BCP: Plan Smart, Change Smart
Introduction of BCP
BCP (Block Change Planner) can be used to identify risk components in affected assemblies such as PCBAs and modules. It helps bring all information together so the redesign can be planned in an organized way. In BCP, a block refers to an assembly or a group of assemblies that need review or redesign.
A common issue in change planning is that a PCBA is redesigned to fix LTB or EOL parts, but other risk components in the same assembly are missed due to lack of visibility. These may be NRND items, parts with low YTEOL, or components that do not meet regulations like RoHS or REACH. When these are skipped, they often become issues later and trigger another redesign. This creates a repeating cycle and makes long‑term risk control difficult resulting in requiring more efforts and cost to conduct redesign cycles.
BCP brings all risks for the affected assemblies into one place so redesigns can be planned more completely and unnecessary repeat work can be avoided.
Importance of BCP in redesign
(Understanding BCP through simple example):
Let us consider the redesign of assembly as fixing the issues on road. A simple way to look at it is through the example shown in the image. In a reactive approach, only the obvious pothole on the road is repaired. Small scratches on the road are ignored because they do not look like a problem yet. Later, those scratches turn into potholes and need another round of repair. This keeps happening again and again. BCP helps avoid this situation. It shows all the issues at the same time, including the ones that will become problems soon. This allows everything to be addressed in one planned cycle rather than going back again for repeated fixes. Once BCP is added in the workflow, the amount of time required to conduct redesign reduces because risks are being addressed proactively.
How the Current Workflow Works Today,
Workflow Without BCP
The standard workflow without BCP generally looks like the one shown below. The starting point is to identify risks or trigger points that lead to redesigning. These include EOL, LTB, NRND and compliance risks. Each risk is then reviewed on its own and addressed through separate workflows and change requests.
Workflow With BCP
When BCP is added to the workflow, it sits after the starting point and looks like the example shown below. Once the risk is identified, the workflow moves through BCP to identify all the other risks like EOL, LTB, NRND, Compliance or parts with low YTEOL in the affected assemblies. This ensures that every related risk within the affected assemblies are visible and can be addressed under the same workflow, creating a single clear path that addresses all risks together.
Long Term Impact of Using BCP
As all visible risks are handled through the visibility provided by BCP, the starting point gradually becomes lighter over time. Fewer redesigns are triggered and fewer risks appear, which brings stability and reduces effort in the long run.
Comparison of Workflows: With BCP and Without BCP
| Without BCP | With BCP |
| The workflow begins with identifying a risk or trigger point like EOL, LTB, NRND or compliance issues. | The workflow also begins with identifying a risk or trigger point as usual. |
| Each risk is reviewed on its own which creates separate workflows and separate change requests. | After the risk is identified, the workflow passes through BCP which reveals all other risks in the affected assemblies including EOL, LTB, NRND, compliance and low YTEOL. |
| Only the visible risk is addressed. Hidden risks remain unnoticed and often trigger redesign later. | All related risks in the assembly are addressed together under one workflow which avoids repeated fixes. |
| Leads to repeated redesign cycles because missed risks surface again. More effort and higher long term cost. | Redesign is completed in one planned cycle. Over time fewer risks appear which reduces redesign triggers and stabilizes the process. |
| Misses hidden risks which later force redesign | Prevents repeat redesign due to missed components |
| Higher effort and cost over time | Reduces long term effort and redesign frequency |
| Reduces long term effort and redesign frequency | Starting point becomes lighter over time as fewer risks appear |
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