as-built record

Core meaning

An **as-built record** is a documented description of the actual configuration, materials, and construction of a product, system, or facility at the time it is completed or released.

It captures what was **actually built and installed**, which may differ from the original design or engineering intent. In regulated manufacturing, as-built records are typically retained as part of product history or device history documentation.

Typical contents in manufacturing

In industrial and regulated environments, an as-built record commonly includes:

– Final bill of material (BOM) with actual part numbers and revisions used
– Lot, batch, or serial numbers of critical materials and components
– Configuration details (options, software versions, parameter sets)
– Records of deviations, nonconformances, or waivers that changed the design or process
– Approved engineering changes applied during build (e.g., ECNs, ECRs)
– Key process data that define the built state (e.g., torque values, calibration data, test results)
– Identification of the specific unit(s) to which the record applies (serial number, unit ID, tail number, etc.)

The level of detail depends on the product, risk classification, and regulatory expectations.

Use in MES, ERP, and traceability

In integrated manufacturing IT/OT landscapes:

– **MES (Manufacturing Execution System)** typically holds or generates the as-built record at the unit, serial, or batch level. It may include:
– Material genealogy (which material lots and components went into each finished unit)
– Route and operation history
– Operator IDs, timestamps, and equipment used
– Test, inspection, and release decisions

– **ERP (Enterprise Resource Planning)** usually contains the **as-planned** and **as-designed** structures (standard BOMs, routings, costing), and may store high-level as-built information (e.g., shipped configuration, top-level serials) but not full process detail.

For high-traceability industries such as aerospace, medical devices, and pharmaceuticals, the combination of MES data and supporting quality records commonly constitutes the authoritative as-built record for a product or batch.

Boundaries and what it is not

– **As-built vs. as-designed:**
– *As-designed* describes the intended configuration from engineering.
– *As-built* documents the configuration that was actually produced.

– **As-built vs. as-planned/as-intended process:**
– *As-planned* describes the standard process route or work instructions.
– *As-built* includes the actual route followed, including rework, holds, or alternative operations.

– **As-built vs. real-time monitoring data:**
– Real-time OT/SCADA data streams support the record but are not, by themselves, the as-built. The as-built record is the curated, contextualized, and retained representation of the final state.

An as-built record is typically not a marketing datasheet or general product specification; it is a formal, traceable record tied to specific manufactured units or installations.

Common confusion and related terms

– **As-built drawing:** A drawing or model updated to reflect the final constructed state. It is often one element of the broader as-built record but does not, by itself, capture full material genealogy or process history.
– **Device history record (DHR) / batch record:** In some regulated sectors, these formal record types include or essentially are the as-built record, augmented with quality and release documentation.
– **Configuration record:** Focuses on the configuration of a unit (options, software, parameters). An as-built record usually includes the configuration record plus the underlying materials and process evidence.

Site context: aerospace material usage and genealogy

In aerospace manufacturing, an as-built record typically links:

– Each aircraft or major assembly serial number
– The exact material lots, components, and subassemblies installed
– The manufacturing and inspection operations performed (with dates, equipment, and personnel)
– Any concessions, deviations, or repairs accepted during build

MES is commonly used to capture this unit-level genealogy and operation history, while ERP maintains higher-level inventory and costing views. Together, they support the as-built record required for long-term traceability and investigations.