The Hidden Risks of Engineering Change Orders - and How to Avoid Them

Stefan S.

Published:

August 4, 2025

•

5 min

Last updated:

Engineering Change Orders (ECOs) are the lifeblood of continuous product improvement. They document modifications to designs, parts, or processes, ensuring that teams across engineering, manufacturing, and supply chain are working from the same playbook.

But ECOs are also double-edged swords. When poorly managed, they can introduce confusion, delays, and unexpected costs that ripple through the business. In this post, we’ll look at the key risks of ECOs — and, more importantly, what you can do to counter them.

‍

1. Data and Documentation Risks

The risk: Version confusion is one of the most common headaches. If multiple versions of CAD files, BOMs, or specifications circulate, teams may build or order the wrong parts. Missing updates to drawings or testing procedures can also lead to costly mistakes.

How to counter it:

Use a centralized PDM/PLM system to maintain a single source of truth.
Enforce strict revision control and automatically update linked documentation (drawings, work instructions, service manuals).
Integrate your PLM with ERP/MRP so production always sees the correct version.

2. Process and Execution Risks

The risk: Delayed approvals, unclear ECO scope, and manual workflows often stall production schedules. An ECO that isn’t well-defined may cause rework, while inefficient approval routing can bottleneck critical changes.

How to counter it:

Define a standardized ECO workflow with clear roles and responsibilities.
Use digital approval workflows with automated notifications to prevent bottlenecks.
Establish clear ECO categories (minor vs. major) to avoid overburdening the process with small changes.

3. Product and Quality Risks

The risk: If an ECO isn’t fully vetted, it may introduce new product defects. Inconsistent implementation across assemblies can lead to product variants that confuse customers or fail compliance checks.

How to counter it:

Require simulation, testing, and DFM reviews before release.
Roll out ECOs in controlled phases to monitor quality impacts.
Maintain complete traceability for audits and certifications, especially in regulated industries.

4. Supply Chain and Cost Risks

The risk: Changing specifications without considering the supply chain can create obsolete inventory, scrap, or unplanned tooling changes. If suppliers aren’t notified promptly, they may continue shipping outdated parts.

How to counter it:

Run an inventory impact analysis before approving the ECO.
Communicate changes to suppliers early through portals or automated notifications.
Implement an ECO cut-in date (e.g., “effective from lot X”) to prevent overlap between old and new parts.

5. Communication and Collaboration Risks

The risk: Not all stakeholders receive or understand the ECO at the same time. Manufacturing, procurement, or service teams may be caught off guard. Global sites or contract manufacturers might continue working with outdated information.

How to counter it:

Use a PLM system that pushes updates to all stakeholders simultaneously.
Provide role-based dashboards so each team sees what’s relevant to them.
Include customer-facing documentation (manuals, datasheets, warranties) in the ECO scope to ensure consistency.

Final Thoughts

ECOs aren’t just paperwork — they’re critical change agents that keep your product competitive, compliant, and manufacturable. But without robust processes, they can create more problems than they solve.

The antidote lies in traceability, standardization, and communication. By investing in the right tools and workflows, you transform ECOs from a risk into a strategic advantage.

‍