Configuration Management J. M. McCarthy Fall 2003

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Configuration ManagementJ. M. McCarthy Fall 2003

• Overview of Configuration Management
• Engineering Documents
• Form of an Engineering Document
• Part Number Structure
• Bill of Material
• Mini Baja Examples
• Change Control Process

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Overview of Configuration Management

• Organize Engineering information
• Provide a systematic or organized approach to
  planning, identifying, controlling, and
  accounting for the status of a products
  configuration from its inception throughout its
  intended life.
• Assign Part Number
• Provide numbering system to identify the
  components and types of documentation for a
  product.
• Release Documents
• Identify part specifications are complete and
  to be integrated into the system Bill of
  Materials.
• Change Control
• Maintain the system by which design changes are
  requested, completed and integrated into the Bill
  of Materials.

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Engineering Documents

• Requirements Document (Input)
• Design input means the physical and performance
  requirements of a product that are used as a
  basis for product design.
• Assembly Drawings
• The assembly pictorial
• Assembled dimensions and tolerances
• Notes and Specifications
• Part Drawings (Fabricated)
• Specification of the features and characteristics
  of a part to be manufactured. Dimensions and
  tolerances and material must be prescribed.
• Part Specifications (Buy)
• Specification of the features and characteristics
  of a purchased part.
• Parts Lists
• List of all the parts needed for an assembly.
• Verification Tests
• Verify performance of the design against every
  requirement (input).

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Engineering Documents

• Approved Manufacture List (APL)
• Specification Control Drawings that show the
  acceptable supplier(s) for each part number.
  This list is refer to as APL.
• Drawings do not have to be revised each time a
  supplier is added or deleted.
• Must be controlled in such a way that Design
  Engineering, Manufacturing, and Quality
  Assurance, all agree to any vendor changes on the
  list.
• Specification Control Drawings can negotiate a
  better package for the company when the supplier
  does not know who the competition is.
• Bill of Materials (BOM)
• One single data base
• Must be 100 accurate
• Allows the accurate determination of the cost
  each specific product.
• Important a tool for defining the system that
  is for sale.
• Allows accurate scheduling of manufacturing.

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General Form of an Engineering Document
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Form of an Engineering Document
Title Block
MATERIAL
FINISH
PROPRIETARY NOTE
DRAWING SIZE
COMPANY LOGO
CAGE
DRAWING TYPE
AUTHOR
ITEM DESCRIPTION
CLASS CODE
PRODUCT (ORIGINAL USED-ON)
PAGE ___ OF ___
PART NUMBER
DRAWING DASH
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Form of an Engineering Document
Revisions Block
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Form of an Engineering Document
Body

• Pictorial
• Dimensions and tolerances
• Notes and Specifications

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Part Number Structure
Part Number The numbers are to be assigned to
specifications, parts, assemblies, parts lists,
test procedures, and to the product as a whole in
order to precisely identify them. Minimize the
use of a Part Number as a Code It is tempting
design a part number as a code that describes the
part in some way. This should be avoided, it
introduces a level of complexity in the
assignment of numbers that is not necessary. At
the top-level many companies use a code to
identify various models of a given product but it
should end there
Significant (Number Code) Non Significant (Just Numbers)
Must Publish Code Book No Code Book
Misinterpretation Likely Eliminates Interpretation
Longer Harder to Memorize Shorter Easier to Memorize
More Error Prone Fewer Errors
Categories Usually Breakdown No Categories Lasts Longer
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Part Number Structure

• Format
• Prefix - Number - Dash Number
• Prefix
• blank Part or component
• AY Assembly drawing
• PL Parts list
• SP Specification, notes, tests
• Dash Number
• -xx denotes item on list of similar items on
  a single drawing that differ in only one or more
  dimensions.

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Bill of Material (BOM)

• Data base of all parts
• Part Number
• Description
• Engineer
• Quantity
• Item

• Size
• Weight
• Unit of Measure
• Used on

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Bill of Material (BOM)

• Indented by subassemblies

400 Braking system 410 uprights 411 Mounting
bolts 412 Nuts 420 calipers 421 Mounting
bolts 422 Brake pads 430 brake discs 440 hubs
(4) 450 tires (4) 460 rims (4) 470 master
cylinder 471 brake cables 472 brake
fluid 480 brake petals
Assembly
Detailed Parts
Subassemblies
Note Last year Mini-Baja chose to encode the
subassemblies in their part numbering system
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Mini Baja Engineering Drawing
Format
01 650 Release for Pilot
01/02/03 EDC
02 722 Chg Mnt Config
01/08/03 EDC
A 817 Release to Prod
01/15/03 EDC
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Mini Baja Part Numbers
Parts List
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Mini Baja Indented Bill of Material
Indented Bill of Material
100 Chassis 110 Steel pipes 120 Vehicle
cover 130 Seat 131 Safety belts 132 Seat
mounts   200 Suspension 210 Suspension Arms
(4) 211 Suspension mounts (8) 212 Nuts 213
Bolts 214 Rear toe adjustment 215 Chamber
adjusters 220 Shocks 300 Powertrain 310
Constant Variable Transmission 311 belt 312
drive shaft 313 Mounts 320 Engine 321
Fuel 322 Mounting Bolts
400 Braking system 410 uprights 411 Mounting
bolts 412 Nuts 420 calipers 421 Mounting
bolts 422 Brake pads 430 brake discs 440 hubs
(4) 450 tires (4) 460 rims (4) 470 master
cylinder 471 brake cables 472 brake
fluid 480 brake petals   500 Steering
system 510 rack pinion 520 Steering
wheel 530 Steering shaft 540 Tie rods 550
Bellows 560 gas petals
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Release Process

• Product and Document Release
• The process that approves the integration a
  drawing, specification, or other document
• into the Bill of Material of the product.
• This means that identifying a part is a two step
  process.
• 1. Obtain a part number from Configuration
  Management as the parts is being designed.
• 2. Verify that the part is appropriate for the
  product and Release to Manufacturing.
• Configuration Management has a list of all part
  numbers assigned,
• AND as separate list of list of part numbers in
  a give product called the Bill of Materials
• for that product.
• A release memo lists the documents associated
  with the part to be released with approval
  signatures
• by Engineering and Manufacturing.
• Revisions
• Prior to Release revisions to drawings and
  other documents should be identified
• with numbers, such as Rev 1, Rev 2.
• After Release revisions should be identified
  with letters, Rev. A, Rev. B.

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Change Control
Change Control The process of identifying
and making changes to released parts and
documents. Engineering Change Request
(ECR) This is a numbered list of design changes
requested by anyone associated with the
organization. The usual sources are
manufacturing, sales and service. Engineering
Change Order (ECO) The document that identifies
(1) the current part or document, and (2) the
changed document, with a description of the
reasons for the change. This is reviewe dby the
Change Control Board. The change approval is
combined with the release memo for the part at
which point the old part is removed and the new
one integrated into the Bill of Materials.
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Change Control Process
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Configuration Management SOP
ISO Standards require a Standard Operating
Procedure for Configuration Management. All
Standard Operating Procedures for a Company are
to have the same format. For example Purpose
Scope Responsibilities Reference
Documents Definitions Procedure Records Attach
ments (Flowchart)