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Release date: 20 June 2023 – One of the most important decisions during the impact analysis of a change is the Part or Item Re-Identification decision. Why is that? Because it has a direct impact on the traceability of the change to your product, the cost of the change, and the risk you will be exposed to. When the part and its successor remain fully interchangeable after the change, the cost and risk of the change are limited. But if you made a wrong part re-identification decision, you run the risk that when something does go wrong, the cost of fixing the situation will be astronomical.

“Part Re-identification decisions are a balance between short-term gains and long-term risks. While you might be able to temporarily mitigate a problem today using short-term thinking, it requires a broader understanding of the problem and a long-term thinking approach to find a path to a sustainable solution that allows you to steer clear of the risks.”

Often terms like Form, Fit, and Function are used to express when you need to issue a new part number, but Form, Fit, and Function are just a subset of the aspects that need to be considered. This book expands on the knowledge gained from the Part Re-Identification decision tree from the Institute of Process Excellence. It offers its readers in-depth background information to equip them with the necessary tools to make quality part re-identification decisions. It contains special cases and considerations, ways to simplify Part Re-Identification, and seven exercises. The ultimate goal is to empower organizations to optimize their processes, minimize risks, and streamline their supply chains for long-term success.

Are you ready to Unleash the power of 
Interchangeability and Traceability?

Table of Contents based on eBook formatting

Note: the paperback is content-wise (chapters) the same. Just the formatting will be different due to the nature of a reflowable ebook and the fact that it would increase the paperback page size by 24 pages which meant I would have to increase the price by 1 US$/Euro and waste practically unused paper. I did not want to do that.

I – INTRODUCTION

1. 1. 1. The Dilemma
      2. Part Re-Identification is complex
      3. Closing Thoughts

II – IDENTIFICATION

1. 1. 4. Identification: Parts versus Units
      5. Rule 1: Use numeric identification only.
      6. Rule 2: Consistent length
      7. Rule 3: Maximum length of 7
      8. Rule 4: Refrain from using delimiters
      9. Rule 5: Do not use blanks
      10. Rule 6: Non-Significant or as little significance as possible.
      11. Rule 7: No leading 0’s
      12. Rule 8: Part Number ≠ Drawing Number
      13. Closing Thoughts

III. IMPACT ANALYSIS

1. 1. 14. Impact Analysis
      15. Identify all parent and dependent parts of the impacted part.
      16. Fade-out level
      17. Model-Based System Engineering
      18. Closing Thoughts

IV – THE PART RE-IDENTIFICATION DECISION TREE

1. 1. 19. It’s Not About The Tree
      20. Start at the end
      21. Understanding ‘Why’ is more important than following a Tree
      22. Part Re-Identification Decision Tree
      23. Closing Thoughts

V- ORDERS

1. 1. 22. Orders
      23. Q1: Has the impacted Part already been ordered and/or produced?
      24. Closing Thoughts

VI – TRACEABILITY

1. 1. 25. Traceability
      26. Product Recalls and Traceability
      27. Q2: Are there any traceability requirements that can only be achieved by issuing a new Part number?
      28. Track
      29. Trace
      30. Control
      31. Parent versus Dependent Parts
      32. Change to Level of Traceability
      33. Closing Thoughts

VII. INTERCHANGEABILITY

1. 1. 34. A Brief History
      35. Interchangeability
      36. Q3: Will the Impacted Part remain fully interchangeable with the Successor Part in all its applications?
      37. Form
      38. Fit
      39. Function
      40. Interface
      41. Categorizing F3I
      42. Closing Thoughts

VIII. RESTORE INTERCHANGEABILITY

1. 1. 43. Restore Interchangeability
      44. Q4: Can all instances and/or all open orders of the Impacted Part be found and reworked or disposed of in a controlled, timely, and economical way?
      45. Closing Thoughts

IX – SPECIAL CASES AND CONSIDERATIONS

1. 1. 46. Special Cases and Considerations
      47. Commercial Parts
      48. Configurable Parts
      49. Buy Parts
      50. Buy versus Make Parts
      51. Phantom Parts
      52. Traceability Not Needed
      53. Implementation Strategies
      54. Export Control
      55. Level of Supplier Integration
      56. Single-use Products
      57. Closing Thoughts

X – WAYS TO SIMPLIFY RE-IDENTIFICATION

1. 1. 58. Ways to Simplify Re-Identification
      59. The blindfolded test
      60. Classification of changes
      61. When in Doubt
      62. Timebox
      63. Always Re-Identify the Part once it has been ordered or produced
      64. Closing Thoughts

XI – AUTOMATION

1. 1. 65. Automation
      66. Risk of not Re-identifying a part
      67. The Probability (P) of Effect
      68. The Severity (S) of Effect
      69. GM’s Detent Plunger
      70. Apply Machine Learning
      71. Closing Thoughts

XII. SUMMARY AND EXERCISES