Kein Folientitel

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CM Workshop SAP, Palo Alto February 1999
Norman Scobie IBU AD/EC, SAP AG
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Configuration Management - CM
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What is it?

• Configuration management is defined as
• a process for establishing and maintaining
  consistency of a products performance,
  functional and physical attributes with its
  requirements, design and operational information
  throughout its life.

• Effective CM answers the questions
• What should it be?
• What is it?
• Are they consistent?
• ...for life!

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Change Management
Current Baseline
New current design baseline
Change Identification
Need for change
Approval
Evaluation Coordination
Documented Change Request
Approved Change
Implementation Verification
Updated Product Baseline Data
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Cost Control

• What will it cost and what did it cost?
• Cost visibility and control at various levels is
  part of an integrated CM process in an ERP system
• Estimated costs to assess change impact are
  necessary as well as continuing control of those
  costs for major change (actual costs).
• SAP has a development project called Claim
  Management to deal with this area.

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Configuring for Life

• Configuration identification and relationships in
  the product lifecycle

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Main Lifecycle Phases
Configuration Management has to be performed in
all 3 main lifecycle phases. The Configuration
data has to be managed across these phases as
well as within to provide consistency
Design
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Sub phases in the lifecycle
Each main phase, will be defined by a progression
of configurations used for specific purposes
as built
as planned
as designed
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Configuration Identification - Baselines

• Central aspect of CM
• Specific status of a configuration item
• Life-cycle Control

as designed
as planned
as built
as maintained

• Baseline Attributes
• Known and defined point of reference
• Agreed reference configuration at a milestone or
  a specific time
• Frozen set of referenced objects and
  relationships (logical bracket)
• Data formally protected from change

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Support of a product life cycle means covering
status and functionality across different areas...
as maintained
as built
as planned
as engineered
as designed
as shipped
as sold
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... across different processes
TCS / MRO
Design Changes Perfective Adaptive Corrective
Production Process Changes
Maintenance and Service
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---and with different relationships...
As designed
Change04
Config Item.d1 initial
Config Item.d2 initial
Config Item.d2 baselined
Change07
Change 01
As planned
Config Item.p2 initial
Change08
Change09
Change10
Config Item.b1 baselined
Config Item.b1 in work
Successor - Predecessor relationship
Derived relationship
1n
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Customers have different profiles
Maintenance Organisation
Design, Manufacture and Maintenance Organisation
Manufacturing Subcontractor
Design Consultancy
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Configuration Managementwhere are you today?
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Configuration Management in R/3
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R/3 today - Objects relevant for CM

• Documents
• Material Master
• Bill of Material
• Routings
• PRT
• Orders
• Projects
• Equipment
• Functional Location
• Maintenance Plan
• Maintenance Strategy

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R/3 today - Life just gets worse with age.
Documents Material Master Bill of
Material Routings PRT Orders Projects
Equipment Functional Location Maintenance Plan
Maintenance Strat
Documents Material Master Bill of
Material (Equipment) (Functional Location)
Documents Material Master Bill of
Material Routings PRT Orders Projects
(Equipment) (Functional Location)
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R/3 today - Some of the objects have sub-types
Bill of Materials Material Equipment
Functional location Standard Sales order WBS
(Project) Document BoM
Routings / Task Lists Reference operation
set Inspection plan Gen. maintenance task
list Equipment task list Master recipe Rate
routing Reference rate routing Functional
location task list
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R/3 today - Configuration Identification

• Structured Object Configuration
• BOM
• Routing
• Effectivity
• Variant configuration
• Object Links
• Document Management System
• Product Structure Browser

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R/3 today - Structured Object Configuration

• Effectivity and variant configuration define a
  flexible basis for product configuration for BOMs
  and Routings

One set of Master Data defines many individual
products!
Master Data
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R/3 today - Object Links
Materials
Materials
Materials
Documents
Functional Locations
Functional Locations
Functional Locations
TEXT TEXT TEXT T EXT TEXT TEXT TEXT TEXT TEXT
TEXT TEXT TEXT T EXT TEXT TEXT TEXT TEXT T TEXT
TEXT TEXT TEXT T EXT TEXT EXT
Equipments
Equipments
Equipments
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R/3 today - Object Links
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R/3 tomorrow - CM Development areas

• ability to freeze a structured configuration
  (collection of objects) of various R/3 object
  types independent of object links
• requires enhanced object functions for CM
  especially baselining at object level
• a single tool behaving
• consistently across the life-cycle
• flexible to match the requirements of a
  particular phase
• able to support analysis and transfer of
  information across phases

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Material Master Versions

• A related CM project in SAP
• Historical R/3 issue is that Material Master
  Revision Levels provide no true material
  versioning.

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R/3 4.5 - Configuration Control -Engineering
Change Management

• Control Process
• Object Management Records
• ECR / ECO
• Workflow
• Digital Signature
• Release Control
• ECM Structure
• Change Hierarchy
• Effectivity

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R/3 4.5 - Configuration Control ECM Control
Process

• Object Management Records (OMR)
• available for BOM, Material, Routings
• captures change texts for that object
• centre of workflow for the object

ECM
RefObject_1
OMR Object_1
OMR Object_2
RefObject_2
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R/3 4.5 - Configuration Control ECM Control
Process

• Object Management Records

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R/3 4.5 - Configuration Control ECM - Release
Control

• Release Key (optional)
• value set in ECM header data
• controls validity of an ECM for
• Simulation
• Costing
• Planning
• Production
• Until released the ECM remains
  invalid for an application

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R/3 4.5 - Configuration Control ECM - Change
Hierarchy

• Structuring Change Masters

Effectivity Release Key
Change Leader
Change Package
Change Package
Change Package
Workflow
Objects
Objects
Objects
Objects
Objects
Objects
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Change Hierarchy - Reporting
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R/3 4.5 - Configuration Control Workflow in ECM

• R/3 ECM is strongly supported by Workflow
  functionality

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R/3 4.5 - Configuration Control Effectivity
Effective for all versions of PRODUCT
PRODUCT
STANDARD_1
Plant Effectivity Plant 0001 from 01.02.98
Plant 0002 from 01.06.98
Mutually exclusive - only one to be selected
STANDARD_2
SPECIAL A
SPECIAL B
Customer Effectivity Customer BA, Serial 5
SPECIAL C
Model/Unit Effectivity Model UH-1, Serial 50
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The MRO Process- Development issues
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An example of an MRO ProcessKLM CFM56 Engine Shop
Engine Delivery
Parts Inspection
Incoming Inspection
Disassembly
Cleaning
Acceptance, Breakdown and Inspection
Certified Task Lists
Interchange-ability
Parts Repair
Assembly Preparation
Assembly
Delivery
Repair, Rebuild and Delivery
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Features of the process

• Characterised by the use of configurations as a
  fundamental element of the business process
• Full traceability
• what is it?
• how was it done?
• who did it?

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CM Issues at KLM

• Engine Configuration required for various reasons
• Target configuration
• as-received configuration
• Part exchanges
• as-shipped configuration
• Document Control
• Illustrated Parts catalogue
• Service Bulletins
• Airworthiness Directives
• Part Interchangeability
• defined at location level in IPC

• Part Configuration Control
• full traceability of each part for
• which part
• location
• work performed
• who performed work
• Task List (Routing) Configuration Control
• task list configuration control in PM Order
• task list certification
• authorisation of operator

ALL INFORMATION TO BE KEPT FOR LIFE OF ENGINE AND
INDIVIDUAL PARTS !
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Configurations at KLM ECM in R/331H - time
based effectivity
They each represent a point in time in the shop
visit
Equipment BOM
BOM configuration at a specific point in time
i.e. shop visit, can then be identified in the
BOM via the ECM number
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ANZES Solution - SB/AD implementation
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Change Management - EIA 649
Current Baseline
New current baseline
Change Identification
Need for change
Evaluation Coordination
Documented Change Request
Approved Change
Implementation Verification
Updated Baseline Data
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Plant Maintenance Structure
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Installed Base
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Implementating ECM and PM integration

• Customers currently link ECM to the applications
  via workflow, add configuration data using
  classification and add their own code extensions
  for status accouting.
• Limitations today in R/3 are
• workflow can link functions but cant provide a
  natural history of the process
• adding own code is difficult and time consuming
• The CM Motivation
• add value to the business process by
• improving process automisation/integration
• improving implementation times

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ECM integration to PM

• Changes to actual equipment occurs in service and
  these are represented by PM Technical Objects in
  R/3 (Functional Locations and Equipments)
• Changes in industry often flow down from design
  to the operating engineering objects described by
  FLs and Equis in R/3.
• The requirement is to link Notifications, PM
  Orders, Functional Locations and Equipments to
  ECM to protocol the following
• initiation of the a change process by
  notification
• confirmation/reporting when changing technical
  objects.
• Also to be considered, Maintenance Plans and
  Strategies

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SB/AD or design change implementation
Notification
Eng. Change Master
PM/QM Order
Service Bulletin Airworthiness Directive
Equipment
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Process example detailed
Effectivity on ECM For FLs and Equis, ECM
Master logs implementation when the PM order is
confirmed.
Analysis
Notification Items Materials
Eng. Change Master Design/Production Object
List Materials Documents BOMs Routings etc.
Maintenance Objects Plans Strategies Items
Technical Objects FLs Equis
Fault Report
Maintenance objects control via ECM
functionality? Change existing plans/strategies Cr
eate new plans/strategies
Generate change master for Notification or DMS
Design Change
SB / AD Document Master created in DMS
PM/QM Orders
PM/QM Orders

• Auto Order generation
• when initiated e.g. at time of maintenance or
• generated immediately?
• Auto Task list generation?

PM/QM Orders
Reporting required? ECM Implementation
status What is the change status of an equipment
FLs
FLs
FLs
1. A fault causes a design change. 2. Analysis of
Notification shows design change required 3. ECM
generated to define design/production change 4.
The change of Docs, Materials, etc. is controlled
via ECM. 5. The change has to be implemented
in exisiting technical objects (FLs,
Equis). 6. Status History is required in ECM to
answer - when/which objects have been
changed? 7. History is required in
FLs/Equipments to answer - when/which changes
have been implemented?
Equipments
Equipments
Equipments
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Effectivity
Service Provider
Update to as-planned configurations for shop
visits
Orders to be generated at time of shop visit
Configuration Service? If company provides a
config. Service, check effectivity and advise
operators
Ffgdfgsdghd dghghfghfghf rhrhrhhfghfdgh
SB/AD
Operator
Check fleet for effectivity, If affected issue
Notifications for work to be performed
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Configuration Item
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Configuration Item - SAP Concept for R/3

• Design Goals
• The configuration object
• CM functions
• Configuration Life cycle
• Design
• Claim Management

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CM in R/3 - Design goals I
Material
Design
BOM
Plant
Routings
Product
structure
Variant
MRP
configuration
planning
definition
PVS
Purchase
Functional
order
location
Document
Equipments

Production
Production
PP-Order
PI-Order
Foreign
Shipment
procurement
Maintenance
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CM in R/3 - Design Goals II

• Baseline of product structure
• Enhanced structure navigation and handling
• History of product definition through complete
  life cycle
• Automatic generation of configuration data
• Cost control of changes

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CM in R/3 - Fixing objects

• Material version
• BOMs and Routings
• Baseline marker on BOM
• Snapshot
• Date/Time
• Complete physical copy
• Version tied to Material Master versions

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CM in R/3 - Fixing objects

• Versions
• Durable storage of different status of an object
  at one time
• Fixing different status of configuration items in
  versions
• Each version has its own status network
• Only specific baseline status prevents changes
  from object

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CM in R/3 - Design Goals III

• Change Management controls configuration object
• keeping history
• trying to get selected state by calculating
  changes with a base and a list of change
  documents
• Attach workflow to support flexible processes.
• Different users with specific roles have specific
  tasks
• Separate Change Management on referenced objects
• Issues
• Date shift of change numbers, Serial number shift
• Observer - fixed flag in objects

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CM in R/3 - Design Goals IV

• Effectivity controls configuration objects
• The configuration object is effective (new
  Effectivity Rel. 45A)
• Parameter effectivity could be used for (e.g.)
• plant specific effectivity
• department specific effectivity
• The referenced objects also have effectivity data
• Effectivity is dependent from
• status of object
• effectivity definition (Serial number, date,
  lot/size, ...)
• Effectivity is attached to Change Management in
  R/3
• Bring effectivity data to the object itself?
• Customer requirement?

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CM in R/3 - Config. Item concept
Effectivity
ECM
Change number
1
Status
Change number
2

network
Configuration Item Header
Contract data
Workflow
Documents
User

Role
Change proposal
User

Role
Change documentation
Distribution
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CM Model - Behaviour - CI Structure
CI Structure
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Requirements (1) Configuration Item -
Configuration Item Version
Config. Item Airbus A300
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Configuration Item Network
Is predecessor of
Is successor of
as engineered
Is origin for
Derived from
as planned
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CM in R/3 - Config. Item data

• Administrative Data
• Version control of baseline/configuration
• Change Management, Effectivity
• Status network
• Workflow
• History data, Change documentation
• Structure definition
• set of references to objects -gt narrow set of
  data
• set of references to relations between referenced
  objects
• stable vs. loose reference
• different depth of structure explosion
• Cost data - Claim Management

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CM in R/3 - Objects in a Config. Item Structure I

• Basic data
• Material (w/wo serial number), BOM, Routings,
  Documents
• Variant configuration data and classification
• object relationships, characteristics
• Plant Maintenance structure data
• Functional locations, Equipment (others?)
• Project data
• WBS, WBS elements, activities, network

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CM in R/3 - Objects in a Config. Item Structure II

• PDM
• PVS - Product variant structure
• QM data
• Test plans, QM certificate
• Orders
• Customer order, production order, process order,
  Purchasing
• Miscellaneous
• Tooling
• Config. Item
• A Config. Item itself may be referenced by a
  Config. Item structure

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Config. Item - Methods (1)

• Maintain
• Create, Change, Display CI, Archiving

• Configuration Control
• Status management, ECM integration

• Freezing
• Creation of Baselines

• Distribution
• Complete Baselines, Delta Baselines, Distribution
  administrative information

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Config. Item - Methods (2)

• Structure Comparison
• Application independent network (tree) comparison
  tool

• Reconciliation
• Compared structures, Repositioning

• Reporting
• WhereUsed Lists, Object --gt CI, CI --gt Object

• Data exchange
• Import/Export CI definitions, STEP, BAPIs

• Template structures
• Predefined (mandatory) product structures,
  Abstract structure object

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Config. Item Methods - Change Control

• Change Management, Status definition
• Change to a Config. Item controlled by ECM/Change
  management
• Status transitions
• Status Baseline to freeze the configuration
• Check referenced objects for released status
• specific status required to baseline the Config.
  Item
• (semi-)automatic release of referenced objects
• stable reference --gt consistency check
  (effectivity)
• not each version of Config. Item needs to be
  baselined
• Document change process

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Config. Item -Example Status network
Initial
Define structure, Enter admin data
Change structure/admin data
In Work
Send to approval
reject
In Ap-proval
Release all referenced objects
releasedRelease effectivity date
Reactivate
Baselined
Activate for MRP
EffectivityProduction date, S/NMRP date,
S/N, status
Active
Inactivate/Archive
Inactive
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Config. Item Workflow Example
TechnicalReview
Cost Review
Department Review
Planned ChangeDescription
Performchange
Change Control Board Review
Distribute changedefinition
BaselineConfig. Item
Freeze referenced objects
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Config. Item Methods - Reporting

• WhereUsedList, Info system, Reporting
• Reporting Config. Item with user specific
  criteria (filters)
• MRP controller
• production scheduler
• effectivity (serial number, date)
• Change number
• Display reporting results
• as list
• structured
• What objects of an object type are defined in a
  Config. Item?
• WhereUsedList for all referenced objects
• In what Config. Items is an object (e.g. material
  version) used?

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Config. Item Methods - Consistency

• Structure comparison, Reconciliation
• Different versions of a Config. Item exist
• Structures may be very different between
  different baseline levels
• Engineering further develops the engineering data
  after planning got its own copy of the Config.
  Item to start planning tasks
• To bring together different developments we need
  to
• compare the structures to see the differences
• build in the differences to one of the Config.
  Items -gt Reconciliation
• store the predecessor versions of a Config. Item

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Config. Item Methods - Miscellaneous

• Archiving
• Archiving, Deletion, Retrieval, Reload,
  Transparent access
• Config. Item referenced objects
• Config. Item ArchivingDont remove objects
  referenced in other applications
• Application ArchivingDont remove objects used
  in a Config. Item
• Authorisation concept
• Who can see what Config. Item data
• Everybody can see the Config. Item structure, but
  the referenced objects itself are saved by their
  own authority checks
• Restricted view of the Config. Item structure
• WhereUsedList from application objects to Config.
  Items available for everybody?

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Config. Item - User interface
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CM in R/3 - User interface
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CM in R/3 - Config. Item creation
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CM in R/3 - Config. Item ECM integration
Baselined
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Phase Definition
CI Network

• CM Life Cycle - Definable in customising
• defines a specific sequence of life cycle phases
  available for a CI. In a company that produces
  products and maintains products but also
  mainatins foreign products there would be two
  different CM life cycles

Life Cycle Phase As designed As planned As
received As built As shipped As maintained
Life Cycle Production
Life Cycle MRO
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CM in R/3 - as planned to as built
Production/Process order
as planned
as built
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Config. Item - Referenced object changes

• How are we to accomodate object change impact on
  CI data?
• A technical object (e.g. BOM) changes --gt Where
  Used
• One Config. Item
• One version
• Version is baselined --gt Create new version to
  build in changes
• Version is in work --gt changes can be
  incorporated directly
• Multiple versions
• Find correct version(s) to incorporate change
• Different Config. Items
• Parallel incorporation vs. Incorporation at a
  specific time

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Claim Management
Claim Management
Effectivity
ECM
Change number
1
Status
Change number
2

network
Configuration Item
Contract data
Workflow
Documents
User

Role
Change proposal
User

Role
Change documentation
Distribution
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Engineering Work Bench
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Configuration Management - next steps

• Complete prototype for user interface
• Review against CMII best business practice
• Finalise integration requirements with exisiting
  objects an dapplications
• Customer workshops
• Initial user testing (pre alpha standard)
• CMII conference May 1999 in Montreal
• Initial release of enhanced CM in R/3 will be in
  the 2000 release