How to control an engineering change while production is running
Control an engineering change by recording its reason, affected parts and documents, impact on inventory and open orders, required approvals and effective date. Then publish the new revision and notify every affected team and supplier. This keeps incompatible versions from being manufactured, inspected or shipped at the same time.
Guilherme Rodrigues ItinoseUpdated 2 min read
Key takeaways
- Record why the change is needed and which items it affects.
- Decide what happens to inventory and open orders before release.
- Set a clear effective point and notify suppliers and production.
- Keep drawings, models, bills of materials and inspection plans traceable.
A drawing change can be simple for the person who requested it and complicated for a shop already building parts. If a new revision arrives without direction for inventory, open orders and suppliers, the company can mix incompatible parts or lose traceability.
Change control does not require an expensive system to start. It requires a consistent record and explicit decisions before files are replaced.
Record the reason and impact
Describe the problem the change solves. List affected part numbers, assemblies, models, drawings, work instructions and inspection plans. Identify whether the change affects fit, safety, performance, material, process or cost. If function is unaffected, record that assessment instead of leaving it implicit.
Decide what happens to work in progress
Before releasing the new revision, count inventory and review production orders, purchase orders and parts in transit. For each group, decide whether it can be used, reworked, segregated or scrapped. Define who approves the decision, especially when customer or regulatory requirements apply.
Set an effective point and distribute
A revision needs a rule everyone understands, such as a specific order, lot or date. Send the updated package to production, quality, purchasing and affected suppliers. Request receipt confirmation for critical changes and remove old copies from workstations.
Keep documents aligned
The 3D model, drawing, bill of materials and inspection plan should describe the same configuration. The history should show who requested, reviewed and approved each change. That way, a future complaint can be linked to the revision actually built.
When drawings are scattered or revisions conflict, organizing documentation before the next change reduces interruptions. Learn about our manufacturing documentation service for engineering packages that are easier to control.
When to outsource this
- Many related drawings need to be consolidated for a change package.
- Suppliers received files through different channels and the package needs control.
When not to
- The change has not been reviewed by the responsible engineer or quality owner.
FAQ
Should we scrap every part from the previous revision?
That depends on risk, function and customer requirements. Record whether each group can be used as is, reworked, segregated or scrapped, with approval from the product owner.
Does a minor change still need a formal revision?
Yes, if it affects geometry, material, process, assembly or inspection criteria. A formal record preserves traceability even when the change seems small.
How do we stop suppliers from using an old file?
Send the new revision through a controlled channel, request receipt confirmation and state when it takes effect. Remove or mark obsolete copies in portals and shared folders.
What should accompany a new revision?
Updated drawings and models, the list of affected documents, reason for the change, approvals, effective date and instructions for existing inventory and production.
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