When creating a new Engineering Revision for a component part (will refer to as lower level) we make the part Active and then Release. At the release stage we check the box to replace the “where used” and select all parent parts (will refer to as sub-level parts) that include the lower-level part in their structures. These sub-level parts are already ‘released’ and previously transferred to inventory. When the lower-level part is replaced, it flips the ‘PDM Preliminary Rev. Change’ from ‘Not Changed’ to ‘Changed’ of all “where used” parent sub-level parts.

After the lower-level part is transferred, its “PDM Preliminary Rev Change” will flip from “Changed” to “Transferred.”  However, the parent “where used” sub-level parts affected will remain in a “Changed” state. Note this condition has been observed through intentional testing. During a normal business operation, the parent “where used” sub-level parts are not typically viewed on the Transfer Actions screen.

Subsequently, at a point in the future, a Parent (refer to as Top Level) will be updated to a new revision and transferred (all levels). When this occurs and an affected sublevel part is included in the Top-Level structure, a new Inventory Revision for the same Engineering Revision of the sub-level part is created. The new revision of the sublevel part is redundant and is “Not in Effect” because a new structure is created in a “Tentative” status. The issue is negatively impacting operations because MRP is not driving demand for the sub-level part. By the time operations identifies the issue, the manufacturing and shipping schedules may be delayed.

If the sub-level has ‘PDM Prelim Rev Change’ of ‘Changed,’ when the top-level is transferred, you can see in the Engineering Transfer in process/ Engineering Structure Transfer Graphic that the Sub-Level requires review by looking at the Eng. Action with the status of ‘Review Existing.’

Questions:

Is this normal behavior?
When a component has a new engineering revision and you replace where it is used which level should you transfer?

That one component part could be used in 100 sub-assemblies. Would you really need to retransfer them all or go into actions and change them back to ‘Not Changed’ to avoid a new tentative inventory revision?