Handling design changes with use-as-is inventory disposition

Mark Meer

Trusted Information Resource
#1
We're updating a product design and associated images in accompanying instructions. It is only a minor/aesthetic change, and as such we'd like to continue to use our current inventory until exhausted.

This presents some complications in terms of using up old inventory:
  • We don't want to "mix-and-match" old and new designs with orders
  • It's important that the version of instructions matches the version of product design
Question: how to handle? To use old inventory as-is, we'd have to devise some system to ensure that only units of a particular generation are shipped together, as well as ensure that printed instructions versions always matches the versions of device shipped. We'd have to somehow simultaneously maintain two versions of instructions and units in inventory. This could get complicated and prone to mistakes. Suggestions welcome. ;)

Not certain if it might not just be easier (albeit economically odious) to just scrap all old inventory...:unsure:
 
Elsmar Forum Sponsor

Miner

Forum Moderator
Staff member
Admin
#3
Quarantine the new product and new instructions until the old is used up. If you have an MRP system, block the new inventory, so it cannot be used. When you run out of old product, you will have to scrap the excess instructions (or vice versa).

This situation is a good argument for keeping minimal inventory, and not building the new until the old was used.
 

Mark Meer

Trusted Information Resource
#4
Why is this important?
Simple aesthetics. The are several packaging configurations with different quantities. If a customer orders a quantity of, say, 5, all should be of the same generation (lest the customer wonder why some look slightly different than others...).
 

Mark Meer

Trusted Information Resource
#5
Quarantine the new product and new instructions until the old is used up. If you have an MRP system, block the new inventory, so it cannot be used. When you run out of old product, you will have to scrap the excess instructions (or vice versa).
This situation is a good argument for keeping minimal inventory, and not building the new until the old was used.
Thanks @Miner , this was the original plan, but for an additional complication: there are multiple variations, and several packaging configurations.
For example, the product comes in 5 colours, and can be shipped in packs of 1, 5, 10 - packs can be either uniform colour or "variety".

This has led to a situation where there is a current shortage of units of a certain colour (these need to be re-ordered and re-stocked ASAP), but a fair-sized inventory of the other colours remaining. As such, new inventory of the new design needs to be admitted to cover any orders for that limited colour (or "variety pack" orders that include the colour) - but this would necessarily result in the problem described: is there a way segregate and still use the old stock without mixup with the new?
 

indubioush

Quite Involved in Discussions
#6
This is not just a use-as is disposition. Use-as-is means you can continue processing the items according to normal procedure. You can't do that in this case. Options:

1. Planned deviation (can be done through your nonconforming product process).
2. Strategic implementation date for the change(s).
3. New specification/document numbers and separate DMR so both iterations can exist at the same time and will not be mixed up as they will be labeled with a different number.
4. Scrap the old inventory.
 

John Predmore

Trusted Information Resource
#7
is there a way segregate and still use the old stock without mixup with the new?
The way that occurs to me is to create new part numbers for the new versions and the new instructions, and rely on your ERP to manage inventory and proper combinations of product and instructions. You save the expense of scrapping old inventory, at the expense of proliferation. One way to maintain control as you liquidate old inventory is to offer the old version to a limited handful of customers, maybe at a discount. The analogy is to the way booksellers discount the previous edition of textbooks, which are functionally adequate, but only 95% identical to the latest edition.
 
Thread starter Similar threads Forum Replies Date
V Handling open points in design reviews 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 4
M Complaint Handling Responsibilities for a Design Partner - ISO 13485 ISO 13485:2016 - Medical Device Quality Management Systems 9
T Is handling chemically treated parts safe? RoHS, REACH, ELV, IMDS and Restricted Substances 18
N Handling B-Grade Products within the QMS ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 15
A Complaint review as part of the complaint handling process? ISO 13485:2016 - Medical Device Quality Management Systems 3
S Advice on how to reduce overhead of handling non-conforming material Nonconformance and Corrective Action 7
B Handling lower detection limits for SPC and process performance Statistical Analysis Tools, Techniques and SPC 1
A ISO 10002:2018 Checklist Needed (Complaints Handling) Customer Complaints 5
G Handling Unpacked (Additive Chemical) Product For Automotive Applications IATF 16949 - Automotive Quality Systems Standard 3
A Handling of contaminated medical equipment Other Medical Device and Orthopedic Related Topics 0
B Procedures for Complaint Handling and Post Market Surveillance EU Medical Device Regulations 10
J KPIs or Metrics to Measure a New Complaint Handling Process 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 9
shimonv Rigid rules for handling supplier audit findings ISO 13485:2016 - Medical Device Quality Management Systems 11
Jimmy123 Handling nonfunctional requirements in DFMEA FMEA and Control Plans 5
F Component Molding and Over-molding - Handling Resin Inventory Manufacturing and Related Processes 2
Q Handling Off-the-Shelf Components 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 1
L AS9100 D- Handling Nonconformance Documentation for an organization that outsources most of the work. AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 11
P HVAC System vs Air Handling Unit (AHU) - Differences Pharmaceuticals (21 CFR Part 210, 21 CFR Part 211 and related Regulations) 1
L GMDN code wanted - Software for handling records Service Industry Specific Topics 9
leftoverture Handling Sort/Return Requests Customer Complaints 8
S Document Handling during an Audit General Auditing Discussions 6
S Handling Cost of Sales requests for Customer Quality Manager and Management Related Issues 2
Q AS9100/AS1180-1 - Handling of Equipment and Calibration Records AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 12
S Merging Post Market Surveillance and Complaint Handling ISO 13485:2016 - Medical Device Quality Management Systems 3
A ISO 9001 Ergonomics and Manual Handling Requirements ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 7
C Suggestions requested on handling batch record papers exposed to hormonal products Pharmaceuticals (21 CFR Part 210, 21 CFR Part 211 and related Regulations) 1
A Production and Post-Production and Complaint Handling ISO 14971 - Medical Device Risk Management 2
C What's Your Process for handling rush jobs, urgent or priority orders ? Manufacturing and Related Processes 6
A Medical Device Handling AFTER the device's specified lifetime has expired 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 2
T Handling of Obsolete Material Work Instruction ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 2
A Risk Management, complaint handling and CAPA system ISO 14971 - Medical Device Risk Management 5
W Aerospace Materials Handling Training AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 9
V Handling decomissioned line/equipment during 1st time product-based inspection US Food and Drug Administration (FDA) 1
D Complaint Handling Call Centers ISO 13485:2016 - Medical Device Quality Management Systems 7
W Contract Initial Importer and Order Handling for a Class I Medical Device Service Industry Specific Topics 2
W SOP on Handling of HCl (Hydrochloric Acid) Document Control Systems, Procedures, Forms and Templates 5
A Handling Normal Capacitor Production Fallout AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 2
K Procedure for Handling of Customer Supplied Material (AS9100 Requirements) AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
M Procedure for Handling Customer Return Part (Defective Part Return) IATF 16949 - Automotive Quality Systems Standard 1
M Manufacturer's handling of Distributor's Historical Complaint Records US Food and Drug Administration (FDA) 5
C Anyone have experience handling Feed Safety Management System (GMP+B2)? Other ISO and International Standards and European Regulations 1
V ISO10002:2004 (Guidelines for Handling Customer Complaints) Self Assessment Checklist Customer Complaints 5
V Ensuring Improvement and Handling Change FMEA and Control Plans 4
S Handling Out-of-Specification Results: FDA's guidance for the industry Pharmaceuticals (21 CFR Part 210, 21 CFR Part 211 and related Regulations) 12
M Internal Warehouse Handling - A Reverse Logistic Case! Process Maps, Process Mapping and Turtle Diagrams 6
C Corrective Action and Preventive Action for Operator Error (Cosmetic - Handling) Preventive Action and Continuous Improvement 15
S PCB Handling Requirements - What to do if we drop a PCB during the assembly Manufacturing and Related Processes 4
M Raw Material Handling & Mixing in Plastic Injection Moulding Manufacturing and Related Processes 5
C Safe Handling of Non-Device Refurbished Medical Equipment US Food and Drug Administration (FDA) 3
Y Handling of Potentially Biohazard Material - Alcohol Cleaning Procedure ISO 13485:2016 - Medical Device Quality Management Systems 12

Similar threads

Top Bottom