Engineering Change Requests (ECR): New Best Practices
Best Practices for ECRs
Introduction - Engineering Change Requests (ECR)
Engineering Change Requests (ECR) are a critical aspect of vehicle product development and parts release. Therefore, proper handling of ECRs ensures that changes are implemented efficiently, effectively, and with minimal disruption to the production process.
Hence, the purpose of this article is to discuss the best practices and methods for handling Engineering Change Requests (ECR), covering key elements such as timeline management, root cause analysis, option generation and verification, incorporation into production, and design failure mode and effects analysis (DFMEA) and process failure mode and effects analysis (PFMEA). Moreover, we will also illustrate these practices with a real-world example.
Timeline Management - Engineering Change Requests (ECR)
Managing the timeline of an ECR is crucial to ensure that changes do not delay the overall project. The timeline should include:
- Initial Assessment: Quickly assess the urgency and impact of the ECR
- Root Cause Analysis: Identify the underlying issues causing the need for change
- Option Generation and Verification: Develop and test potential solutions
- Approval and Documentation: Obtain necessary approvals and document the changes
- Implementation: Incorporate changes into production time line for the released parts
Best Practice: Use project management tools to track the timeline and milestones for each stage of the ECR process. Regular status meetings and updates can help keep the team aligned and on schedule.
Root Cause Analysis - Engineering Change Requests (ECR)
Fundamentally, understanding the root cause of the issue prompting an ECR is essential for developing effective solutions. Followed by techniques such as the 5 Whys, Fishbone Diagram, and Failure Mode and Effects Analysis (FMEA) can be used to drill down to the root cause.
Best Practice: Assemble a cross-functional team to conduct the root cause analysis. Sequentially, this team should include members from engineering, quality, production, and any other relevant departments. Consequently, this collaborative approach ensures a comprehensive understanding of the issue (ECR).
Generation of Options and Verification of Chosen Solution Set - Engineering Change Requests (ECR)
Once the root cause for the ECR is identified, generate multiple potential solutions. Each option should be evaluated for feasibility, cost, impact on production, and potential risks.
Best Practice: Use a decision matrix to compare the options against key criteria. Furthermore, prototyping and simulation tools can help verify the effectiveness of each solution. Followed by selection of the solution that best meets the project’s requirements and constraints. (Generally, the DFSS – Design for Six Sigma methodology is highly advisable.)
Incorporation into Production - Engineering Change Requests (ECR)
Generally, incorporating the chosen solution (for the ECR) into production involves updating design documents, production processes, and quality control procedures. Therefore, it is essential to communicate changes to all stakeholders and ensure that the implementation is seamless.
Best Practice: Develop a detailed implementation plan that includes:
- Updated design and process documents
- Training programs for production staff
- Quality control checklists
- Communication plans to inform all stakeholders
DFMEA and PFMEA for Engineering Change Requests (ECR)
Inherently, Design Failure Mode and Effects Analysis (DFMEA) and Process Failure Mode and Effects Analysis (PFMEA) are systematic methods for evaluating potential failures in the design and production processes, respectively. Consequently, these analyses help identify and mitigate risks associated with the ECR.
Best Practice: Conduct DFMEA and PFMEA sessions for the new design and process changes. Document the identified risks and mitigation strategies. Regularly review and update the FMEAs as part of the continuous improvement process.
Real-World Example: Handling an ECR in Automotive Design
Consider a scenario where an automotive manufacturer identifies a recurring issue with the braking system in a new vehicle model. Sequentially, customer feedback and warranty claims indicate that the brake pads are wearing out prematurely, leading to decreased braking performance. Thus generating the ECR for the corrective action.
- Timeline Management: Generally, the project manager sets up a timeline with clear milestones for assessing the issue, conducting root cause analysis, generating options, and implementing the solution. Sequentially, tegular updates ensure the team stays on track
- Root Cause Analysis: Consequently, a cross-functional team uses the 5 Whys technique and a Fishbone Diagram to determine that the premature wear is due to the material composition of the brake pads, which is not suitable for the vehicle’s weight and braking system design
- Generation of Options and Verification: Furthermore, the team generates several options, including changing the material of the brake pads, redesigning the brake system, and introducing additional cooling mechanisms. Moreover, these options are evaluated using a decision matrix. Additionally, prototyping and testing reveal that changing the brake pad material to a more durable composite offers the best balance of cost and performance
- Incorporation into Production: Consequently, the chosen solution is documented, and updated design and process documents are created. Sequentially, training sessions are held for production staff to ensure they understand the new material and any changes to the manufacturing process. Additionally, Quality control checklists are updated to include checks for the new material
- DFMEA and PFMEA: Furthermore, the team conducts DFMEA and PFMEA sessions to identify potential risks associated with the new brake pad material and updated processes. Moreover, mitigation strategies, such as additional quality checks and supplier audits, are put in place to address these risks
Therefore, by following these best practices, the automotive manufacturer successfully addresses the braking system issue, resulting in improved vehicle performance and customer satisfaction, solving and closing the ECR with proper documentation.
Conclusion: Engineering Change Requests (ECR)
In conclusion, handling Engineering Change Requests (ECRs) effectively is crucial for maintaining the integrity and performance of vehicle products. Best practices in managing ECRs involve meticulous timeline management to ensure timely resolution and minimal disruption to the production schedule.
Furthermore, conducting thorough root cause analysis with techniques like the 5 Whys and Fishbone Diagram is essential for identifying the true source of the problem. Moreover, generating multiple solution options and verifying them through prototyping and simulations allows for informed decision-making. In addition, the chosen solution must then be seamlessly incorporated into the production process, with updated design documents, comprehensive training for production staff, and revised quality control procedures.
Employing DFMEA and PFMEA further mitigates risks by identifying potential failure modes in the new design and processes, ensuring robustness and reliability. Consequently, as illustrated by the automotive braking system case study, these practices not only resolve the immediate issue but also enhance overall product quality and customer satisfaction. Moreover, by adhering to these best practices, engineering teams can navigate the complexities of ECRs with greater efficiency and effectiveness, ultimately driving continuous improvement and innovation in vehicle product development.
References:
- Engineering Change Request – https://en.wikipedia.org/wiki/Change_management_(engineering)
- Design for Six Sigma – https://en.wikipedia.org/wiki/Design_for_Six_Sigma
- Root Cause – https://en.wikipedia.org/wiki/Root_cause_analysis
- Root Cause – Future Discussion Deep Dive – separate topic
- Knowledge Generation – Epistemology – https://georgedallen.com/epistemology-in-engineering-systemic-knowledge/
About George D. Allen Consulting:
George D. Allen Consulting is a pioneering force in driving engineering excellence and innovation within the automotive industry. Led by George D. Allen, a seasoned engineering specialist with an illustrious background in occupant safety and systems development, the company is committed to revolutionizing engineering practices for businesses on the cusp of automotive technology. With a proven track record, tailored solutions, and an unwavering commitment to staying ahead of industry trends, George D. Allen Consulting partners with organizations to create a safer, smarter, and more innovative future. For more information, visit www.GeorgeDAllen.com.
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