What is an Engineering Review?

It may have been a long time since you've evaluated how your company handles its quality initiatives, or you may know you can do better but need help identifying process improvements. An internal review of processes can seem arduous, but taking the time to identify measurable business improvements will lead your company to deliver higher-quality products. With a plan to improve your quality processes, becoming a more efficient and agile manufacturer is easy.

In the realm of quality management within manufacturing environments, the significance of engineering reviews cannot be overstated. These reviews serve as critical checkpoints throughout the lifecycle of a project, ensuring that the engineering design process, development, and quality management software (QMS) implementation align with established standards, requirements and objectives.

An engineering review aims to understand your company's general manufacturing and quality challenges. Conversations with executives and department managers help to define quality objectives, pain points and strengths. Needs are identified, and quantitative gains are presented in a detailed engineering review summary. An engineering review is a low-risk investment that often uncovers some impactful opportunities for organizational change.

If your company needs to examine its quality initiatives, an engineering review can help identify some of the following:

• Key compliance issues
• Redundant processes
• Reductions in labor cost
• Reductions in Nonconformances and Corrective Actions
• A path to a paperless shop floor

A senior-level consultant will begin with an on-site visit to survey your quality processes. If you decide to move forward with new quality software, information concerning implementation plans that can facilitate a future solution deployment will be gathered. Major topics covered include ERP/MRP systems interfaces, implementation schedules, product demonstrations and a review of your current factory systems and processes.

The review will consist of two significant elements: a review of your business processes, documents and shop floor operations; and a look at the software modules under review as they relate to your defined processes. You can discuss your company's processes to show the vendor how the software solution should be applied to meet your objectives.

Collecting documentation of your quality processes before the consultant's arrival, whenever possible, is essential. These documents will help identify gaps, module utilization and implementation scheduling/planning. Computerized screen printouts are helpful supplements to existing hard-copy documentation. Documents in electronic format are more accessible to transport and can included in the engineering review summary.

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1. Scope definition: Before commencing an engineering review, it is imperative to define its scope, objectives and evaluation criteria clearly. This narrative ensures that the review team focuses on pertinent aspects of the project and facilitates a comprehensive assessment.
2. Multidisciplinary participation: Engineering reviews involve participation from diverse stakeholders, including engineers, the design team, subject matter experts, project managers and quality assurance professionals. This multidisciplinary approach ensures that various perspectives are considered, fostering thorough scrutiny and comprehensive feedback.
3. Documentation review: A fundamental aspect of engineering reviews is examining project documentation, including the design process and specifications, requirements documents, test plans and progress reports. Reviewing documentation enables the identification of discrepancies, inconsistencies and deviations from established standards.
4. Technical analysis: Engineering reviews entail a detailed technical analysis of the project's design, methodologies and implementation strategy. This analysis assesses the feasibility, efficiency, robustness and adherence to best practices.
5. Risk assessment: Identifying and mitigating risks is integral to the success of any manufacturing endeavor. Engineering reviews incorporate risk assessment activities to evaluate potential threats, vulnerabilities and uncertainties that may impact project outcomes.
6. Decision making: Based on the review's findings, decisions are made regarding the acceptance of deliverables, approval to proceed to the next phase, revision of designs, or implementation of corrective actions. The collective insights and recommendations inform the review team's decisions.

1. Identify systems for replacement: The first step in an engineering review is identifying the systems needing replacement. This identification involves assessing the current software and hardware, determining their limitations and shortcomings, and establishing the requirements for a new solution. By thoroughly analyzing the existing systems, the review team can pinpoint areas for improvement and define the project's scope.
2. Manufacturing site walk-through and system review: Upon identifying the systems to be replaced, the next step in an engineering review involves conducting a manufacturing site walk-through and system review. This on-site assessment provides the review team with firsthand knowledge of the production environment, equipment layout, workflow processes and interdependencies between systems.
3. Identify ERP and other required system integrations: Integration activities are crucial to engineering reviews. Once the systems to be replaced have been identified and the manufacturing site has been assessed, the next step involves identifying any required Enterprise Resource Planning (ERP) and other system integration activities. The integration effort includes evaluating how the new systems interact with existing software, hardware and processes to ensure seamless operation. Furthermore, integration activities may involve coordinating with third-party vendors or internal departments to facilitate data exchange and interoperability.
4. Risk assessment and mitigation: A comprehensive risk assessment involves evaluating potential risks such as technical challenges, resource constraints, regulatory compliance issues and operational disruptions that may impact project execution. Once risks are identified, appropriate mitigation strategies are developed.
5. Describe any data conversion activity: A review of data conversion requirements involves assessing the existing data formats, structures and quality to determine the feasibility of transferring data to the new systems. Data conversion activities may include migrating databases, transforming file formats and ensuring data consistency.
6. Review software modules of interest in detail: Companies should assess their quality management needs and choose the appropriate modules in a configurable quality management solution to include in their implementation. A demonstration of functionality may be required to thoroughly understand an individualized use case for each module of interest.
7. Identify process improvement opportunities and define quality objectives: When conducting an engineering review, it is essential to identify any process improvement opportunities and quality objectives that may arise from implementing new systems or software. This effort involves evaluating current processes and workflows to determine where efficiency gains, bottlenecks are eliminated, or quality is improved. By identifying and addressing these opportunities during the engineering review, companies can optimize their operations, avoid costly mistakes and maximize the benefits of system integration.
8. Answer subject matter expert (SME) questions concerning software capabilities: During the engineering review process, subject matter experts (SMEs) may have questions regarding the software's capabilities being considered for integration. These questions could range from how the software handles specific data types to managing user permissions and security protocols. Addressing these questions is crucial in ensuring that the chosen software meets the organization's requirements and aligns with its long-term goals.
9. Document desired software or process change requirements: To document any desired software or process change requirements, companies should create a detailed list of modifications to align the existing systems with the new software or processes. This may include changes to user interfaces, data input procedures, approval requirements, workflow automation or reporting capabilities. By documenting these requirements thoroughly, organizations can ensure that all necessary adjustments are communicated and addressed during the implementation phase.
10. Create a high-level implementation plan, including implementation phasing and functional deployment priorities: To ensure a smooth QMS implementation process, it is crucial to create a high-level implementation plan that includes the phasing of the implementation and prioritization of functional deployment. This plan should outline the stages of the implementation and identify the key functionalities that need to be deployed first. Companies can effectively manage timeframes and resources to integrate new systems or software successfully by having a clear roadmap for the implementation process.

1. Quality assurance: Engineering reviews serve as a mechanism for quality assurance, ensuring that the project adheres to defined quality standards, regulatory requirements and customer expectations. Engineering reviews mitigate the risk of costly rework and schedule delays by detecting and rectifying defects early in development.
2. Continuous improvement: Engineering reviews facilitate continuous improvement in processes, methodologies and deliverables through constructive feedback and iterative evaluation. Lessons learned from previous reviews inform future decision-making and foster a culture of innovation and excellence.
3. Risk mitigation: Engineering reviews enable proactive risk mitigation strategies by systematically assessing risks and vulnerabilities. Early identification of potential issues allows for timely interventions, minimizing the likelihood of project failures or setbacks.
4. Alignment with objectives: Engineering reviews ensure alignment between project objectives, stakeholder requirements and technical solutions. By validating that project deliverables meet specified criteria and address stakeholders' needs, engineering reviews enhance the likelihood of project success and customer satisfaction.
5. Regulatory compliance: In regulated industries such as aerospace and defense, energy and utilities, and medical devices, engineering reviews are essential for demonstrating compliance with industry standards, statutory regulations and safety protocols. Compliance with regulatory requirements is imperative to uphold product integrity, reliability and safety.

In conclusion, engineering reviews are pivotal in quality management for manufacturers. By facilitating comprehensive assessments, informed decision-making and continuous improvement, engineering reviews contribute to achieving project objectives, adherence to quality standards and customer satisfaction. Embracing engineering reviews as an integral part of the project lifecycle fosters a culture of excellence, innovation and reliability in manufacturing endeavors.

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