Week 12:- Documentation Challenge

AIM: 

To create the BOM and Hardware list(BOP) for the complete Fixture assembly.

BOM : (Bill Of Material)

• A bill of materials – BOM – is the full list of every item necessary to build a product. It enumerates all parts, assemblies, subassemblies, raw materials, and components that building the product involves. It also accounts for the quantities of every item.
• A BOM may be called a product structure, assembly component list, or production recipe. “Production recipe” is the preferred term in process manufacturing industries.
• A BOM is the basis of production planning systems. The information it contains provides the primary data for other business processes such as manufacturing resource planning (MRP) and product costing. Others include plant maintenance and material provision for the product.
  BOM is a collection of all possible information that goes into building a final product. It also applies outside the manufacturing field, as in engineering, design, and material management. Other examples are sales and plant management.

• A proper BOM helps companies achieve the following:

  1. Plan raw materials purchases
  2. Estimate cost of materials
  3. Gain control of inventory
  4. Track and plan material requirements
  5. Ensure the accuracy of records
  6. Ensure robust supply and reduce the incidence of waste

Structure of a BOM:

A BOM is intrinsically hierarchical. The finished product sits at the top, and the hierarchy includes costs, quantities, part descriptions, and product codes in addition to other specifications.

The most common representations for BOMs include:

1. Single-level bill of materials – This is a simple list for a product. Each assembly or subassembly only appears once. The corresponding quantity necessary for each product is also on display. The single-level bill of materials is easy to develop, but it is not suitable for complex products. The reason is that it does not explicitly state the relationship between assemblies and sub-assemblies, or between parent and child parts. Therefore, if the product fails, a single-level BOM makes it challenging to determine what needs repair or replacement.
2. Multilevel bill of materials – This is more involved and demands more work to create than the single-level bill of materials. However, it provides more details and specificity on the parent and child parts in the product. A multilevel BOM shows the total material necessary. The product structure is also essential to show the relationship between assemblies and sub-assemblies, as well as the parent and child product.

Types of BOM:

1. Manufacturing bill of materials
2. Engineering bill of materials
3. Sales bill of materials

Manufacturing bill of materials (MBOM)-

• The manufacturing bill of materials (MBOM) consists of a structured list of all sub-assemblies or items essential to produce a shippable finished product. In addition to presenting information on individual parts, it includes information on the parts needing processing before assembly. It also explains how the different components inter-relate within a product.
• Manufacturing bill of materials (MBOM) information interrelates with all the integrated systems involved in the ordering and building the product. These include enterprise resource planning (ERP), material requirements planning (MRP), and sometimes, manufacturing execution systems (MES).

Engineering bill of materials (EBOM)-

• An engineering bill of materials (EBOM) specifies parts or assemblies designed by the engineering department. An engineering BOM showing the component structure from a functional perspective will comprise of a technical or mechanical drawing of a product.
• An EBOM is unrelated to the concepts of configurable BOM (CBOM) or modular BOM. Configurable and modular BOMs are to reflect the selection of items to create saleable end-products.
• The engineering bill of materials makes available the necessary components and directions for making a particular product. It includes things such as raw materials, parts, items, sub-assemblies, interrelated data layers.
• Other factors like those that influence the cost of the product are also part of the engineering bill of materials.

• Accuracy of engineering bill of materials is critical since the manufacturing bill of materials depends on the EBOM. Inaccurate or incomplete engineering bill of materials can translate to any of the following:

  1. incorrect product costs
  2. incorrect inventory levels
  3. inaccurate accounting
  4. production issues and details
  5. needless revision cycles

Sales bill of materials (SBOM)-

• A sales bill of materials (SBOM) provides information about a product in the sales stage. The data means the details of the product before assembly. In other ERP systems, a sales bill of material may be synonymous with kits or kitting. In an SBOM, the list of finished products and the components essential to developing them appear as separate entities in the sales order document. Rather than as an inventory item, the management of the finished product is as a sales item.

While MBOM, EBOM, and SBOM are standard, specific ERP solutions may include many different types of bills of materials such as,

1. Production bill of materials: Necessary for all Materials Requirements Planning (MRP) runs and standard production orders.
2. Sales bill of materials: Used for sales documents in cases where the parent item is listed not as an inventory item, but as a sales item only.
3. Assembly bill of materials: Similar to sales BOM, since it is the set of individual items with a specific price. The final product is also not managed as an inventory item, but as a sales item.
4. Template bill of materials: While it is flexible, there are also no real instructions with template BOM. Sales and production documents use this bill of materials type. The parent item displays first with the components listed below.

Bought Out Parts/ Bill Of Parts (BOP):

A ‘bought-out’ part is a part used in a machine or equipment that is not manufactured in-house by the manufacturer of the machine or equipment. These can be standard off-the-shelf parts from another manufacturer, for example a power supply cable or a rechargeable battery. The part appears in the Bill of Materials of the equipment with the Part / Model Number of the original manufacturer. Or a part that is custom-designed by the equipment manufacturer, but manufactured by a specialist manufacturer against design and material specified. In this case, the Bill of Materials contains the internal Part reference of the equipment manufacturer.

• Bill Of Material of Fixture assembly (P001_Z01_ST010_00_00) top level and child level:

• BOP of fixture assembly (P001_Z01_ST010_00_00) :

Conclusion:

    Thus the BOM and BOP for the top level and child part level of the fixture assembly are created.