Patent Publication Number: US-2004059615-A1

Title: System and method for planning and executing an engineering change

Description:
FIELD OF INVENTION  
       [0001] The invention relates generally to a process for planning and implementing engineering changes during the manufacture of a product. More specifically, the invention relates to mapping and communicating data interactions throughout a lifecycle of an engineering change implemented during manufacture of a product. Additionally, the invention relates to aids for communicating functional tips and feedback during a set of iterative steps of the lifecycle.  
       BACKGROUND OF THE INVENTION  
       [0002] Ideas for improvement of a product often occur after development and manufacture of the product have begun. Generally, when these ideas for improvement occur an engineering change is proposed. The process of proposing and incorporating the engineering change for complex products involving numerous functional representatives is very involved, time consuming and often causes unnecessary feedback process errors, thereby adding to flow times and associated costs. Also, technical and non-technical errors can arise between designers and support disciplines, e.g. manufacturing, quality assurance, tooling, and data management, during the development and implementation of the change. These errors often necessitate reworks that add further unplanned flow time and costs.  
       [0003] Therefore, an objective of the present invention is to map and analyze engineering changes over the entire lifecycle of the change such that the typical iterative steps within the lifecycle are executed more efficiently. Mapping and analyzing the entire lifecycle of the change enables better identification of where process bottlenecks may occur due to inadequate communication and/or insufficient resources, e.g. people, tools and facilities. By improving the identification of process bottlenecks and their causes, it is possible to implement only those changes that efficiently improve throughput and cost of that critical process.  
       BRIEF SUMMARY OF THE INVENTION  
       [0004] In a preferred embodiment of the present invention, a method is provided for identifying and executing complex engineering changes. The method includes developing an engineering change plan utilizing a process sequence template and reviewing the engineering change plan utilizing a tip sheets/design aids tool. Additionally, the method includes implementing the engineering change plan and utilizing a system survey/metrics tool to gather discrete engineering change error information, data resulting from the engineering change and abstract perceptions of the engineering change during a lifecycle of the engineering change.  
       [0005] In another preferred embodiment of the present invention, a system is provided for executing a six box process for implementing an engineering change. The system includes a process sequence template utilized to develop an engineering change plan, a tip sheets/design aids tool utilized to review the engineering change plan, and a system survey/metrics tool utilized to gather information during a lifecycle of the six box process.  
       [0006] In yet another embodiment of the present invention, a method is provided for executing a six box process for implementing an engineering change using a web-base system. The web-based system includes at least one client system, at least one database, and a server system coupled to the client system and the database. The method includes utilizing a process sequence template to develop an engineering change plan by mapping a plurality of interactions between a plurality of organizations impacted by the engineering change plan Additionally, the method includes utilizing a tip sheets/design aids tool to review the engineering change plan by educating design organizations on at least one functional requirement that needs to be satisfied to generate a completed engineering change record (ECR). Furthermore, the method includes utilizing a system survey/metrics tool to understand errors that occur during a lifecycle of the six box process by gathering discrete engineering change error information, data resulting from the engineering change, and abstract perceptions of the engineering change throughout the lifecycle of the six box process. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0007] The present invention will become more fully understood from the detailed description and accompanying drawings, wherein;  
     [0008]FIG. 1 is a block diagram of a server system utilized in accordance with a preferred embodiment of the present invention;  
     [0009]FIG. 2 is a flow chart showing a six step process for implementing a 6+ box process, in accordance with the present invention;  
     [0010]FIG. 3 is a graphic representation of a Process Sequence Template tool utilized by the 6+ box process shown in FIG. 2;  
     [0011]FIG. 4 is a graphic representation of a Schedule Template tool utilized by the 6+ box process shown in FIG. 2;  
     [0012]FIG. 5 is a graphic representation of a Tip Sheets/Design Aids tool utilized by the 6+ box process shown in FIG. 2;  
     [0013]FIG. 6 is a graphic representation of a Training Module tool utilized by the 6+ box process shown in FIG. 2;  
     [0014]FIG. 7 is a graphic representation of a System Survey/Metrics tool utilized by the 6+ box process shown in FIG. 2; and  
     [0015]FIG. 8 is a flow chart describing the operational steps of the 6+ box process shown in FIG. 2. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
     [0016]FIG. 1 is a block diagram of a server system  10  utilized in accordance with a preferred embodiment of the present invention. Server system  10  includes a server  12  and a plurality of client systems  14  connected to server  12 . In one preferred embodiment, client systems  14  are computers connected to server  12  via a network such as a local area network (LAN). In another preferred embodiment, client systems  14  are computers including a web browser, such that server  12  is accessible to client systems  14  via the Internet. In this embodiment the client systems  14  are interconnected to the Internet through any suitable interface, for example, a LAN or a wide area network (WAN), dial-in-connections, cable modems and special high-speed ISDN lines. In which case, client systems  14  could be any type of electronic device capable of interconnecting to the Internet, including a web-based phone or other web-based connectable equipment.  
     [0017] A database server  16  is connected to a centralized database  20  containing web-site information, data, and graphics for implementing an engineering change process mapping and communications tool (ECPMC), as described below. The ECPMC web-site provides a place for centralizing information and data related to a plurality of engineering change processes. Database  20  can be accessed by potential users at any one of client systems  14  by logging on to server  12  through one of client systems  14 . Thus, all authorized individuals such as managers, lead engineers and integrated product teams can access server  12  using one of the client systems  14 . However, server system  10  has different access levels to control and monitor the security of the system. For example, access authorization can be based on job function or job titles, or management authority within the business entity. Additionally, server system  10  allows addition of new information, deletion of the current information, and editing of the current information stored in database  20 . Administration and editing capabilities within server system  10  are restricted to ensure that only authorized individuals have access to modify or edit the information that exists in database  20 .  
     [0018] The architectures of server system  10 , as well as the various components of server system  10 , are exemplary only. Other architectures and database arrangements are possible and can be utilized in connections with practicing the invention as described below.  
     [0019]FIG. 2 is a flow chart  100  showing a six step process for implementing an engineering change, referred to herein as the 6+ box process. The 6+ box process represents the sequence of steps for the entire lifecycle of an engineering change from conception to being released as a ‘Make’ package to an internal factory and/or a ‘Buy’ package to suppliers/vendors. The first step of the 6+ box process is shown in FIG. 2 as a ‘Develop &amp; Release Committed Change Plan’ process, or module  104 . Module  104  requires an input  108  consisting of a corrective action. The corrective action is triggered any time a change is needed or proposed. For example, input  108  can be triggered by a request for an engineering change (RFEC) that is generated to implement an improvement to a present process, or by a rejection report from a factory floor generated when a process produces a flawed product. Also, input  108  can be triggered by a material discrepancy report from the factory floor generated when there is not enough material or the wrong material to manufacture a product, or by a newly conceived idea for a new process. Additionally, module  104  has other external inputs  112  that includes such things a vendor data and other functional data.  
     [0020] An output  116  of module  104  is a ‘Committed Change Plan’. The committed change plan is a set of documents delineating the proposed change plan, e.g. a plan for implementing the change and schedules for implementation. In one preferred embodiment, the ‘Develop &amp; Release Committed Change Plan’ process, or module  104 , incorporates the use of a process sequence template and a schedule template to streamline and improve the process of developing and releasing the committed change plan. The process sequence template and the schedule template are described in detail below. As shown in FIG. 2, the ‘Committed Change Plan’ output  116  is utilized as an input by other down stream processes, or modules.  
     [0021] The second step of the 6+ box process is shown in FIG. 2 as a ‘Review &amp; Change Designs &amp; Drawings’ process, or module  120 . Module  120  uses as inputs the ‘Committed Change Plan’  116 , a design data input  124  and other external inputs  112 . Design data represents the baseline configuration and analysis that exist prior to proposing the change, for example drawings, parts list, and test data, Other external inputs include vendor/supplier information that needs to be incorporated into the proposed updated design, or information in the form of requirement updates from a customer&#39;s use of the product in the field. At module  120  the committed change plan is reviewed by all the organizations, or disciplines, that are impacted by the change plan. During the ‘Review &amp; Change Designs &amp; Drawings’ module  120  at least one designer of the change plan interacts with specialists for all the different disciplines impacted. During this interaction the various disciplines begin to write and review instruments that would be needed or affected by the proposed engineering change, for example, documents, drawings, test data, designs and parts lists.  
     [0022] In one preferred embodiment, the designers utilize a tip sheet/design aids tool, described in detail below, to facilitate better communication and coordination of the interactions among the specialists of the different disciplines during the review. The ‘Review &amp; Change Designs &amp; Drawings’ module  120  can generate various outputs. For example, module  120  can generate an output  128  consisting of engineering reports and an output  132  consisting of requests for additional external inputs. Additionally, module  120  can generate a plan changes output  136  that is fed back into module  104 . The plan changes output  136  is generated when review of the committed change plan by the impacted organizations generates a need to rework the change plan because the committed change plan is not workable. If review of the change plan by the impacted organizations is successfully completed, module  120  generates a ‘Completed Engineering Change Record (ECR) Package’ output  140  consisting of all the materials reviewed and updated in module  120 , such as drawings, designs, instructions, and schedules.  
     [0023] The completed ECR package  140  is then input to the third step of the 6+ box process, shown in FIG. 2 as a ‘Signoff ECR Package’ process, or module  144 . At module  144  the completed ECR package  140  is signed off on by all the impacted organizations signifying that all the impacted organizations agree that the completed ECR package  140  will implement the desired engineering change. Module  144  generates a ‘Fully Signed ECR Package’ output  148  that is input to the forth step of the 6+ box process, shown in FIG. 2 as a ‘Review &amp; Release ECR Package’ process, or module  152 .  
     [0024] The fully signed ECR package enters the ‘Review &amp; Release’ process, or module  152 , where a non-technical review is performed by a data management/data quality staff member to verify all the necessary contents of a release package are present. For example, the data management/data quality staff member verifies all the necessary signatures have been obtained, verifies affected drawing numbers are appropriately labeled and correspond to the correct change document, and verifies the parts list is correct in referring to the affected drawings. Once the package has passed all the checks, it is sent back as a pre-released ECR package  156  to module  144  for final approval by the originator of the change. After final approval no further changes can be made to the ECR and a master copy of the fully signed ECR package is stored in a secure environment accessible only by authorized persons. If all the necessary contents of the package are not present, the package is sent back to module  144  as a rejected ECR package  160 , where the necessary contents are obtained.  
     [0025] Module  152  generates a ‘Released ECR Package’ output  164 , which indicates that the signed ECR package is simultaneously input to the fifth and sixth steps of the 6+ box process. The fifth and sixth steps are respectively shown in FIG. 2 as a ‘Complete Make/Buy Packages’ process, or module  168 , and a ‘Review &amp; Distribute ECR Package’ process, or module  172 . At module  168  the released ECR package is utilized to generate Make and/or Buy packages that are released at output  176  to down stream groups such as an internal ‘Make’ packages factory operations group and/or to ‘Buy’ packages suppliers/vendors. At module  172  engineering instruction data contained in the released ECR package is reviewed and routed, at output  180 , to the factory floor or to a vendor/supplier&#39;s site. This involves data delivery of engineering instructions, e.g. drawings. parts list, and electronic datasets, that may arrive at the factory floor or vendor/supplier site before the ‘Make’ or ‘Buy’ packages. The complexity of the ‘Make’ or ‘Buy’ packages determines whether the engineering instructions arrives before or with the ‘Make’ or ‘Buy’ Packages.  
     [0026] The 6+ box process implements five tools that aid in avoiding bottlenecks that can cause flow time errors during the 6+ box process. In one preferred embodiment, the five tools are web-based, which makes implementation of the tools easier and more efficient. However, it should be recognized that the scope of the invention should not be limited to web-based implementation. The five tools can be implemented in a non-web-based manner and remain within the spirit and scope of the invention.  
     [0027]FIG. 3 is a graphic representation of a process sequence template  300 . The process sequence template  300  is a tool utilized during the ‘Develop &amp; Release Committee Change Plan’ process, module  104 , of the 6+ box process (shown in FIG. 2). The process sequence template  300  is used to simplify and expedite development of the committed change plan  116  (shown in FIG. 2). The process sequence template  300  is the product of a Constructing Processes Around Data (CPAD) system that maps the interactions that occur across all the different disciplines/organizations that are impacted by the 6+ box process and creates a data-driven process in accordance with a process disclosed in U.S. Pat. No. 6,141,776, entitled Data-Driven Process Generator, issued Oct. 31, 2000, herein incorporated by reference in its entirety.  
     [0028] The process sequence template  300  includes a list of generic 6+ box change process steps  304 , a list of organizations  308  that are responsible for executing a related step, and an input/output section  312  that shows the respective inputs and outputs of each step properly sequenced to deliver the outputs of the 6+ box process. The process sequence template  300  is tailored to every ‘instance’ of a change being planned in module  104 . The engineer responsible for the change opens a file using the CPAD tool then adds/or removes affected steps, inputs, and outputs. He then uses the analysis capability of CPAD to determine where the iterative cycles, parallel steps, sequential steps, and key outputs are within the 6+ box change process. This information is then used by the schedule template described below in reference to FIG. 4.  
     [0029]FIG. 4 is a graphic representation of a schedule template  400 . Schedule template  400  is a tool also utilized during the ‘Develop &amp; Release Committed Change Plan’ process, module  104 , of the 6+ box process (shown in FIG. 2). The schedule template  400  is created from the process sequence template  300  (shown in FIG. 3) and is used by engineering to plan and coordinate a schedule based on the mapped interactions between the various organizations impacted by the change proposed in the committed change plan  116  (shown in FIG. 2). The schedule template  400  includes a task name column  404  that sets forth steps that need to occur in the proposed change process. The steps are listed in the task name column  404  in the order the steps should occur in accordance with the sequence of processes as established by the preceding process sequence template  300  (shown in FIG. 3). Additionally, the schedule template  400  includes a duration column  408  where the duration of each step is indicated, and a start column  412  that indicates a projected start date of each task listed in the task name column  404 . Furthermore, the schedule template  400  includes a graphical timeline section  416  that graphically shows a lifecycle timeline of the change as well as the timelines and interrelation of each of the change process steps listed in the task name column  404 . It is envisioned that schedule template  400  could include other information such as what organizations are going to be impacted by the proposed change process.  
     [0030] More specifically, the schedule template  400  is a generic file created in schedule software, such as MSProject®, using the process sequence file from CPAD. The schedule template  400  is then modified by the engineering change originator to add corrected durations, along with edited resource quantities, e.g. people, tools and facilities. Other calculations such as a critical path analyses are performed using the schedule template  400 . When completed, the schedule template generates a schedule file representing a flow schedule for all the remaining steps in the 6+ box process. Occasionally changes to the schedule may be required after it is released, and if so, it can be easily updated.  
     [0031]FIG. 5 is a graphical representation of a first page of a tip sheets/design aids tool  500  that is utilized during the ‘Review &amp; Change Designs &amp; Drawings’ process, module  120 , of the 6+ box process (shown in FIG. 2). The tip sheets/design aids tool  500  educates users, such as designers and/or engineers, on the functional requirements that need to be met before routing the completed ECR package  140  (shown in FIG. 2) to the affected support disciplines for ‘signoff’ signatures. Specifically, the tip sheet/design aids tool  500  is used by the design organizations during the processing of a committed change plan  116  (shown in FIG. 2) and provides designers with data and information that needs to be considered to generate a completed ECR package that meets the requirements of the affected support disciplines. For example, the tip sheet/design aids tool  500  provides the designers with information and data pertaining to the interactions that will occur between all the different engineering and manufacturing disciplines during the 6+ box process. More specifically, the designers access the tip sheet/design aids tool  500  and read from it design content information that must be considered prior to outputting the completed ECR package  140  to the ‘Signoff ECR Package’ process  144  (shown in FIG. 2).  
     [0032] In a preferred embodiment, the tip sheets/design aids tool  500  is a web based tool wherein the first page includes a plurality of site navigation links  504  that assist a user in navigating the tip sheets/design aids tool  400 . Additionally, the first page of the tip sheets/design aids tool  500  includes direct selection links  508  and functional links  512 . The direct selections links  508  allow a user to access a tip sheet by title, category, or function. The functional links  512  are password protected and allow authorized user to perform maintenance task on the tip sheets/design aids tool  400 , for example, edit tip sheets, add new tip sheets, delete old tip sheets, and add a new category of tip sheet. Furthermore, the first page of the tip sheet/design aids tool  500  includes external links  516  linked to sites outside of server system  10  (shown in FIG. 1), and internal links  520  that are linked to sites other than the tips sheets/design aids tool internal to server system  10 .  
     [0033] More specifically, the tip sheets/design aids tool collects functional tips from all the support organizations, and assembles them into unique categories of design type problems. For example, in an aerospace program, the designers are organized into groups such as airframe, hydraulics, avionics, electrical, vehicle management systems, and fuel systems. The tip sheets created by the functional support disciplines such as stress, weights, manufacturing, and quality assurance, would be mapped to either a generic design aids document or to design aids documents unique to the different types of designer, for example airframe or hydraulics. These tips represent the requirements that support disciplines often view as overlooked by the deign community. The use of this tool greatly reduces the iterations between the designers and the affected functional support disciplines.  
     [0034]FIG. 6 is a graphic representation of a training module  600 , which is a tool utilized during all stages of the 6+ box process (shown in FIG. 2). It is envisioned that the training module  600  comprises a plurality of self-paced web enabled training sub-modules that are designed to teach all the different discipline specialists necessary information pertaining to the process of planning and executing an engineering change. For example, the training module  600  includes sub-modules on how to create and utilize the process sequence template  300 , the schedule template  400 , and the tip sheet/design aids tool  500 . For exemplary purposes FIG. 6 shows the training module  600  displaying a tip sheets/design aids tool sub-module  604 . Each sub-module includes a plurality of learning objective links  608  that link the user to various training information relating to the respective training sub-module. The self-paced, web based training module  400  is available for use by anyone involved with the lifecycle of the typical engineering change.  
     [0035]FIG. 7 is a graphic representation of a system survey/metrics tool  700  which is utilized during all stages of the 6+ box process (shown in FIG. 2). The system survey/metrics tool  700  comprises a plurality of web enabled questionnaires and surveys for gathering discrete error information, data and/or abstract perceptions of the engineering change process. The information and data gathered is utilized to understand the errors that occur during the 6+ box process lifecycle and what changes need to be made in order to make the 6+ box process more efficient. Specialists for the various disciplines impacted by the change can periodically provide information and data pertaining to such things as the types of errors that occur, the frequency of errors and flow times gathered during implementation of the ECR, via the 6+ box change process.  
     [0036] The system survey/metrics tool  700  includes at least one metrics questionnaire  704  that is completed frequently, for example daily, to monitor implementation of the ECR and expedite flow times. The metrics questionnaire gathers information such as the current 6+ box process step of the engineering change, a change identification number, a change title, the name of the reviewer for the related step, the date the ECR was received, the originator of the ECR and errors that have occurred at the related 6+ box process step. The information gathered using the metrics questionnaire  704  is fed back upstream in the 6+ box process where it is utilized to make corrections, which are then fed down stream in the 6+ box system as described above. Thus, creating an iterative process that constantly monitors and makes any necessary improvements to the implementation of an ECR using the 6+ box system.  
     [0037] Additionally, the system survey/metrics tool  700  includes at least one survey  708  that is periodically completed on a less frequent basis, for example once a month. Periodically the specialists complete a survey  708  by answering a plurality of questions  712  presented in the survey  708 . In a preferred embodiment the survey  708  is web based and is automatically provided by the system survey/metrics tool  700 . It is envisioned that the survey  708  include the questions  712  and corresponding interactive response fields  716  that provide the users with a list of predetermined responses to the question from which the user can choose an appropriate response. The survey collects information and data pertaining to the specialists&#39; perception of the 6+ box change process and are utilized to improve the overall function of the 6+ box process.  
     [0038]FIG. 8 is a flow chart  800  describing the operational steps of the 6+ box process (shown in FIG. 2). The 6+ box process is initiated when an engineer receives a corrective action from the factory floor or conceives a new idea for improving production of a product, as indicated at step  804 . The engineer then begins to develop the change plan by utilizing the CPAD to generate a process sequence template  300  (shown in FIG. 3), as indicated at step  808 . Using the process sequence template  300 , the engineer creates a schedule template  400  (shown in FIG. 4), as indicated at step  812 . Based on the information provided by the process sequence template  300  and the schedule template  400 , the engineer develops and releases a committed change plan, as indicated at step  816 . The committed change plan is then reviewed by a plurality of specialists from the various organizations that will be affected by the proposed change plan, and appropriate changes are made, as indicated at step  820 . During the review and change process the various engineers and specialists utilize the tip sheet/design aid tool  500  (shown in FIG. 5) to organize and expedite the process, as indicated at step  824 . Additionally, if needed, the training modules  600  (shown in FIG. 6) are utilized to educate and aid in the review and change process, as indicated at step  828 .  
     [0039] The completed review and change process produces the completed ECR package, as indicated at step  832 . The completed ECR package is signed off on by all the impacted organization, as indicated at step  836 . A master copy of fully signed ECR package is then stored in a secure environment accessible only by authorized personnel, as indicated at step  840 , and copies of the ECR are released down stream to the factory floor and to ‘Make’ and ‘Buy’ organizations, as indicated at step  844 , where implementation of the ECR begins. During all phases of the 6+ box process errors in the process or in the implementation of ECR often occur. To monitor and correct such errors in a timely manner the system survey/metrics tool  700  (shown in FIG. 7) is utilized throughout the 6+ box process, as indicated at step  848 .  
     [0040] Thus, the present invention maps and analyzes engineering changes over the entire lifecycle of the change such that the typical iterative steps within the lifecycle are executed more efficiently. Mapping and analyzing the entire lifecycle of the change enables better identification of where process bottlenecks may occur due to inadequate communication and/or insufficient resources, e.g. people, tools and facilities. By improving the identification of process bottlenecks and their causes, it is possible to implement only those changes that efficiently improve throughput and cost of that critical process.  
     [0041] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.