CE ENGINEERING CHANGE ORDER PROCESS – CE-ECO-001

DOCUMENT INFORMATION

Title: Engineering Change Order Process

Document Number: CE-ECO-001(Your Company Standard Naming Here)
Date of Issue:
Process Owner: Components Engineering
Author: Douglas Alexander

APPROVALS
Director Engineering: ______________________________
CEO: ______________________________

DOCUMENT HISTORY

REVISION DATE SUMMARY of CHANGE

1 Initial draft
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1.0 PURPOSE:

To define the required activities in the generation, processing and implementation of an

Engineering Change Order (ECO).

2.0 SCOPE:

This document summarizes the activities involved in the Change Control Process.

3.0 RESPONSIBILITIES:

3.1 Components Engineering is responsible for verifying ECO technical content, cost
evaluation, material disposition, effective date and incorporation into manufacturing
operations.

3.2 Personnel responsibilities are as follows:

3.2.1 Director of Engineering - The primary contact for ECO initialization.

Responsible for coordinating and processing ECOs through initial steps until ECO is
released to Operations for implementation. Also responsible for organizing and
overseeing ECO review meetings. (This varies from company to company)

3.2.2 Development Engineer - Responsible for technical content of ECOs relating to

design and manufacturability of products affected by proposed change.

3.2.3 Planning/Material/Program Manager - Responsible for overall assessment of

change impact on schedules, developing effective implementation plans (including
material usage and procurement requirements) and verifying proposed effective dates
entered on the ECO. They are also responsible for advising Purchasing and Sales of
changes which will affect open purchase orders and open sales orders.

3.2.4 Purchasing - Responsible for notifying all suppliers of changes, cancelling

purchase orders and RFQ's (Request for Quote).

3.2.5 Operations Support - Responsible for ensuring that technical aspects of

changes are incorporated in the manufacturing process (on site and at supplier
facilities) and no degradation of quality or reliability occurs as a result of the change.

3.2.6 Components Engineer - Responsible for all component level compliance with
the ECO specifications, requirements, processes and material disposition. Component
Engineering verifies the technical integrity of the change and ensures, along with the
Process Engineer that proper methods and procedures are in place to incorporate the
change in production.

3.2.7 Mechanical/Printed Circuit Designers - Responsible for updating assembly,

fabrication and schematic drawings.
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3.2.8 Document Control - Responsible for issuing approved ECOs, updating the MRP
system, authorizing and monitoring the update of all Product documentation and the
timely processing and distribution of related documentation (electronic and hardcopy).

4.0 DEFINITIONS:

4.1 Initiator Any TVS employee representing a technical function, with the assistance
of their manager can initiate an ECO.

4.2 Effective Date - Based on type (urgency) of change, effective dates are defined
with consideration to quantity on hand, work in process, and items on order.

4.3 ECR - Engineering Change Request , to be completed prior to ECO

4.4 ECO - Engineering Change Order, Document of final record of change

4.5 ECO Review Team - Participants representing impacted departments plus

administrative leads

4.6 MRP/PCMRP - Materials Requirements Planning/ Part Master Data Base

management system

4.7 Red-lines - Document change mark-ups including schematics, BOMs, and

mechanical and assembly drawings

4.8 R & R - Repair and Return, associated with Customer Service

5.0 PROCESS FLOW:

Refer to Appendix A (Change Control Process Flow Chart). Paragraph numbers

reflect process step numbers i.e. 5.1 = process step number 1.

5.1 Need for an ECO is identified - Change requests come from many sources both
internal and external. Change requests can be verbal or in writing and should be
directed to the engineer responsible for the particular design, product, or document
which may require change.

5.2 Engineer(s) evaluates requested change - The Engineer or Component Engineer

will isolate and identify the root cause(s) responsible for creating the need for a change.
The Component Engineer along with the Responsible Engineer performs the initial
research, modeling and any other background work required to justify the change,
including cost benefit analysis. The evaluation process shall include review for impact to
product performance in the following areas:
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 Design Improvement  Manufacturing Process

Improvement
 Reliability  Specifications/Documentation
Impact
 Serviceability  Component Availability
 Installability  Cost Reduction

5.3 Engineer red lines affected documents - Engineer red lines affected documents
in accordance with the procedures.

5.4 Rework Required ? - Dev/Component Engineer /Sustaining Engineering

determine if proposed change is to be incorporated into work in process and at what
levels of impact including suppliers and customers.

5.4a R & R/Field Affected ? - If installed field units would see this problem
Dev/Component Engineer Engineer(s) work with Customer Service to outline R&R/Field
rework requirements.

5.4b Issue Customer Service Bulletin - Customer Service issues a Customer Service
Bulletin to alert customers of potential problems/hazards if necessary.

5.4c Write Rework Instructions - Dev/Component Engineer(s) writes factory rework

instructions in accordance with standard red-lines; also writes R&R/Field rework
instructions when required.

5.5 Component Problem ? - If proposed change highlights a technical problem with

components or sub-assemblies manufactured by outside suppliers, then the Component
Engineer(s), Development Engineer(s) and Purchasing will be notified of the problem.

5.5a Notify Supplier - Components Engineering and Purchasing will take whatever
advance steps are necessary to best serve the company interests in implementing the
proposed change. This may include the introduction of a Suppliers Corrective Action
Request, (SCAR), or the initiation of a root cause failure analysis effort.

5.6 Generate ECR - Engineer completes ECR and assembles the change package,
including all attachments required for review to detail change for processing by
Operations. The change package shall include all documentation (specifications,
redlines, rework instructions, etc.) necessary to clearly define the change requirements.

5.7 Transfer to ECO/Operations Coordinator - Engineer reviews the technical

aspects of the change with the ECO/Operations Coordinator after passing on the
change package via email for earliest possible review. ECO Coordinator verifies that all
necessary information to complete the ECR is included as part of the change package.
The ECO Coordinator will then submit the ECR to the Engineering management for
approval to proceed to the ECO stage.

5.8 Will change affect Form, Fit, Function, or Reliability ? - The Component
Engineer determines if the change affects Form, Fit, Function, or Reliability in
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accordance with Standard Operating Procedures; the information provided by the

engineer is entered on the ECO form. If a change is determined to be a Record Change
only, Cost Analysis and Material Disposition are not required and ECO is submitted for
approval to the ECO review.

5.9 Cost Analysis, Material Disposition, Effective Date - ECO coordinator works
with the Component Engineer and Material Planner to complete cost analysis, material
disposition, and determine effective date.

5.10 ECO Coordinator completes ECO - ECO coordinator completes ECO and
prepares change package for submission to the ECO review team. ECO must be
complete prior to being submitted to the ECO review team for sign-off.

5.11 Distribute ECO to review team - ECO coordinator distributes advance copies to
ECO review team via Email Notification prior to meeting for change validation and
resolution of potential problems.

5.12 ECO Review team meeting - ECO coordinator arranges and chairs the ECO
review team meeting. The ECO review team conducts a technical and logisitcal review
of the proposed change and verifies that all issues relative to the change are properly
addresssed. Material disposition, rework instructions, and effective date(s) are agreed
upon and verified with MRP.

5.13 Is ECO correct ? - Corrections which are minor in nature are made during the
meeting in order to expedite the ECO. If corrections require additional analysis or input
from other sources ECO is returned to the coordinator for resolution.

5.13a ECO Coordinator corrects and redistributes ECO - ECO coordinator

acquires needed corrections and redistributes to team members for review if needed. If
additional review is not needed coordinator presents ECO at next scheduled team
meeting.

5.14 ECO Review Team Signs off ECO - Acceptance and sign-off must be
unanimous. The preliminary and final “Approval” process will be performed via a routing
procedure. All names required for “approval” will be included in the routing. An “advisory
only” list may also be included in the email notification and routing. Only those
signatures required for approval will be necessary before the ECO is released.

5.15 Class I or cost > $?K - If proposed change is classified as CLASS I (Non-
interchangeable) or cost of change exceeds $?K CEO/VP/Director approval is
obtained by ECO coordinator.

5.15a Is Field Upgrade required ? - If proposed change affects units in the field
customers are to be notified and a field upgrade/rework plan is required.

5.15b VP/Director assigns Program Manager - If field upgrade/rework is required

Product VP/Director assigns program manager and notes name of person assigned on
rework instruction page of ECO.
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5.15c VP/Director signs off ECO

5.16 ECO handed-off to Document Control - ECO coordinator hands off ECO to
Document Control for number assignment and incorporation.

5.17 Document Control assigns ECO # - Operations support will review the ECO for
proper completion, all required routing signatures, all parts or BOMs effected, revisions
are correct, cost sheet is completed, material disposition is addressed, red-lines and
rework instructions are attached where required. After verifying the items listed the ECO
coordinator or Documentation Control will log the ECO, assign an ECO # and begin
processing.

5.18 Document Control updates MRP - Document Control updates PCMRP.

5.19 & 19a CAD Update required ? - If CAD files require updating Document Control
sends ECO and redlines to CAD Services.

5.19b CAD Services updates files - CAD Services schedules work to be done and
provides Document Control with updated documents.

5.20 ECO Distribution - Document Control distributes copies of ECO and redlines to
all for implementation.

5.21 Updated Documents assembled for sign-off - Upon receiving updated

documents from CAD Services and/or other departments which may be charged with
updating product documentation, Document Control assembles the ECO and all
documentation affected by the ECO and notifies the initiator that the documentation
package is ready for sign-off.

5.22 ECO Initiator signs off ECO - ECO Initiator verifies that changes were
incorporated into the product documentation as specified by the ECO and any hard
copy documentation or drawings are signed by responsible engineer. Initiator signs off
ECO releasing updated documentation.

5.23 Master Files Updated - Document Control files original documents in master
files, removes and archives obsolete documents, removes and replaces copies in
computer files. ECO process is completed.
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APPENDIX A - CHANGE ORDER PROCESS FLOW

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1
Need for ECO
identified

2
Engineer evaluates
change request

3
Engineer red-
lines
documents

4 4a
Rework Yes R&R/Field Yes
Required Affected
? ?

No

5
Is this a 4b
Yes Component Issue
Problem Customer
No
? Service
Bulletin
5a
Notify
Supplier and create No
(SCAR) as required

6 4c
Write
Complete
Rework
ECR
Instructions

APPENDIX A - CHANGE ORDER PROCESS FLOW (cont’d)

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7
Transfer change
package to
ECO coordinator

8
Will change affect
form, fit, or function
?

Yes

9
Complete cost
analysis, material No
disposition, and
determine Effective
Date

10
ECO Coordinator
completes ECO after
ECR has been approved
as complete

11
Distribute
ECO to review
team

12
ECO review team
meeting

B C

APPENDIX A - CHANGE ORDER PROCESS FLOW (cont’d)

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B C

13 13a
No Coordinator
Is ECO correct
corrects and
?
redistributes ECO

Yes

14
ECO Review Team
Signs off

15
15a
Class I Yes Field Upgrade
or cost over
?
$?K

15b
No No VP/Director assigns
Program Manager

16
15c
ECO hand-off
VP/Director
to
signs off ECO
Document Control

17
Document Control
assigns ECO #

18 18a 18b
Customer Customer Document Control
Approval/Notification Yes Approval No sends copy of ECO to
Required Required Program/Account
? ? Manager

No Yes

D E

APPENDIX A - CHANGE ORDER PROCESS FLOW (cont’d)

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D E

18c
19 Document Control works
Document Control with Program/Account
updates MRP Manager to obtain
Customer Approval

No

20 20a
Document Control
CAD Update Yes sends ECO and
Required
redlines to CAD
?
Services

No

21 20b
Document Control
CAD Services
distributes ECO for
updates files
Implementation

22
Updated
documents
assembled for
signoff

23
Initiator signs
off ECO

24
Master files
updated
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The routing path and signatories. (This is where you would put in your organizations
names that match the titles for your ECO routing and approval signature processes.)

CEO/VP Engineering
Director of Engineering
Development Engineer
Software Engineer
Planning/Materials/Program Manager
Manufacturing Manager
Purchasing
Operations Support
Component Engineer
Printed Circuit Designer
Mechanical Designer
Documention Control
ECO Coordinator
PCMRP Administrator
Cad Services
Customer Service/Support -R/R