Revision History

Approved: David Cue

Approved: Craig Rigby

Signature/Date

Signature/Date

10/10/2007

10/10/2007

Released: Joyce Kaiser

Signature/Date
10/10/2007

Revision Level
01

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Revision Date
10-Oct-07

Description of Changes
Initial release

Johnson Controls - Saft

Page 1 of 12

Instructions for the Engineering Change Request Form

The Engineering Change Request (ECR) form:
1) States the recommended action to solve problems / initiate improvements / release documents; defines the need for
the change
2) Includes a Parts Affected Worksheet (P.A.W.) to describe the physical items and supporting documents impacted by
the recommended action
3) Provides the basis for the business decision
4) Initiates Cost/Price evaluation and Manufacturing Feasibility evaluation.
5) Documents approval for action requested
The ECR form is comprised of the following data fields:
1)
ECR Number:
Tracking number from change database
2)
Date Initiated:
Date on which the ECR was initiated
3)
Originator:
Name of person originating the ECR
Location
Site and building location
Phone #
Telephone number
4)
Description:
Action being requested to solve problem / initiate improvement / release documents /
quantity changes
5) Programs / Product Affected / List Lead Program/Product and other programs/product(s)/Model Years impacted by
Model Year:
the ECR
6)

Plants Affected:

6)
7)

Customer:
Assembly:
Component:
Supplier:
ISSUE/DA #
CR/PCR #

8)

Customer Auth #

9)

Category of change: Select

one
Cost Reduction:
Customer / Scope Change:
Initial Release:

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

List all plants impacted by the ECR

List all customer assembly plants affected by the ECR
List all JCS system assembly plants affected by the ECR
List all JCS component (cell/module) plants affected by the ECR
List all supplier plants/codes shipping to JCS affected by the ECR
Associated Issue Report and/or Deviation Authorization number (as applicable)
CR/PCR No.: Commercial Request number or Product Cost Request number used for
gathering cost impact of proposed action
Customer approval (if required)
When more than one reason code applies, choose the one which best describes the
majority of the change:
The product changes associated with VA actions or VE action during the development
after baseline costs (tooling & piece price) are met.
The product changes associated with Customer driven scope changes, such as
feature(s) addition/deletion, product specification changes, etc.
ECR/ECO to release a new part.

Johnson Controls - Saft

Page 2 of 12

Instructions for the Engineering Change Request Form

Internal Product Corrections:

The product changes required due to Internal Engineering or Internal Design

Corrections, such as product does not meet agreed customer requirements, validation
failure due to engineering issues, etc. Changing a released design to meet baseline
cost, quality, manufacturability, mass or functional requirements fall under this
category.

Manufacturing Improvement:

The product changes driven by manufacturing improvements implemented by JCS

Plants, such as Poka Yoke, Kaizan, Ergonomics/Safety etc.
The product changes driven due to quality improvements needed such as
RPPM/CPPM, J.D. Power etc.

Quality Improvement:
Record Change:
Supplier Improvement:
Other:
10)

11)
12)
13)

Reported By: Select one

Customer:
Design:
Engineering:
Manufacturing:
Prog Mgmt / Sales:
Purchasing:
Quality:
Supplier:
Tooling:
Other:
Reason for Change
Reviewers Comments
Proposed Implementation
Date:
Proto Build:
SOP:
Running:

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

ECR/ECO to make a record change only with no impact on product design,

performance, or manufacturing.
The product changes driven by suppliers due to product design, manufacturing,
quality, etc , other than VA/VE type improvements
This box can only be checked, if change can not be bucketed in any other category. It
must require an entry of the change reason.
Function that initiated the change proposal
ECRs reported based upon a customer direction/request
ECRs reported by Design
ECRs reported by Engineering
ECRs reported by Manufacturing (advanced or plant)
ECRs reported by Program Management or Sales
ECRs reported by Purchasing
ECRs reported by Quality (business unit or plant)
ECRs reported by supplier
ECRs reported by Tooling (business unit or plant)
A change category to be used on an "as needed" basis.
Facts that define Reason for change
Reviewers comments that define approval or rejection of the ECR
Estimated date for change implementation
Date by which changes to components and/or assemblies must be completed to
support the customer's prototype build date
Date by which changes to components and/or assemblies must be completed to
support the start of production (SOP) date
Date by which changes to fit, form and function to the vehicle or product robustness to
components and/or assemblies are to be implemented; FIFO out cancelled parts until
inventory is exhausted, then begin building with added parts

Johnson Controls - Saft

Page 3 of 12

Instructions for the Engineering Change Request Form

Urgent:

14)

Other:
Approvals:

15)

Engineering Manager:
Program Manager:
Approval Path:
AFM / Controller:
AME / Mfg. Manager

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Date by which changes driven by safety or warranty issues to components and/or

assemblies must be completed
A change category to be used on an "as needed" basis.
Authorization for the CM/Release Group to initiate a Change Notification (provided that
no additional approvals are required by the business unit or program)
Signed and dated approval from the Engineering Manager (all programs affected)
Signed and dated approval from the Program Manager (all programs affected)
The Program Manager is required to select the approval method for the ECR (Check
Path 1, 2, 3 or 4)
Signed and dated approval from the Controller (business unit)
Signed and dated approval from the Plant Manager (affected plants)

Johnson Controls - Saft

Page 4 of 12

Engineering Change Request

Date Initiated
Originator:

Location:

Phone# _____________

* Description

Programs/Product Affected / Model Year

Lead Program/Product: _________________

Plants Affected
Customer
Assembly
Component
Supplier

General Information

Issue / DA #:

Category of Change (Select one)

CR #:

Customer Auth #:

Internal Product Correction

Supplier Improvement

Cost Reduction

Manufacturing Improvement

Other

Customer / Scope Change

Quality Improvement

______________________________________

Initial Release

Record Change

______________________________________

* Reported By (Select one)

Manufacturing

Supplier

Customer

Prog Mgmt - Sales

Tooling

Design

Purchasing

Other

Engineering

Quality

Reason for Change

Reviewers Comments

* Proposed Implementation Date

SOP
Approvals

Urgent

Proto Build

Running

Other

Name

Signature

Date

Approval

Engineering
Finance
Manufacturing
Program Manager
Quality
Continued on additional sheet

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Johnson Controls - Saft

Page 5 of 12

INSTRUCTIONS FOR FILLING OUT PARTS AFFECTED WORKSHEET (PAW)

1
2
3
4
5

Model Year
OEM/Program
Engineer/ Phone
Item
Action Code:
CU
DL
RV
NW
Effectivity Class
Development:
Prototype:
Production:

7
8
9
10
11

Assembly Level:
Current JCS Part #
(was):
Rev:
Qty
Updated JCSPart # (is):

12
13
14

Rev:
Qty
CPP Code

15
16

C1
C2
C3
C4
SP
N/A
CPP Tplt #
Part / Pattern
Description:
HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Enter Model Year of Program

Enter OEM and Program Name
Enter name and phone number or responsible engineer
Sequential number
Add action code from selection below
Change Usage
Delete / Remove part
Revise Part
New Part
When part configuration is required but drawings are not (i.e., initial eBOM release in Phase 2).
Required attachments: eBOM - no drawings or specifications are required.
Kick off prototype tooling and to procure material for specific builds
Required attachments: Specifications required including drawings, CAD/Math data, tech specs or BOM.
Kick off production tooling including pull ahead and to procure material for specific build events.
Required attachments: Specifications required including drawings, CAD/Math data, tech specs or BOM.
Indicate a number that is properly indented in the appropriate column
Indicate the current part number which is being affected from the current bill of material
Indicate the current revision level of the part
Indicate the current quantity of the part in the bill of material shown
When the ECO is processed, enter the updated part #
When the ECO is processed, enter the updated revision
Indicate the new quantity of the part in the bill of material shown
Enter and select the Core Product Portfolio code from the choices below. Note the CPP identification may have to be
identified during the ECR process.
Primary Part
Package Part
Part Template
Custom Part
Standard Part
Not Applicable
Enter the Core Product Portfolio template number as applicable
List the description of the parts or patterns affected by the ECR.

Johnson Controls - Saft

Page 6 of 12

INSTRUCTIONS FOR FILLING OUT PARTS AFFECTED WORKSHEET (PAW)

17
18
19
20

Drawing #
Layout / Chart #
Rev:
Current External Part

21

Updated External Part

22

Stock Disposition
U
S
R
X
Service
Interchangeability:
S1

23

Enter the drawing number for the parts affected by the ECR.
Enter the layout or chart drawing number.
Refers to the revision of the drawing
Any current customer and/or supplier number for the item may be entered. Use the prefix, base, and suffix numbers
as applicable
Any new customer and/or supplier number for the item may be entered. Use the prefix, base, and suffix numbers as
applicable
Enter the stock disposition code
Use
Scrap
Rework
Not Affected
Indicate how to handle the obsolescence of a service component and/or assembly built to the current revision by
noting:
Backward interchangeability - The old part stock can only service the old. The new part services both the old and
the new. The old part tooling does not need to be maintained. The new part requires a new part number to be
assigned. The old part too

S2

Two way interchangeability - the old and new parts can be mixed together and used in place of each other,
complete two way interchangeability. The old part tooling does not need to be maintained.

S3

Not interchangeable - The old part only services the old part applications. The new part only services the new part
applications. The new part requires a new part number to be assigned. THE OLD PART TOOLING MUST BE
RETAINED FOR SERVICE. If S3 is entered

S4

Delete from configuration, old part remains in service and is not being replaced. SI=4 may also be used when
correcting a release error. THE OLD PART TOOLING, IF EXISTING, MUST BE RETAINED FOR SERVICE.
N/A (Old part is not serviced, it is not a service part)

24

S5
IMDS

25
26
27

Issue #
ECR #
ECO #

Enter Issue number

Enter ECR number
Enter ECO number

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

This box should be checked "Yes" if either of the following is true:

1. An all new material is being added to the complete end-item.
2 A material is being wholly eliminated from the complete end-item.

Johnson Controls - Saft

Page 7 of 12

INSTRUCTIONS FOR FILLING OUT PARTS AFFECTED WORKSHEET (PAW)

28

Page __of __

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Enter page number and total pages

Johnson Controls - Saft

Page 8 of 12

Engineering Change Request

PARTS AFFECTED WORKSHEET

Issue #
ECR #

Model Year: ______________

OEM/Program: _____________________
Engineer/Phone #: ____________________
ACTION Effectivity
ITEM CODE
Class

ECO #
Page ___ of ___

Assembly Level Current JCS

Updated JCS
CPP
Rev Qty
Rev Qty
0 1 2 3 4 5 Part # (was)
Part # (is)
C-Code Tplt # **

Part/Pattern Description

Drawing # /
Layout/Chart #

Rev

Current External #
Updated External # Stk
SI
IMDS
Base
Sfx Pref
Base
Sfx Disp Code Y / N
Pref
`

Action Code Legend:

CU - change usage, DL - delete/remove part, RV - revise part, NW - new part
** For further Detail, please refer to Reference Page
** C2 and C4 Must have templates (C3)

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

CPP Code Legend:

C1 = Primary Part
C2 = Package Part
C3 = Part Template
C4 = Custom Part
SP = Standard Part
N/A

U - Use, S - Scrap, R- Rework, X - Not Affected

Note: stock disposition affects production/build (not prototype)

S1 - Backward interchangeability, S2 - Two way interchangeability,

S3 - Not interchangeable, S4 - Delete from configuration
S5 - N/A

Johnson Controls - Saft

Page 9 of 12

PRODUCT COST SUMMARY

JCS Business Team :
PROGRAM RELATED INFO
OEM / Program:
Body Type:
OEM Annual Car Volume:
Production Life (Years):
SOP:
OEM-Location:
Other OEM relevant info:

JCS Volume:
JCS Amort. :

10,000

JCS Manufacturing Location:

Labor Economics:
Material Economics:
Issued by / Core Team:
Reviewed by:
PLUS Phase (Profile):
Currency:

Date Issue:
Reviewed Date:

EDT
Labor

( EDT USE ONLY )

Project Management
Design and Engineering
Machine Build
Electrical Engineering / Prog
Electrical (I.e.:Panel build, etc)

Quoted

Actual

Quoted

Actual

$0
$0
$0
$0
$0
$0

Totals

Purchased Parts

Mechanical
Electrical
Other
Totals

$0
$0
$0
$0
$0
$0

$0
$0
$0

$0

PRODUCT RELATED INFO

$0
$0
$0

$0

MAIN CALCULATION ASSUMPTIONS

Cost Source:
Cost Accuracy (Estimate/Detail/Production):

PRODUCTION COST
COSTING / PRICING

in currency

Model Mix (% of yearly Volume)

Annual Volume
HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Base Model
100%
10,000

Cost Model
#2

Cost Model
#3

Cost Model
#4

Cost Model
#5

Avg. Rate &

Percentages

Average per
Carset

TOTAL / Avg.
Year

100%
10,000

Average values

Johnson Controls - Saft

for info.only !

Page 10 of 12

PRODUCT COST SUMMARY

JCS Business Team :
Direct Material Cost
Freight-In & Packaging
Total Material Cost
Material Scrap
Material Overhead
Material Related Cost
Direct Labor Cost
Production Overhead
Production Scrap
Production Cost
Manufacturing Cost
General Plant Overhead
Plant Cost
Special Amortization
Capital Cost
SG&A
Product Cost
Margin

0.00
0.00 on Manuf. Cost:
0.00
0.0%
0.00
on S. Price:
0.0%
0.0%
0.0%
0.00
0.0%

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0.00

0.00

0.00

0.00

0.00
0.00

0.00

0.00

0.00

0.00

0.00

on Dir. Mat.:
0.0%
on Material:
0.00%
0.0%
on Dir. Lab.:
0.0%
0.0%

0.00

0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Added Value (without Inbound Freight)

Turnover (ex-works)
Return on Sales (R.O.S)

0.00
0
0.0%

0.00
0
0.0%

0.00
0
0.0%

0.00
0
0.0%

0.00
0
0.0%

0.00
0.00
0.0%

0
0

Freight-Out & Packaging

Selling Price (free delivered & packed)

0.00

0.00

0.00

0.00

0.00

0.00
0.00

Selling PRICE ex-works

()

0.00
0.00

0.00
0.00

0.00

0.0%
0
0

check row:

CAPITAL INVESTMENT
(included in piece price)

TOTAL

in currency

Subtotals
PRODUCTION TOOLING
(NOT included in piece price)

0
in currency

Base Investment
Others (e.g.Options):
Subtotals

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Base Model

Cost Model
#2

Cost Model
#3

Cost Model
#4

Johnson Controls - Saft

Cost Model
#5

TOTAL
0
0
0

Page 11 of 12

Engineering Change Request

Name

Signature

Date

Approval

Title / Location

ECR #:

HV-PLUS-FR-09-02, Rev. 01 (10-Oct-2007)

Johnson Controls - Saft

Page 12 of 12