Engineering & PLMFree worksheetPDF, Excel, Word exportDiscrete Manufacturing

Engineering Change Open Stock Disposition Worksheet

Every released engineering change leaves old-revision stock somewhere: on the shelf, on the floor and on open purchase orders. This worksheet lists those parts, assigns a disposition and shows the value at risk before the change is cut in.

Download:

Part number	Old rev	On hand	In WIP	On order	Unit cost	Disposition	Total affected qty	Value at risk	Owner
							10000	$400
							3800	$1,178
							160	$2,960
							108	$15,336
							900	$108

Total affected qty

14,968

Total value at risk

$19,982

Average value per part

$3,996

Largest single exposure

$15,336

Value at risk is the total cost of every unit affected, not the write-off. The actual loss depends on the disposition chosen: use up has near zero loss, scrap loses the full value, and vendor returns depend on restocking terms. Add a column for expected recovery if your finance team needs it.

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How to use the worksheet

Pull the affected parts from the ECN, then add on-hand, WIP and on-order quantities from your ERP inventory and purchasing reports. Choose a disposition for each line and an owner. The calculated columns add the quantities and multiply by unit cost so you can sort by value and focus on the lines that matter first.

Sort by value at risk and decide the largest lines first.
Use up is only valid if the old and new revisions are interchangeable.
Cancel open purchase orders before the supplier ships, not after.
Record the owner so each line has one person closing it.

The disposition options

Use up consumes old stock until it runs out and then switches to the new revision, often the cheapest choice for non-critical changes. Rework brings old parts to the new revision. Scrap and return to vendor write off or recover value. Cancel PO stops inbound old parts. Hold freezes stock pending an engineering or customer decision. The right option depends on interchangeability, safety and cost.

Reading the totals

Total value at risk is the exposure before decisions. A large number with mostly use-up lines is manageable, while the same total mostly in scrap needs management approval. Compare the figure to the benefit of the change; if the one-time cost wipes out the savings, revisit effectivity.

Common mistakes

Forgetting WIP and open purchase orders, ignoring stock held at suppliers or in consignment, and assuming interchangeability without engineering sign-off are the main traps. Also remember spare parts stock and service kits, which are often outside the production ERP view.

Frequently Asked Questions

What does effectivity mean for old stock?

Effectivity defines from which date, lot, serial number or work order the new design applies. The disposition of old stock follows from it: if effectivity is at depletion, old stock is used up first.

Who decides to scrap old inventory?

Engineering decides whether stock is still usable, quality confirms condition and finance approves the write-off according to your policy. The change board is a good place to record the agreement.

How do I handle stock at the supplier?

Ask the supplier for on-hand finished goods and raw material tied to your parts, and add them as lines with a note in the owner column. Many cost surprises come from supplier-held stock.

Can I export this to Excel?

Yes, the worksheet exports to Excel with the calculated columns, so you can share it with purchasing and finance.

If gathering on-hand, WIP and on-order data takes hours in your ERP, we can build a read-only agent that assembles it for each ECN.

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