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Introduction & Contents 2 This brief explains the essential requirements of the Engineering change control process including major and minor changes, and how design change authority is flowed down from Rolls-Royce to the supplier. This briefing pack will explain: Engineering Change Control Purpose Engineering Change Control Scope Engineering Change Control Process Engineering Change Control PCB Process Engineering Change Control General Requirements Supplier Authorisation Process
Engineering Change Control - Purpose The Engineering Change Control process ensures that decisions about changing the product are made with due consideration of all relevant factors. To show how the change forms used by Rolls-Royce in the UK, US and Germany interrelate with the overall generic Engineering Change Control process. This includes the principle of Rolls-Royce Authorised Approver Process, together with the vital disciplines of design control and configuration management (i.e., no design change permitted, unless agreed by Rolls- Royce).
Engineering Change Control - Scope 4 The procedure covers both pre- and post- Entry Into Service (EIS) products. All suppliers operating to SABRe processes in accordance with Rolls- Royce approval and purchase order requirements. All suppliers of goods and / or services that impact upon Rolls-Royce or our customer requirements. Application for engineering change process. All changes to designs including those which affect fit, form, or function requiring Rolls-Royce engineering project action, where the change does not meet the criteria for the Design Alteration Request (DAR) process. Changes to contractual scope as a result of requirements change or clarification.
Engineering Change Control - Process 5 The process requires a defined baseline against which changes can be managed. The processes detailed within the following flow charts are applicable to all generic requirements related to Engineering design changes. When major design changes (as defined in appendix D of RRES90009) are proposed then one of the following forms is completed, depending on Rolls- Royce location: - Rolls-Royce UK: Design Change Process (DCP) - Rolls-Royce Deutschland : Request For Alteration (RFA) - Rolls-Royce Corporation: Definition Alteration Request (DAR) For all minor changes (as defined in appendix D of RRES90009) the DAR form is completed for all sites. All templates and guides are available on the Global Supplier Portal.
Engineering Change Control PCB Process 6 ESID/DDQP
Engineering Change Control PCB Process 7
Engineering Change Control 8 General Requirements For changes made in development prior to type certification, the process shall continue up to the point that the change has been incorporated into the main development programme and all impacts agreed. Rolls-Royce will not accept liability for changes to contractual scope as a result of technical requirements change or clarification, unless formally agreed through this process or through contract renegotiation. Where the supplier identifies that such a change has been requested informally, the supplier shall request the change is formalised in accordance with this process.
Engineering Change Control 9 PCB Process The control of change shall be applied by the use of formal Product Change Boards (PCB) that review and authorise a change package at four stages. The PCB reviews a set of prerequisite deliverables appropriate to the stage of approval. The PCB is a business-driven process, not an engineering process, and makes decisions on the basis of the business case and programme policy. This process is intended to ensure full integration of supplier activity with the Rolls-Royce Product Change Review process.
Engineering Change Control 10 PCB 1 PCB1 reviews a problem or improvement opportunity presented on an investigation/change request and either approves the launch of an investigation into the solution or rejects it. Approval at PCB1 authorises the exact amount of work that the task owner is expected to perform before returning for PCB2 review and approval (i.e., understanding of the issues and development of a proposed solution with preliminary costs and plans). Any work beyond that authorised above requires further PCB approval.
Engineering Change Control 11 PCB 2 PCB2 reviews the proposed solution concept, business case, associated costs and plans. If these are approved, PCB2 authorises the full concept definition work together with verification and validation planning, production planning and customer approval processes. Ordering of any validation hardware may also be authorised provided appropriate risk analysis and technical reviews have been done. Potential changes to key product attributes (e.g., weight, cost, component classification) may be managed using specific processes and system. PCB2 is the key business decision-making meeting in the change board process.
Engineering Change Control 12 PCB 3 PCB3 reviews and, if appropriate, approves the updated business case. PCB3 also reviews the complete list of engineering definitions in a change package, and all committed plans associated with it. If validation hardware is not already available, PCB3 authorises orders for such hardware required to validate the change package in the development programme on the agreed test vehicles. PCB3 will also consider approving change packages for advance release ahead of standardisation or certification. PCB 4 PCB4 ensures the final business case is satisfactory, reviews the verification and validation evidence and all other relevant aspects of the modification plans. PCB4 is the final release by the programme of a modification for production. Standardisation reports must be complete before any change package can be launched to production.
Engineering Change Control 13 Forms Required for PCB The site-specific forms relevant to each stage of PCB will be used as the basis of presentations to the relevant PCB. Direct supplier attendance at the review may or may not be required, dependant upon sitespecific/project requirements. The Product Change Process is intended to support the staged consideration of all business factors affecting a proposed change. As well as the technical aspects of the change, the process considers the impact of the change on such aspects as manufacturing, purchase, assembly, test, shipping, overhaul, repair, and decommissioning or disposal. The PCB decisions reflect the formal acceptance of these factors by the accountable individuals or organisations within Rolls-Royce.
Engineering Change Control Supplier Authorisation Process (For detailed process description see RRMS process LP ES 0-3 Manage Supplier Approvals) Purpose The following process is to be used to enable a supplier to self-approve predetermined categories of defined engineering change. Demonstrably competent individuals within the supplier organisation will be authorised by Rolls-Royce to approve the changes on behalf of the applicable Rolls-Royce technical authority. 14 Scope Design Sub-Contract and Design & Make suppliers only. Only applicable to changes that do not affect form, fit, and function as defined in appendix D of RRES90009.
Supplier Authorisation Process (For detailed process description see RRMS process LP ES 0-3 Manage Supplier Approvals) /ESID? ESID