Bill of Material (BOM)
This represents what items are consumed to produce a given item. The first consumed item is always a raw material and the final produced item is the sellable item. BOM defines the following:
-
What items are consumed to produce an item
-
Quantity of consumed item to produce a single unit of item. For instance, two quantities of consumed items are needed to produce one quantity of the produced item.
-
Lot sizing constraints of either consumed or produced item. For instance, whenever a produced item is manufactured, it has to be manufactured in multiples of 100.
-
Routing used by the BOM.
Entering Data
The BomScreen helps define the produced items, consumed items and the routing which transforms the items. The screen is divided into three parts. The first part defines the Bom, the second part defines the produced item and the third part defines the consumed item. The basic field in the bom master screen is
| Field | Description |
|---|---|
| BomId | Name of the bom |
| BomDesc | Description of the bom |
Validation
- BomId should be unique
Click on the add button and define the name of the BOM. To expand the BOM, and define the consumed item and produced item, right click on the BOM, and select Items.
The following two sub-screens define the produced and consumed Items.
-
BOM Production
-
BOM Consumption
BOM Production
Defines the list of items produced by the bom. Important definitions that need to be known while modelling at Bom Production are
Alternate Routing
An item can be produced from more than one routing. Alternate routing can be used either partly or entirely. A separate work order is created for each routing.
Selection of Alternate routing can be controlled in three ways:
-
Based on priority. The lower the number, the higher the priority. So, the first routing with a lower priority number is checked for capacity. If not available, then alternate routing will be considered
-
Based on lot size. If priority is not specified and if the routing has a different lot size, the routing is selected based on work order size. Suppose there are two routing with a lot size of 100 and 200. When a work order for 100 comes, then it will be loaded on routing with a lot size of 100. If a work order of 200 comes, then it will be loaded on routing with a lot size of 200.
-
Based on load. If both priority and lot size are the same, then a route is selected which is the least loaded. Hence a load balancing is done between routing.
Lot Sizing
Manufacturing constraints would force the breaking of one big order into multiple small orders. By default, a sales order of 73 units will be met by single work order with the size of 73 units.
Suppose lot-sizing constraints have been placed with minimum quantity = 20 units, maximum quantity = 50 units and multiple quantity = 10 units. Given lot-sizing requirements, the demand order for 73 units will be met by two work orders with sizes 50 and 30 respectively.
| Field | Description |
|---|---|
| BomId | Name of the bom |
| BomDesc | Description of the bom |
| BomId | Name of the bom |
| Item | Item produced by this bom |
| RoutingId | Routing used to produce this item |
| QtyPer | The quantity of the component to be used in the production per unit |
| MaxLotSize | Maximum lot size while creating a work order for this item |
| MinLotSize | Minimum lot size while creating a work order for this item |
| LotSizeIncrement | This indicates the multiplier in which the minimum lot quantity can be incremented till the maximum lot quantity is reached. This is to be used with minlotsize and maxlotsize field identifiers. For example, if the maximum lot quantity is 10,000 and the minimum lot quantity is 1000, the lot size multiplier could be 1000. This means the item may be manufactured in lot sizes starting at 1000 and going up to 10,000 by 1000 increments. For example, 1000, 2000, 3000, etc. A lot of 4500, would not be allowed under these constraints. |
| Priority | The relative importance of this routing with respect to other routings that produce the same end item. Used if multiple routing exists per item. The lower the value, the higher the importance. |
| Attribute | If the selection of routing needs to be done in the 2nd or 3rd level of BOM, then the attribute has to be populated. The same attribute value should be populated in the SalesOrder as well. |
| ConsiderAlternate | If the value is set to be ‘False’ then particular routing will not be considered for generating new work orders. Any open orders that are available with this routing will be considered for planning. |
| OrderSpecific | If the value is set to "True" then SalesOrderId and SalesLineId specific work orders will be generated. |
| CheckMaterial | If multiple routings are available for a manufactured item and for all the routings if the value is set to “True” then, the routing selection will be based on consumed item availability. |
| ValidFrom | Routing validity from date. It checks this date with the Requested Delivery Date of the demand order. The valid from date should be either null or greater than the Requested Delivery date for the routing to be considered. |
| ValidTo | Routing validity to date. It checks this date with the Requested Delivery Date of the demand order. The valid to date should be either null or less than the Requested Delivery date for the routing to be considered. |
Validation
- Item and RoutingId combination should be unique
BOM Consumption
Defines the list of items consumed by the BOM.
| Field | Description |
|---|---|
| BomId | Name of the bom |
| Item | Item consumed by this bom |
| RoutingId | Routing where this item will be consumed |
| Operation | Operation where this item will be consumed |
| QtyPer | The quantity of the component to be used in the production per unit |
| CheckMaterial | If the value is set as “True” the routing selection will be made based on that particular consumed item's availability. |
| ValidFrom | Consumed validity from date. It checks this date with the Requested Delivery Date of the demand order. The valid from date should be either null or greater than the Requested Delivery date for this consumed item to be considered. |
| ValidTo | Consumed validity to date. It checks this date with the Requested Delivery Date of the demand order. The valid to date should be either null or less than the Requested Delivery date for this consumed item to be considered. |
| FixedQtyPer | Requirement of consumed quantity is dependent on QtyPer of BomConsumption, QtyPer of BomProduction and WorkOrder quantity. If produced item quantity is 100 and QtyPer is 2, then the consumed item required quantity is 100 * 2. Sometimes, the required quantity of the consumed item is only dependent on the QtyPer of BomConsumption. In that case, the required quantity of a consumed item for the above example will be 2. The value of this column is either True or False. If the value is True, then it will only take the QtyPer of BomConsumption. By default, it is False. |
| AlternateMixing | If we don't want to mix the primary consumed item and alternate consumed item while allocating to the same work order demand item, then this flag should be False. By default, it is True. |
Validation
-
BomId and Item combination should be unique
-
BomId and Item association specified in BomConsumption cannot be repeated in BomConsumptionAlternate (BomId and AlternateItem) and BomProduction
BOM Consumption Alternate
One or more alternate items can be specified in BOM to substitute for a primary consumed item. They can substitute either partly or entirely. The main field definitions are:
| Field | Description |
|---|---|
| BomId | Name of the bom |
| Item | Primary item consumed by this bom |
| AlternateItem | Alternate item consumed by this bom |
| RoutingId | Routing where this item will be consumed |
| Operation | Operation where this item will be consumed |
| QtyPer | The quantity of the component to be used in the production per unit |
| Priority | The relative importance of the alternate component if more than one alternate exists for a specific primary component. The lower the value, the higher the importance. |
| CheckMaterial | If the value is set as “True” the routing selection will be made based on that particular consumed item's availability. |
Validation
-
BomId, Item and Alternate Item combinations should be unique
-
BomId and Alternate Item association specified in Bom Consumption Alternate cannot be repeated in Bom Consumption and Bom Production (BomId and Item)
BOM By Products
There could be a situation when routing can produce multiple items. These are termed by products.
Here Route 1 produces two products B1 and B2. These two items can go into a different routing to produce an entirely different item. Item B is an imaginary item and is specified in BomProduction. This is not an actual item.
| Field | Description |
|---|---|
| BomId | Name of the bom |
| Item | Item produced by this bom |
| RoutingId | Routing used to produce this item |
| ByProduct | Byproducts produced by this routing |
| Portion | Portion of by product produced in this routing |