This document discusses electronic component management plans (ECMP) and obsolescence management in the avionics supply chain. It notes that 57% of reported counterfeit parts involve obsolete or end-of-life parts. The document outlines the 11 step ECMP process defined in IEC/TS 62239-1, including component selection, qualification, and obsolescence management. It provides an example where monitoring of manufacturer product change notices through the ECMP process allowed alternatives to be found for 40% of last-time buys. The document also discusses related standards like IEC/TS 62239-2 for COTS assemblies and third-party audit schemes through organizations like IECQ.
Control Systems Obsolescence – Support Strategies and Key ConsiderationsOptima Control Solutions
Naturally, robust steel frameworks of machines age much more slowly than their moving parts and also have an extremely long life span if well-maintained. However, with those same machines’ control systems the case is different. Modern technology advances so quickly that a system can be out of date in as little as 10-12 years.
In this article, Michael Hill, managing director of Optima Control Solutions, looks at three different manifestations of control system obsolescence and offers practical advice on how to deal with each case. The last part of the article contains a checklist of the key factors to consider before moving forward with any obsolescence support strategy.
The secondary market is often the supply chain of last recourse when a component product goes obsolete or is under production constraints. While it is possible to get high quality, genuine parts, it is also possible to get nonconforming, reworked, or counterfeit components. What is most frustrating is that it is increasingly difficult to differentiate genuine parts from their counterfeit equivalents.
Historically, the secondary market provided a mechanism for finding parts in short supply or at reduced cost. Today, high-reliability system manufacturers are less willing to risk contamination of their supply chain with potentially substandard parts in order to save a few dollars on the cost of a part. The proliferation of counterfeit components has led to a contraction of the secondary market and an increase in the cost of parts in the marketplace.
RS Components and DesignSpark launch a new tool that can help OEMs and product developers to manage the problem of obsolescence, and plan for when the End-of-Life (EOL) notices are placed on parts that will soon cease to be produced, repaired and supported by component vendors.
Find out more here: https://www.rs-online.com/designspark/obsolescence-manager
Design for Manufacturability Rapid Fire April Bright
Design for manufacturability (DFM) is a broadly-implemented step in today’s development process to ensure that a designed product can actually be manufactured. While the concept sounds simple, there are nuances to every supplier relationship and every new process.
Three suppliers—a contract manufacturer, additive manufacturer and plastics company—will each spend 15 minutes answering the following question: With orthopaedic customers, our greatest DFM pain point is ___ and the best strategy to change that is ___.
OEMs will learn best practices and ways to approach DFM with their supplier partners.
Reliability Strategies for Combating Obsolescence RisksCheryl Tulkoff
This presentation will cover test and management strategies that can be used to protect your company and products against obsolescence risk. Topics include relevant industry standards, use of Managed Supply Programs (MSP) and Contract Pooled Options, long term storage recommendations and practices, and descriptions of the appropriate tests to use in various situations.
Component obsolescence management is a strategic practice that also mitigates the risk of counterfeit parts. Left unchecked, obsolescence issues increase support, development and production costs. So, planning ahead is critical. For companies that proactively manage component availability and obsolescence, the impact of long-term storage on manufacturability and reliability is an area of major concern. Effective test strategies are crucial in detecting and preventing problems.
Control Systems Obsolescence – Support Strategies and Key ConsiderationsOptima Control Solutions
Naturally, robust steel frameworks of machines age much more slowly than their moving parts and also have an extremely long life span if well-maintained. However, with those same machines’ control systems the case is different. Modern technology advances so quickly that a system can be out of date in as little as 10-12 years.
In this article, Michael Hill, managing director of Optima Control Solutions, looks at three different manifestations of control system obsolescence and offers practical advice on how to deal with each case. The last part of the article contains a checklist of the key factors to consider before moving forward with any obsolescence support strategy.
The secondary market is often the supply chain of last recourse when a component product goes obsolete or is under production constraints. While it is possible to get high quality, genuine parts, it is also possible to get nonconforming, reworked, or counterfeit components. What is most frustrating is that it is increasingly difficult to differentiate genuine parts from their counterfeit equivalents.
Historically, the secondary market provided a mechanism for finding parts in short supply or at reduced cost. Today, high-reliability system manufacturers are less willing to risk contamination of their supply chain with potentially substandard parts in order to save a few dollars on the cost of a part. The proliferation of counterfeit components has led to a contraction of the secondary market and an increase in the cost of parts in the marketplace.
RS Components and DesignSpark launch a new tool that can help OEMs and product developers to manage the problem of obsolescence, and plan for when the End-of-Life (EOL) notices are placed on parts that will soon cease to be produced, repaired and supported by component vendors.
Find out more here: https://www.rs-online.com/designspark/obsolescence-manager
Design for Manufacturability Rapid Fire April Bright
Design for manufacturability (DFM) is a broadly-implemented step in today’s development process to ensure that a designed product can actually be manufactured. While the concept sounds simple, there are nuances to every supplier relationship and every new process.
Three suppliers—a contract manufacturer, additive manufacturer and plastics company—will each spend 15 minutes answering the following question: With orthopaedic customers, our greatest DFM pain point is ___ and the best strategy to change that is ___.
OEMs will learn best practices and ways to approach DFM with their supplier partners.
Reliability Strategies for Combating Obsolescence RisksCheryl Tulkoff
This presentation will cover test and management strategies that can be used to protect your company and products against obsolescence risk. Topics include relevant industry standards, use of Managed Supply Programs (MSP) and Contract Pooled Options, long term storage recommendations and practices, and descriptions of the appropriate tests to use in various situations.
Component obsolescence management is a strategic practice that also mitigates the risk of counterfeit parts. Left unchecked, obsolescence issues increase support, development and production costs. So, planning ahead is critical. For companies that proactively manage component availability and obsolescence, the impact of long-term storage on manufacturability and reliability is an area of major concern. Effective test strategies are crucial in detecting and preventing problems.
Yokogawa’s Vigilant Plant solutions deliver visibility, predictability and agility for your chemical business.
Being a producer in the chemical industry has
become more and more challenging over the years.
Customer needs for products, pricing, and delivery
are more demanding and material requirements
are complex and ever-changing. Additionally,
health, safety, security, and environment (HSSE)
compliance has always been a primary requirement
for doing business.
Over the years, Yokogawa has worked with many
chemical companies to provide technology
solutions that meet these challenges. We stand
ready to partner with you to take on whatever
challenges you face and help you achieve your aims
safely and profitably.
Enablers to increase predictability and service in a demanding and complex commercial supply chain, presentation made to MERCK SUN Conference, September 2013
In this ebook, we will look at consensus recommendations for preventive maintenance including industry standards from the Institute of Electrical and Electronics Engineers (IEEE) and regulatory requirements specific to utilities as stipulated by the North American Electric Reliability Corporation (NERC).
As these standards and regulations outline minimum maintenance activities, we will also share how many critical facilities can and should go beyond these minimums for additional system protection and added peace of mind.
Process Safety Life Cycle Management: Best Practices and ProcessesMd Rahaman
Learn how to transform your current process safety program to deliver intelligent and integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety.
Managing your OnStream Inspection Program and External vs Internal inspectionsEdwin A Merrick
API 510 recognizes the need to be able to obtain valid inspection results from conducting and external inspection in-lieu of an internal inspection of Pressure Vessels.
Better Bioprocessing Efficiency Through Centralized OrchestrationMilliporeSigma
Use this link to participate in the interactive on-demand webinar: http://bit.ly/Bio4COrchestrator
Detailed description:
In this talk, we discuss how orchestration software improves bioprocessing efficiency through the centralized configuration and management of connected unit operations for process and workflow automation across the plant floor.
A browser-based software solution, Bio4C™ Orchestrator software connects to individual unit operations from a centralized orchestration layer for remote access to systems, recipes, reports, user accounts and alarms from a holistic process dashboard.
USP <665> draft standard : A rational risk-based approach to characterization...MilliporeSigma
This webinar will cover risk-based characterization of filters and single-use systems used in biopharmaceutical manufacturing according to USP <665>.
Novel innovative biomanufacturing systems such as single-use assemblies often comprise of polymeric materials. There is a lack of standards for characterization of these polymeric systems. USP <665> draft standard is the first standard in development addressing this topic. This chapter recommends risk assessment with respect to patient safety, risk level assignment and risk level appropriate characterization of components.
In this webinar we will discuss:
● Risk assessment to assign a risk level
● Risk level based testing
● Our approach for compliance
● Emprove™ Dossiers for Filters and Single-use systems
This poster focuses on three single-use technologies suited for use in antibody drug conjugate production and shows examples of performance data for the following:
• Mixers
• Chromatography
• Tangential Flow Filtration
To learn more about this topic or collaborate with our technical experts, schedule an in-person or remote visit at our M Lab™ Collaboration Centers: www.merckmillipore.com/mlab
Hello Everyone!
This is the best ppt on 'Industrial Maintenance' that you can ever find. I tried to include all the topics related to the maintenance of industry. These notes will also be helpful from university exam point of view. Go through the whole ppt and leave a feedback in the comment box. Learn and Enjoy!
Thank You!
Yokogawa’s Vigilant Plant solutions deliver visibility, predictability and agility for your chemical business.
Being a producer in the chemical industry has
become more and more challenging over the years.
Customer needs for products, pricing, and delivery
are more demanding and material requirements
are complex and ever-changing. Additionally,
health, safety, security, and environment (HSSE)
compliance has always been a primary requirement
for doing business.
Over the years, Yokogawa has worked with many
chemical companies to provide technology
solutions that meet these challenges. We stand
ready to partner with you to take on whatever
challenges you face and help you achieve your aims
safely and profitably.
Enablers to increase predictability and service in a demanding and complex commercial supply chain, presentation made to MERCK SUN Conference, September 2013
In this ebook, we will look at consensus recommendations for preventive maintenance including industry standards from the Institute of Electrical and Electronics Engineers (IEEE) and regulatory requirements specific to utilities as stipulated by the North American Electric Reliability Corporation (NERC).
As these standards and regulations outline minimum maintenance activities, we will also share how many critical facilities can and should go beyond these minimums for additional system protection and added peace of mind.
Process Safety Life Cycle Management: Best Practices and ProcessesMd Rahaman
Learn how to transform your current process safety program to deliver intelligent and integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety.
Managing your OnStream Inspection Program and External vs Internal inspectionsEdwin A Merrick
API 510 recognizes the need to be able to obtain valid inspection results from conducting and external inspection in-lieu of an internal inspection of Pressure Vessels.
Better Bioprocessing Efficiency Through Centralized OrchestrationMilliporeSigma
Use this link to participate in the interactive on-demand webinar: http://bit.ly/Bio4COrchestrator
Detailed description:
In this talk, we discuss how orchestration software improves bioprocessing efficiency through the centralized configuration and management of connected unit operations for process and workflow automation across the plant floor.
A browser-based software solution, Bio4C™ Orchestrator software connects to individual unit operations from a centralized orchestration layer for remote access to systems, recipes, reports, user accounts and alarms from a holistic process dashboard.
USP <665> draft standard : A rational risk-based approach to characterization...MilliporeSigma
This webinar will cover risk-based characterization of filters and single-use systems used in biopharmaceutical manufacturing according to USP <665>.
Novel innovative biomanufacturing systems such as single-use assemblies often comprise of polymeric materials. There is a lack of standards for characterization of these polymeric systems. USP <665> draft standard is the first standard in development addressing this topic. This chapter recommends risk assessment with respect to patient safety, risk level assignment and risk level appropriate characterization of components.
In this webinar we will discuss:
● Risk assessment to assign a risk level
● Risk level based testing
● Our approach for compliance
● Emprove™ Dossiers for Filters and Single-use systems
This poster focuses on three single-use technologies suited for use in antibody drug conjugate production and shows examples of performance data for the following:
• Mixers
• Chromatography
• Tangential Flow Filtration
To learn more about this topic or collaborate with our technical experts, schedule an in-person or remote visit at our M Lab™ Collaboration Centers: www.merckmillipore.com/mlab
Hello Everyone!
This is the best ppt on 'Industrial Maintenance' that you can ever find. I tried to include all the topics related to the maintenance of industry. These notes will also be helpful from university exam point of view. Go through the whole ppt and leave a feedback in the comment box. Learn and Enjoy!
Thank You!
ARC Advisory Group's 2014 European Industry Forum in the Netherlands included this interesting presentation from Willem Hazenberg of Stork on control system migration.
Facility personnel often face the choice of maintaining aging equipment or buying new. Now there is another, more cost-effective, option to increase equipment reliability, efficiency and productivity….modernization. Learn key considerations and advantages of upgrading existing equipment to current technology.
Measuring Up to Chemical Compliance ChallengesYokogawa1
Regulatory compliance can come from many different directions and cost impacts in different points.
Cost pressures associated with regulatory compliance can be impacted from not on the non-compliance, but also equipment, sample systems, man power with manual checks and audit preparations.
View the full webinar here: https://info.us.yokogawa.com/20200730-Measuring-Up-to-Chemical-Compliance-Challenges_Webinar-Recording-Page-v2.html
Application of PLC’s for Automation of Processes in IndustriesIJERA Editor
Several industries utilize sequential industrial process which is respective in nature. For such processes
industries have to depend upon use of relays, stepping drum, timers and controls, considerable difficulties
experienced in reprogramming necessitated due to change in the nature of production. Often the whole system
has to be scrapped and a redesigning is required. To overcome these problems PLC control system was
introduced. The PLC can be described as a control ladder comprising a sequence program. PLC sequence
program consists of normally open and normally closed contacts connected in parallel or in series. It also has
relay coils, which turns ON and OFF as the state of these contacts change. In this paper, about all aspects of
these powerful and versatile tools and its applications to process automation has been discussed.
Introduction to Reliability Centered MaintenanceDibyendu De
Introduces Reliability Centered Maintenance, strategies employed, formulation of effective maintenance plan, reduction of consequences of failures and failure rate.
Reliability Centered Maintenance for minimizing integrity failure by Bhavesh Shukla at APAC 2015 Process Safety Management Conference 9th March 2015 Singapore.
2. 2
GE Title or job number
9/29/2015
2
The Avionics Supply Chain
1. Parts &
Materials
Suppliers
2. Board
Assemblers
3. Avionics
OEMs,
Logistics,
Maintenance
and Repair
4. Platform
Integrators
5. Operators
& Regulators
Parts
Boards
Contract Mfg.
Suppliers CustomersSolder etc.
Suppliers
Customers
15 - 40 yr
Lifecycle
3 - 6 yr
Lifecycle
Suppliers managed per
ECMP and Anti-counterfeit
Most life cycle
costs are incurred here
and managed by ECMP
Global Supply Chain
Avoiding counterfeit components
Requirements
flow-down vs.
products flow-up
process is
disrupted here
Aerospace
Captive
To build products that must
meet mil-aero requirements
(what we must control)
Using COTS components
targeted for other markets
(what we cannot control)
Aerospace Electronics
• Depends on
materials and
components
developed for other
industries
• Vastly different
lifecycle applications
3. 3
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How does obsolescence drive the counterfeit problem?
• In 2010/2011 the USA DoD identified upwards of a million counterfeit components
in their Military supply chain.
This resulted in the 2012 NDAA section 818 anti-counterfeit clause which was
published May 2014 as DFAR 252.247.7007
• Researcher IHS analysed electronics industry data in 2013 concerning counterfeit
parts that were reported from 2001 until early 2012:
More than 12 million counterfeit parts have been reported over the last five
years to 2013
57% of counterfeit part reports involved obsolete or end of
life parts.
Nearly 37% of counterfeit parts involve components still being produced by
manufacturers.
A single incident of a counterfeit part can cause up to 64 weeks of production line
downtime and cost up to $2.1 million to resolve.
Counterfeit parts are mostly sold on the open market.
4. 4
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Obsolescence management process
• Avionics producers must ensure continued supply of components for
maintenance cycles of 20+ years
• Microcircuits are the most dynamic components often with production
lifecycles of 5 years or less
• Avionics producers need a reactive and pro-active component
obsolescence management process which allows:
Reactive solutions:
o Last Time Buys and One Time Buys etc.
Pro-active solutions:
o The periodic review of component obsolescence predictions
through the use of third party tools, sourcing intelligence, review of
manufacturer product change notices (PCNs) and Last Time Buys
etc. in order to substitute ‘form fit and function active’ alternatives
o Obsolescence risk assessment of the product to plan redesigns or
product upgrades as considered necessary in a timely manner to
meet the needs of the business and customer
• An ECMP manages all of the above
5. 5
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ECMP specifications:
The recommended ECMP processes for the Avionics industry ( can be
adapted or used by any industry) are:
IEC/TS 62239-1 (International standard which is Third Party
auditable using an IECQ CB)
EIASTD4899 published by the SAE in 2015 (preferred by one
US company which allows IEC/TS 62239-1 plans)
These two standards are very similar and interchangeable
There are also new ECMP processes for COTS assemblies:
EIA933 published by the SAE in 2015 (preferred by one US
company)
IEC/TS 62239-2 ( for international use and in draft which will be
Third Party auditable using an IECQ CB)
IEC/TS 62239-2 will allow the use of EIA933 plans and are very
similar.
All refer to: IEC/TS62402 and/or TechAmerica STD0016
obsolescence management standards
6. 6
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IEC/TS 62239-1 Electronic Component
Management Plan
• Based on the concept of ‘manage the component application
process’ rather than customise or screen components for the
Avionics applications
• Allows the use of Mil specified components where considered
necessary
• Main advantage is that it provides the process to maximise the
use of reliable COTS components
• Assists Avionics OEMs in using small quantities of COTS
components
• Is essentially a ‘eleven step’ horizontal Process Management
Plan which can be integrated with the OEM’s AS9100 processes,
including lead-free management, anti-counterfeit management,
obsolescence management and flow-down to suppliers.
• Facilitates the substitution of alternatives
7. 7
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IEC/TS62239-1, 11 step OEM ‘systems level’
ECMPThis is a cross functional process linked to a company’s AS9100 procedures:
1. Component Manufacturer approval i.e. ISO9001, AS9100, TS16949, S/0001
including COTS assemblers and subcontractors ( jointly with Supplier
quality)
2. Component selection i.e. use of PPL, approved manufacturers, minimise
uprated components (jointly with hardware design)
3. Component application i.e. derating, thermal management, vibration
environmental requirements, SEU mitigation, semiconductor wear-out
mitigation etc. for each application
4. Component qualification i.e. component testing or analysis of data for each
application
5. Component quality assurance every lot ordered i.e. outgoing ppm rate,
product ESS testing
6. Component dependability (reliability) , which includes obsolescence
management, reliability predictions etc.
7. Component compatibility with the equipment manufacturing process, e.g.
reworking lead-free BGAs, refinishing component terminations
8. Component data and Component configuration control, including PCN
monitoring
9. Anti-counterfeit management e.g. special testing of untraceable components
and audits of suppliers
10. Lead-free management, e.g. capture termination finishes and rework as
required
11. Subcontractor and COTS assembler ECMP approval and management (jointly
with Supplier Quality)
Colour key: could be managed by component engineering, Managed by other
8. 8
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IEC/TS 62239-1 Electronic Component Management Plan
IEC/TS 62239-2 (
allows the use of SAE
EIA-933) for COTS
Assemblies
9. 9
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Evidence that the ECMP process enables and mitigates the
number of LTBs a business makes
Manufacturer Product Change Notices (PCNs) are monitored as part of
the ECMP process over 12 months from one franchised broad-line
distributor representing 28 manufacturers:
220 PCNs were analysed
Of which 25 were EOL i.e. 11.36% of PCNs were LTBs
10. 10
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PCN analysis
• This resulted in 25 LTBS being found impacting our
business from one broad-line franchised distributor
requiring analysis
• Using the IEC/TS 62239-1 ECMP process we were able
to find and approve alternatives for 40% of these LTBs
and only 5 LTBS were actioned e.g.
Manufacturer Recommended alternatives were
approved
Lead-free alternatives were approved
Second sources were approved
New suppliers alternatives were approved.
11. 11
11
IEC publications
THIRD PARTY AUDITED
on annual basis
ECMP
IEC/TS 62239-1
owned by IEC TC107
equivalent to SAE EIA-4899
IEC/TS62647-XX
series
(adopting GEIA-STD-
0005 series
(Lead-free)
IEC/TS 62668-X
Counterfeit avoidance
which
allows use of
SAE AS5553
IEC 62396-X
series
(SEU Radiation)
IEC/TS 62402
(Obsolescence
owned by TC56 )
Embedded Requirements:
•Life-limited
semiconductors, etc.
IEC/TR 62240
(Uprating)
IEC/TS 62564-1
(AQEC) for
Enhanced Plastic
components
IEC/PAS 62435
(Long term
Storage owned
by TC47 WG3 )
IEC 62340-5
(ESD)
IEC/TS 62500
(Highly
accelerated
tests)
IEC/TS 62668-1
(adopts
STACK S/0001)
IEC/TS 62239-2
Allows the use of
SAE EIA 933
For
COTS
assemblies
12. 12
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International anti-counterfeit standards
SA
E
IEC
IEC/TC
107
WG3
G-14
AAQS
C
IEC/TS6
2668-2
G19A
IEC/TS6
2668-1
G19A
D G19C
AS6171
Test
Methods
AS6496
Franchise
d
distributor
AS6301
,AS646
2
audit
checklist
s
G19CI
AS5553
electronic
component
s
G21
AS617
4
materiels
AS9100
Rev D for
publicatio
n 2016/17
13. 13
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IEC/TS 62239-1 Electronic Component Management Plan
Third Party audit schemes
Third Party audit schemes which support IEC/TS 62239-1:
1. IECQ
o Is the auditing side of the IEC , see http://www.iecq.org/
o Establishes auditor training schemes, audit rules of procedure and maintain
copies of the audit certificates, see http://certificates.iecq.org/
o Can establish audit schemes for IEC specifications and other specifications
from other standards bodies providing there is no competing IEC
specification
o IECQ audits all National Certifying Bodies auditors ( BSI, ECCB, CEPREI,
DNV, UTE etc.) to ensure consistency of auditing.
o IECQ have training schemes for Certifying Bodies to audit:
o AS9100 and AS9110
o IEC/TS 62239-1 ECMP
o SAE AS5553
o IEC/TS 62668-1 ( to be established in 2016 )
o Planning general industry traceability audit scheme for 2016.
o Planning an IEC/TS 62239-2 COTS assembly audit scheme for
2016/2017
14. 14
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IEC/TS 62239-1 Electronic
Component Management
For further information contact:
• Jo Vann, jo.vann@ge.com, TC107 convenor of:
MT1 IEC/TS 62239-1 ECMP and IEC/TS 62239-2 COTS Assemblies
WG2 Aerospace Qualified Electronic Components
WG3 Anti-counterfeit
WG4 atmospheric radiation SEE effects.
• Jo Vann, GEL/107 convenor , UK mirror
committee to TC107