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BOMs & Test Procedures - Electronic and electro-mechanical systems

R

RudyB

#1
Before I make my post - We do not have a quality system.

We manufacture various electronic and electro-mechanical systems. Many of the systems need to be tested at various stages. We have test procedures, but many are not referenced, tracked, controlled etc. Some procedures are used with different products that do not share the same part number.

I've proposed placing them on the BOMs (bill of materials) so they would at least be referenced (right now there is no link between the TP and the item except some drawings reference the TPs), but was told it was an "Insane idea" by the engineer the would be responsible for adding them. Of course, she didn't offer another solution.

Without adding them to the BOM, we would be required to create and maintain a seperate database to do so.

We have "Assembly books", but many times pages are ruined, thrown out, or lost.

So here is my question - how many of you (your company) attach TPs to your BOMs and/or how do you otherwise insure your products are tested (remember - we do not have a quality system)?

Thanks,
RudyB
 
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D

ddunn

#2
Do you use a MRP (Material Requirements Planning) system. If so the test procedure could be added to the MRP BOM as a reference item. All of the test procedures need to be controlled items. A change to a test can have a significient impact on the product quality and operation.

You may also find other items that need to be on the MRP BOM such as assembly procedures, work instructions or calibration procedures. All those little things that people doing the work just know but are not documented.
 

Jim Wynne

Staff member
Admin
#3
Before I make my post - We do not have a quality system.

We manufacture various electronic and electro-mechanical systems. Many of the systems need to be tested at various stages. We have test procedures, but many are not referenced, tracked, controlled etc. Some procedures are used with different products that do not share the same part number.

I've proposed placing them on the BOMs (bill of materials) so they would at least be referenced (right now there is no link between the TP and the item except some drawings reference the TPs), but was told it was an "Insane idea" by the engineer the would be responsible for adding them. Of course, she didn't offer another solution.

Without adding them to the BOM, we would be required to create and maintain a seperate database to do so.

We have "Assembly books", but many times pages are ruined, thrown out, or lost.

So here is my question - how many of you (your company) attach TPs to your BOMs and/or how do you otherwise insure your products are tested (remember - we do not have a quality system)?

Thanks,
RudyB
Without knowing more about your material and manufacturing control documentation, it's hard to give good advice, but I can say that while adding document references to BOMs might not be insane, it's usually not a good idea. The purpose of a BOM is to document all of the parts required to build an assembly. Adding superfluous clutter will make it more difficult, sooner or later, to use the BOM for its specialized purpose.

Do you have work orders/routers/travellers? If so, that's the place to put references to things other than parts that are needed in production--test requirements, references to work instructions, tooling requirements, etc. If you're using your BOMs as catch-alls, you really should look into creating a separate document for production use.
 
R

RudyB

#4
Jim Wynne's post just reminded me also say that although we control our drawings on the floor, we depend on the revision in the part description to tell what revision should be in use.

We have no system (centralized or otherwise to tell us what the current revision should be).

Your BOMs exist to support MRP only, our part numbering scheme gives you no hint to the revision. We must rely on the description.

We are trying to work around the problem by creating manufacturing packets that include the test procedure, but we can never be sure the procedure is the current revision

Our approach (revision in description only) introduces fit, form and function issues as well, but that is challange for another day.
 
I

iso factotum

#5
Rudy:
I know this question and posts are several months old, but I just read the discussion today and wanted to tell you how we handle the situation. We have a manufacturing plan for each item we build. In the manufacturing plan, there is a reference to "Inprocess Test 1" or Inprocess Test 2", etc.

Exactly what those tests entail is at the end of the MP so that the person testing knows what to do.

Hope this is helpful.

iso factotum
 
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