market opportunities that have been
won
Map the way forward
Define alternative
implementation strategies
Determine project costs and
investments and evaluate the
benefits
Build the cost justification
Prioritize the strategies
Write and publish the
statement of requirements
Select the preferred solution
Prepare the project plan and
the corresponding budget
Prepare and deliver a
successful presentation to
management
Explain the project objectives and the metrics
to measure its achievements
Outline the proposed solution
Describe the potential benefits and costs and
the underlying assumptions
Present the cost justification from various
organizational points of view
Demonstrate the approach for managing the
changes to the work environment
Outline the project plan, project team
membership and the budget estimate
Implementing the new ECM
process and systems in less
than 6 months
Detail the chosen solution
Prepare the project support
infrastructure
Run a successful pilot implementation
Use various methods to train users in
several stages
Roll out ECM
Detail the Chosen Solution
Design the new ECM process
Define the required information, documents
and data
Select two systems to pilot, define
requirements for integration with existing
systems
Document key organizational issues, major
roles and main rules
Define new work procedures
Complete the implementation plan
Get management sign-off
Prepare the project support
infrastructure
Define the main support
processes
Assess and select support team
members
Train the team on ECM, change
management and systems
Run a successful pilot
implementation
Implement key processes
Test new ECM rules if they
are different to existing ones
Describe new roles and verify
their acceptance
Prepare a coaching
environment that will stay
available 6 months after
project completion
Link major documents to the
new information structure
Organize a test run of your
two favorite systems
Implement sample
procedures to test
organizational aspects
Use various methods to
train users in several stages
Define training needs and the metrics
for measuring performance
Purchase training material and adjust it
to organizational needs
Select the trainer
Run the initial training
Prepare refresher training to be given
shortly after going live
Roll out ECM
Review the pilot and make any
adjustments
Finalize documents and systems
Integrate the system with the
organizational architecture
Go live
Coach all users
Assistance With ECM
Due to changes in customer requirements,
increases in competitive pressure and
advances in technology, engineering change
management is becoming increasingly
important.
We provide training, consultancy and e-mail
assistance to help companies improve their
engineering change management processes.
Assistance With ECM
We have worked with the engineering
management of companies ranging
from multinational corporations such as
ABB, allied signal, coca-cola, ford, HP,
IBM, Kodak and Xerox to small- and
medium-sized companies.
Assistance With ECM
We have the experience and skills to
advise engineering management and to
enable their project managers and team
members to work more effectively and
meet their objectives. We have the
technical know-how and competence to
be accepted by individual engineers.
Assistance With ECM
Our consultancy covers all the components of
the engineering environment such as:
Vision and strategy
Markets and customers
Products
Corporate structures
Development processes
Company structures
Department structures
Assistance With ECM
Team structures
Human resources
Engineering data
Best practices
Computers in engineering
Project management
Management of change
ECM Related Publications
ECM case studies
A comparative study of engineering change
management in three Swedish engineering
companies.
Peter Pikosz and Johan Malmqvist
(PDF, needs adobe acrobat reader, 92kb, 12 page
article in proceedings of DETC'98, paper no
DET98/EIM-5684, Atlanta, GA, USA.)
ECM articles
cost justification
YAT(5~8)
YAT(5~8)
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