Meridian Aerostructures machines bracket 5120-100 for Customer A (example). On September 29, 2026 the customer released drawing rev D. This is how the change moved through every tool in the kit, with the record numbers you will find in each tool's own worked example.
The change arrives (D11 change log)
Customer A change notice CN-8812 reached the contract review mailbox on September 30 with drawing 5120-100 rev D. Three changes: the two mounting holes open from 0.250 in to 0.257 in for a larger fastener; their position (0.010 in) becomes a key characteristic; the anodize note calls CPS-41 at rev F. PO 4500-1182 was amended the same week: rev D from line 4, deliveries from November 16.
R. Chen logged ECN-26-071 on October 1 and gave the assessment to M. Okafor, quality engineer, with J. Alvarez for manufacturing.
The impact assessment (D11)
Seventeen of twenty impact lines came back Affected. Not affected: special processes (same anodize, already at CPS-41 rev F under ECN-26-064), delivered product, product safety (the hole size and position follow the customer's own joint analysis; no safety characteristic on this bracket per the drawing).
Seventeen actions went on the Change actions tab, A-301 to A-317, among them: O5120 to rev 7 with a reaming pass and rev 6 deleted from the Mill 2 and Mill 7 controls; CMM program CM-5120 to rev 4; inspection plan IP-5120-100 to rev D; setup sheet SS-5120-100 to rev C; router to rev E; pin gauges PG-257 and PG-260 into calibration recall before first use; the hole-position KC on the KC register and control plan; a partial FAI on the first rev D lot.
Effectivity: lot L-2702 onward. Lot L-2698 (24 parts, already drilled at rev C) was completed to rev C against PO line 3, inside the old effectivity. Eighteen finished rev C parts in stock were reamed to rev D and re-marked, with Customer A's approval C-2238 of October 8.
The change board approved ECN-26-071 on October 7.
The process change (E13)
The new hole size needed a reaming pass, so J. Alvarez opened PC-26-019 on October 7: op 20 on Mill 7 only, drill 0.246 in then ream 0.2570 in. Risk screen: five Yes (key characteristic, inspection method, PFMEA and control plan, new tooling and gauges, training), none Not sure.
Customer A's quality clause asks for notice of process changes on key characteristics: PCN-26-07 went on October 12 and was acknowledged October 14, with no approval required. The criterion, set before the trial and approved October 9: all five trial parts within size and position, and Cpk of 1.33 or more on position over the first thirty production parts.
Trial on October 13: five of five in tolerance, position 0.0021 to 0.0034 in. Capability on lot L-2702: Cpk 1.46 on position (D16 , KC-5120-01). Three lots watched clean; PC-26-019 closed on November 2.
The documents and programs (A13)
Four issues on the issue log, October 15 and 16: IS-26-140 (setup sheet rev C), IS-26-141 (inspection plan rev D), IS-26-142 (program O5120 rev 7) and IS-26-143 (router rev E). For the program, L. Nguyen listed both controls' directories and deleted rev 6, and signed for it; for the setup sheet and plan, K. Wells swapped the copies in the Mill 2 and Mill 7 binders and at the inspection bench.
Point-of-use checks PU-26-066 and PU-26-067 on October 23 found rev C of the setup sheet in the Mill 7 binder and rev 7 on the Mill 7 control: both OK.
Earlier the same month, the same checks had found a superseded work instruction on Mill 6 and a printed rev B characteristic list behind the rev C plan for rib 6120-305: the kind of copy this change was designed not to leave behind.
The configuration (D10)
On October 22, K. Wells updated the 5120-100 line: released revision D; router rev E; O5120 rev 7 and CM-5120 rev 4; IP-5120-100 rev D; KC-5120-01; partial FAI FAI-26-071; effectivity lot L-2702 onward. Status accounting entry CSA-26-118 recorded the change, its effectivity and every item updated, and R. Chen verified it on October 23.
Configuration check CC-26-033 on October 23 took lot L-2702 at the machine: traveler rev D, drawing at the machine rev D, O5120 rev 7 on the control with rev 6 gone, CMM program and plan current, FAI covering rev D. Result: Matches.
Closure
Customer A accepted FAI-26-071 on October 28. Every action was done with its evidence, the old revision was gone from every point of use, and the registers were current. All six closure checks on D11 read Yes, and R. Chen closed ECN-26-071 on October 30, twenty-nine days after it arrived and seventeen days before the first rev D delivery was due.
What made the difference compared with ECN-26-058 in July, which ended in NCR-26-287 (a lot of ribs drilled to the old revision from a program in Mill 2's memory): the program purge was an action with an owner and a signature, the setup sheet now shows the program revision to check, and the configuration check looked at the control before the lot ran.
Date Event Tool and record Sep 29 Customer A releases drawing 5120-100 rev D CN-8812 Oct 1 Change logged; assessment starts D11 : ECN-26-071Oct 7 Change board approves; process change opened D11 ; E13 : PC-26-019Oct 8 Customer approves rework of rev C stock C-2238 Oct 9 Process change approved, criterion set E13 Oct 12 to 14 Process change notice sent and acknowledged PCN-26-07 Oct 13 Trial: five of five in tolerance E13 Oct 15 to 16 Documents and program issued; rev 6 deleted from both controls A13 : IS-26-140 to 143Oct 19 First rev D lot L-2702 released D11 , E13 Oct 22 Partial FAI; configuration updated FAI-26-071; D10 : CSA-26-118 Oct 23 Configuration and point-of-use checks: match D10 : CC-26-033; A13 : PU-26-066, 067Oct 28 Customer accepts the FAI FAI-26-071 Oct 30 ECN closed D11 Nov 2 Process change closed after three clean lots E13
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