Indented Bill of Material: The Top-down breakdown of the structure of a product. In an indented BOM listing, every subassembly and component is indented one level from the assembly or subassembly into which it goes.

Parent and Child Relationships in BOM’s: Each product “parent” has an indented list of “child” components and subassemblies that go into it. Each child item is indented under its parent and may in turn have child components indented under it.

Accepted Manufacturer List (AML): The AML is the list of manufacturer part numbers entered in the Inventory Control Mgt.- Quantity Info screen. A manufacturer must first be set up in the Inventory Control Mgt./ Part Manufacturer Setup before its approved part number can be added.

Accepted Vendor List (AVL): AVL’s show which manufacturers are approved or qualified for use for a particular customer’s product line or individual product. Only manufacturer part numbers that have been entered in the AML for a particular item can be selected or deleted from the AVL for a customer. A customer’s Approved Vendor List of manufacturers for each internal part is maintained in that customer’s Consigned Inventory record for that part.

Consigned Inventory AVL Record: When a Customer part number is assigned in the Inventory Control Mgt.- Customer Reference screen, a Consigned Inventory Record is generated for that item and customer. The Quantity Info screen for the Consigned Customer part number is where the Customer’s AVL is maintained. Q.Do I have to go into the Inventory Control Management module and assign a customer to the part number? A.Only if the user wants the cross-reference to the customer part number to show for internal parts on the BOM. This field will show up if a BOM Assembly is attached to a specific customer.

Anti-AVL: Normally the AVL for each customer applies to all of their product BOM’s. However, if a customer wishes to disqualify a manufacturer from use in one particular BOM, removing a check-mark from the Anti-AVL field may be used to keep the otherwise approved manufacturer from being used on specific BOM’s.

Generic and Manufacturer Preferences: A Generic (Genr) manufacturer means that any manufacturer’s part can be used.Generic is generated by the system as the default manufacturer if no other is specified. If specific manufacturers are listed for a part, preferences for use in an Internal or in a Customer’s product may be entered. Preferences are entered in the Inventory Control Mgt.- Quantity Info screen as 1 for 1^st, 2 for 2^nd, etc. next to the manufacturer.

Functions  

Bills of Material serves many functions in the manufacturing environment. They are central to all manufacturing operations and are used for everything from product specification to quotation document. BOM’s are key to material requirements planning, kit organization, product structure, and configuration control.

Material Requirements Planning (MRP): The BOM is the master plan for building product. An indented BOM from the product top level down to the lowest level component provides the entire material picture for a product. Its quantity and manufacturer preferences are used to kit materials for production to assemble. Its linkage to Item Master Purchase and Production Lead Times and Work Center offsets are used by the MRP to determine which parts to purchase or make and when to provide them. By listing multiple manufacturers and alternate part numbers, the BOM can be used to manage work order shortages.

Kitting by Work Center: Selection of a Work Center for each BOM Line Item causes that item to be kitted with other parts for that Work Center. Grouping of the parts needed for the first Work Center helps determine when to start a work order and eliminates the need for sorting out needed parts at each Work Center. Also if parts are not kitted until needed for later work centers, they need not be purchased or made until closer to the time they are actually needed.

Production Offset: This time difference between the start of the kit for the first Work Center and the kitting for the Work Center where the part is needed is called Production Offset and can be entered for each line item in the BOM. For example, mechanical parts and chassis parts may not be needed until the work order reaches the final assembly work center. By identifying those parts as Final Assembly parts and entering “x” number of days of Production Offset, the parts will not be scheduled for delivery by the MRP nor need they be kitted for “x” days later than the rest of the Work Order. An entry in this field will displace the due date required by the amount of offset established in the BOM. If the user wanted a part or assembly to be ready on the third week of an order that took 4 weeks, then the user would enter a 3 week offset, and the MRP module would suggest ordering the parts three weeks later than otherwise. Please refer to the Material Requirements Planning Management manual.

Engineering Change Control: BOM’s are unique by their revision number and as such are used to control changes to the structure or components in a product. By creating a new Revision level of the BOM with an Effective Date the next day after the Obsolete Date for the old BOM Revision, the user can drive changes in material requirements, kitting and work orders. Or if the new BOM Revision level is to co-exist with the down-rev. Revision, the new BOM is just activated without obsoleting the old BOM. With BOM Revision control, several revisions may exist with different definitions for each. BOM Notes may be used to record Engineering Changes for tracking purposes in the absence of a formal ECO system or documentation.

This is the screen that appears when opening the module. The product number is displayed in the Bill of Material Module screen header as a reference.  The product information will remain on screen while viewing other sections of the BOM module.  BOM Main may be used to view, edit, add or delete a Bill of Material.  BOM Header information is displayed for any item located after a FIND.  If any Line Items have been added to an assembly in the BOM Header, they will be displayed in the Detail Window below.  The lines that are inactive will be highlighted in purple. Selection of a Line Item in the Detail Window will cause the other BOM screens to be populated with default and/or added information for that Line Item. Start with this screen to add a new BOM, edit an existing BOM, add a new Line Item or change detail information for existing Line Items.                

The Header Information fields across the upper half of the screen are populated from the item master and from keyed-in assembly data. The fields in the Body (Detail Window) show information about the components included in the assembly.

BOM Main Field Definitions

Depressing the down arrow will display the history of the BOM components. Current reflects the most recent listing; BOM History will display the history of changes. Selected Date will bring up a selection screen.   Note:  If the effectivity and obsolete dates are used, then it is possible to check the specific parts list at any given data using the BOM history.

Status	The BOM Status:  Active - BOM is Active;  Inactive - BOM is Inactive which will affect Cost Roll up.   NOTE:  Changing the BOM status to Inactive will NOT remove the MRP demands you MUST Inactivate the part number in ICM to remove the MRP demands.  See Article #3430 for further detail. Quote -  This status is in case a BOM is in a quote stage and the user needs a reminder that the quote for this BOM is pending.      This status is for the BOM ONLY, it will NOT change the status of the Inventory part.  The Inventory part status and BOM status can be different.  This is to allow flexibility so the BOM can be inactive and will NOT be displayed in the BOM module, but the part will still be displayed in the inventory listing.   Users will be allowed to change the status on a BOM from Active to Inactive with open SO, WO, etc. and MRP will still show demands.  Users will also still be allowed to Create NEW SO, WO, etc if ONLY the BOM status is Inactive.  Users will NOT be allowed to change the status on the Inventory part from Active to Inactive with open SO, WO, etc.
	When the BOM is made Inactive this field will display the status along with the date and Initials of the user that Inactivated the BOM.
	This allows the user to find part by Reference Designator.  If user starts typing reference designator into the text box it will auto fill the information, when done entering user can press "Enter" or click on the search button next to it and the record pointer in the grid will advance to the part if a match is found.
Customer Name	The name of the customer for whom the user is making the assembly.Select from pull-down list. Add new customers in Customer Information Management. Use Standard Pricing as the customer or leave blank if the assembly is built to stock or has more than one potential customer. This field must match the Customer for any Consigned parts used in the BOM.
Setup Stscp	This box MUST be checked if you wish for the setup scrap qty’s to be included in the Kitting and MRP calculations,  Checking this box along with a Standard Bld qty will tell the system to use Setup Scrap when calculating the standard cost.   Note:  The "Exclude Scrap & Setup Scrap" options within the  Kitting Setup module will overwrite this option.
Standard Bld	The quantity normally built. Entering a quantity in this box will be used when calculating the Standard Cost.  See Article 3040 for information on how this affects the Std Cost.  See Articles #3067 , #3053 , and #3320 for information on how this affects the Configuration Variance.
Last Change	The date and time of the last change to the BOM automatically enters this field.
By	Initials of user that made last change to BOM.
Mgmt Lock	This option is for BOM's that need to be protected, even from those users that have edit capabilities.  Only Supervisors or users with Lock/Unlock rights within the Security/User rights can modify this checkbox.   If locked, all users can access the screen,  but only supervisors or those with Lock/Unlock rights will have the capability to bypass the lock and make changes, while the BOM is still in lock mode.  The reason we do NOT force the user to unlock the BOM before making any changes, is to protect it from anyone else making changes while the  'authorized" user is making their changes.
Lock Date	The date the Managment Lock Box was checked.
By	The initials of the user that check the Managment Lock Box.

COMPONENT INFORMATION (Displayed in the Body (Detail Window)

When the user has displayed component parts on the BOM Main screen, and has highlighted one of the parts, pressing on the Item Detail Tab will display information about

that component part.  The NEXT and PRIOR buttons are activated in the Detail Information Tabs. Clicking on either button will display the details of the next component in the BOM.

The first row of Header information repeats the assembly Product information.

The remaining fields describe Detail information about the component part.

HEADER INFORMATION 

 COMPONENT INFORMATION

DIRECTIVE BUTTON

The following button is displayed on the BOM Item Detail screen:

Pressing the BOM Item Note button will allow the user to create a notation specific to the component shown, in the current BOM.  To enter a note, depress the BOM Item Note button.  Depress the edit button.  Type in the note.  Depress the Save button.  Depress the Exit button.

When the user has displayed component parts on the summary screen, and has highlighted one of the parts, pressing on the AVL & REF Tab will display Part Manufacturer and Reference Designation information about the component part.  The NEXT and PRIOR buttons are activated in the AVL Information Tab. Clicking on either button will display the AVLs of the next component in the BOM.

The first row of Information displays the selected detail part information.The Customer Part Number will be displayed if entered in the Item Master.

The Right Center portion of the screen displays the reference designators assigned to the component. These fields are optional, but must be completed if reference designator information is to be used in the quality defect collection information.  (The ref designators are case sensitive).

The bottom portion of the screen is available to list alternate parts that may be used in the absence of the primary part. However, these alternate parts are not listed on kit lists, and are only displayed on this screen. On the BOM, Manex provides a place for users to identify “Alternate Part” for each part called out in the BOM. However, this is for information and cross reference ONLY and there is no connection with the MRP, Purchasing or Kitting, etc. modules. The concept here is that if the engineers want to include alternate (not preferred, and not on AVL) parts for the possibility that in case purchasing can’t get the original parts called for by MRP, they could look up the alternate part on the BOM, and then order that part. However, to get the part into the kit, they will have to add the alternate part as a line shortage to the Work Order, and also check the “ignore shortage” for the part(s) originally required and short on the Work Order. Then MRP will work as needed, and the kit will show the alternate part as a (line) shortage until filled. Incidentally, creating the line shortage and checking the ignore shortage for the original part will result in an MRP directive (the next time it is run) to buy the alternate (line shortage) part. Please refer to the Material Requirements Planning and the Kitting, Allocating & Shortage Management modules.

AVL & Ref Designator Field Definitions

COMPONENT INFORMATION

AVL INFORMATION

REFERENCE DESIGNATOR INFORMATION

Number	The sequential number assigned to each occurrence of the component on the assembly.
Ref Designator	The assigned location for each occurrence of the part. (The ref designators are case sensitive).
Prefix	A prefix assigned to reference designators for the current component. Is usually a “C” for capacitors, “R” for resistors, etc
Start No	If the user wishes to fill in the reference designators automatically, then the start number will be the beginning number in the sequence of reference designators assigned.
End No	If the user wishes to fill in the reference designators automatically, then the end number will be the last number in the sequence of reference designators assigned.
	Pressing the Calculate button will fill in all reference designators with the prefix plus incremental numbers beginning with the start number entered.
Quantity	The quantity of components used in the assembly.

ALTERNATE PART INFORMATION

These items are the same as previously described.

DIRECTIVE BUTTONS

	Pressing the Add button in the ALTERNATE area will allow the user to add additional item master part numbers as approved alternates.
	Pressing the Delete button in the ALTERNATE area will allow the user to remove item master part numbers as approved alternates.

To enter the Bill of Material Module depress Quality/Engineering/Integrated BOM & AVL

When the screen first opens, the user is limited to only three of the eleven action buttons shown: Find an assembly, run a Report or Exit.  After finding an assembly, the user may page ahead or back through all Make items using the > right arrow or < left arrow button.  Assemblies having Bills of Material will display the components in the Body (Detail Window) below. Selection of one of the components in the window will cause detail information for that item to be displayed if any other BOM screen Tab is selected. Use the Add icon to add components to the BOM of a displayed assembly.  Use Edit to change or add Header information. Use the Delete icon to Delete the entire BOM ONLY (See Deletions section).  Note: Go to the Item Detail screen to delete only one item from the BOM.

Find a Bill of Material

Find an existing BOM screen selection will display: Select the desired search radials by clicking on them. Choose between Active, Inactive or All for the status, (Note:  The status of the BOM may be different than the status of the Inventory Part).  Since you are doing a find for the BOM you would search by the status of the BOM.   Check the "Display Customer Part #..." box to display the Customer Part number for the "Buy" parts if the BOM is linked to a customer.  Selecting this option may slow down the results.  The system will retain the last choice the user makes for this check box until the module has been exited.

If you know the product number, click on the Search by product number radial and then type the part number into the red box and depress the OK button. If the part number entered cannot be found you will receive a message (shown in the screen) asking you if you would like to select Product from the list of Products.

Depress "YES" and a List of Products will be displayed in the bottom section of the screen.  The parts are listed in alphanumeric order, with the Revision, Product ID, Class and Type.  Note:  The status listed on the right of the screen is displaying the status of the Inventory Part not the status of the BOM, which may be different.  The user selects the Part Number by either entering it into the red box, or scrolling down the list and clicking on the selected part.

Find a BOM by Part Class

If you know the Part Class, click on the Search by part class radial and then type the part class into the red box and depress the OK button.

When the user is searching for an assembly through the part class option, a screen appears listing all of the products within that  class in alphanumeric order. Note:  The status listed on the right of the screen is displaying the status of the Inventory Part not the status of the BOM, which may be different.  The user selects the Part Number by either entering it into the red box, or scrolling down the list and clicking on the selected part.

Find a BOM by Customer

If you know the Customer, click on the Search by Customer radial and then type the Customer into the red box and depress the OK button.

When the user is searching for an assembly through the Customer option, a screen appears listing all of the product numbers assigned to that customer in alphanumeric order. Note:  The status listed on the right of the screen is displaying the status of the Inventory Part not the status of the BOM, which may be different.  The parts are listed in alphanumeric order, with the Revision, Class and Type. The user selects the Part Number by either entering it into the red box, or scrolling down the list and clicking on the selected part.

BOM Search Results

A BOM Header is created by the system when a Make Item is added to the Inventory Control Mgt Item Master and Saved. When the user wishes to create a BOM by adding Line Items to the header, the existing Header is used. The Header identifies the assembly or product and its revision level, shows the status and after creation,  allows Viewing BOM components by Current, All, or Selected Effective Dates.

Depress the Find button. See Article #571 for Find procedures.

 

 

 

 

Depress the Edit button.   Enter your password. The following selection screen will appear: Select BOM Header Information button.

Select status from the drop down menu.  When selecting the status, this status is for the BOM ONLY, it will NOT change the status of the Inventory part.  The Inventory part status and BOM status can be different.  This is to allow flexibility so the BOM can be inactive and will NOT be displayed in the BOM module, but the part will still be displayed in the inventory listing.   User will be allowed to change the status on a BOM from Active to Inactive with open SO, WO, etc. and MRP will still show demands.  User will also still be allowed to Create NEW SO, WO, etc if ONLY the BOM status is Inactive.  Users will NOT be allowed to change the status on the Inventory part from Active to Inactive with open SO, WO, etc.

If there is a Customer associated with this product, select the customer by depressing on the down arrow next to the customer box. A list of customers will appear. Highlight the customer name and double click. Assigning the customer name to the BOM is an option which you can elect to use or not as long as there is no consigned part. If you do not assign an assembly to a customer, this BOM can be used for any customer you want and not limited to a customer. Assigning to a customer is a requirement if you have any consigned part within the BOM. For the sales price, we allow you to add one or more customers in the Price List module and you can determine the quantity breaks and prices by each customer for the same assembly. When they are assigned in the Price List, SO module will show those assemblies only tied to the customer and avoids having to wade through all assemblies. If BOM is assigned to specific customer, and if there is CONSG part in the BOM -- Only that customer will be available in the WO customer list If BOM is assigned to specific customer, and no CONSG parts in the BOM -- Default to that customer, but all other customers are available to be selected. If BOM is not assigned to specific customer, all customer should be available.

To enter a BOM Note depress the BOM Note button.  Depress the Edit button. Enter in the note. Depress the Save button. Depress the Exit button.

If you want set up scrap to be considered in Standard Cost calculation, check the Setup Stcrp box.

Bills of Material may be built up using one of three methods:

1. Using the mouse to Drag and Drop
2. Keyboard data entry (Manual Entry)
3. Copying an existing BOM 

1.  Procedure for Drag & Dropping

The Drag and Drop Operation allows the user to select components in the Summary screen of Inventory Control Management and drag the items into the Integrated Bill of Material & AVL Main screen to add them as line items in the BOM.

Use this procedure as an alternative to Manually Adding Line Items to a BOM.

Open the Inventory Control Mgt. Summary screen and use Find to display the desired components.

Size the Inventory Control display by placing the cursor on the far right hand side of the display.  Wait until it turns into an arrow.  Holding the mouse button down, move it to the left until just the following displays:

Open the Integrated Bill of Material & AVL BOM Main screen, position it in the lower right hand corner of the Manex screen. Depress the Edit button and enter your password.

The following selection screen will appear: Choose Drag and Drop.
The following message will appear:

Move the cursor to the Inventory window. Highlight the desired component. Use the left mouse button to select an item in the Inventory Control Management screen. Release the left mouse button. RIGHT click on the mouse button and CONTINUING TO HOLD THE RIGHT MOUSE BUTTON DOWN, move the mouse cursor over to the BOM screen. Release the right mouse button.

Note:  When you drop (release the mouse button), be sure that you have the cursor over the white area,. Drag each component into the BOM in Line Item # sequence.

Enter the quantity of the part per assembly when prompted.  Select the Work Center.

Type in the prefix for the Reference Designator. Type in the Reference Designator Start Number. Depress the Calculate button.

The Number and Reference Designator Fields will fill in.

Depress the Item Detail tab in the BOM module. The following screen will appear:

Review the detail. If you want to make any changes, depress the Edit button while this screen is open. Type in your password. You may change Item Number, Work Center, Quantity, Production Offset days, Used in Kit, and may add Effectivity Date and Obsolete Date. Depress the Save button.

The following selection option will appear:   If you select Internal Part Number, then enter the Part Number into the Red Box.

If you select Consigned Part Number, Select the Customer from the Pull Down list, then enter the Customer PN into the Red Box.

Information regarding the alternate part will display in the bottom section, as displayed below:

Depress the Save button.

Procedure for Manually Adding Line Items

Use this procedure as an alternative to Drag and Dropping from the Inventory Summary screen.

Open the Integrated Bill of Material & AVL BOM Main screen and Find desired Header.

To add a component, click on the Add Record button, enter password.

The following screen will appear: Select "Yes" or "No" to Auto Line Item Numbering.

The item detail screen will appear:

 

In the Item Detail screen select Work Center to Kit to (use Material Staging if not known), from the drop down menu:

Then select Source (Make, Buy, Consigned or Phantom), from the drop down menu:   When building a BOM in order to have the Source "CONSIGNED" displayed a Customer MUST be assigned to the BOM.   When building a BOM and you enter the source as a “Phantom”, then when entering the part number that is a “Make/Phantom”, the source changes to a Make” part.   The reason the source field shows at all is to limit the number of part numbers that are available to choose from.   But you can enter any valid part number and the source will change to the source of the part number entered.  So, yes, the source of the sub-assemblies will show as a “Make” part, even though they are actually “Make/Phantom” parts. The details of the BOM will also show they are “Make/Phantoms”.   We allow nested phantoms, of either the “PHANTOM” or the “Make/Phantom” variety.  In kitting, we have the code to blow down through the first level of make/phantoms, so that the parts included in the first sub-assembly level down are listed as kit requirements. We have extended this further so that if there are Make/Phantom parts in the first sub-assembly level, those also break down to the components in the second sub-assembly level.  This process extends as long as there are “Make/Phantoms” in the indented BOM.

Either enter the item number by typing it directly into the Part Number field or select Part Class and Part Type, as illustrated below:

Select the Part Class.
Select the Part Type.
Depress the down arrow next to the Part Number box. A list of all of the inventory parts within the selected Class and Type will appear. Type the Part Number into the Red box or highlight and double click to select. If the item is a Consigned Item, enter either the Customer part number OR the Internal Part number, in the respective fields

If you added an internal part and if there is a matching Customer part number in the Inventory Customer screen, it will automatically appear as soon as the internal inventory part is selected.  Conversely, if you typed in a customer part number, the internal part number information will automatically appear.

Enter the Quantity of the item required for each assembly produced.

(Note: Extra parts for setup or run losses should be added in the Inventory Control Mgt. Item Master Run Scrap % or Setup Scrap Qty. field, not in the Bill of Material.)

Enter the production offset days by toggling on the up and down buttons.

If the component is to be pulled in the kit, leave the Y in the Kit box.If not, remove it.

Enter the effectivity and obsolete dates, if desired.

Depress the AVL & Reference Designator tab

If you want to add alternate parts, depress the AVL and Reference Designator tab. Depress the Add button next to the alternate parts section of the screen.

The following selection option will appear, Select Internal Part Number, enter the part number in the red box.

If you select Consigned Part Number, select a Customer from the pull down list, enter in the Customer Part Number in the Red Box.

Information regarding the alternate part will display in the bottom section, as displayed below.

Once user has completed entering all information for line item number, depress the Save button.

Procedure for Copying from an Existing BOM

Depress the Copy button and enter the user’s password will prompt the user for the existing bill of materials from which to copy the components.

If the BOM being copied from contains references to a customer, and or consigned part numbers, the following message appears:

MANEX will populate the new assembly with all of the part information from the existing assembly, except for parts belonging to a customer. Those items will have to be added manually. The filled in BOM is displayed below:

Depress the Edit button to add the customer name and any other needed changes, in any of the screens.

The Delete button takes on dual meanings.  If the user is in the BOM Main Tab when the button is pushed, the button will delete ALL items on the BOM.   You will be prompted for your password. The following message will appear: 

If there are open work orders for the assembly, then the user is presented with a prompt advising that the bom cannot be deleted while open orders exist, as displayed below: 

If the user is in the Item Detail Information Tab when the button is pushed, the button will delete only the item highlighted.  You will be prompted for your password.  The following message will appear:

Use this procedure to edit Line Item details after entering BOM Header information and Line Item Part Numbers and Quantities per assembly manually, using drag and drop, or copying.

Click on the Item Detail tab.  Depress the Edit button and enter password. 

The Item number, Work Center, Qty, Production Offset, Used in Kit, Effective Date, and Obsolete Date can be edited on this screen. 

The Production Offset would be edited, If an item is to be kitted to a Work Center that will not be reached by the Work Order until X days later, enter X days in the Production Offset to allow kitting to that Center X  days later.  NOTE: This will affect the MRP demands until the kit status has been changed to "KIT IN PROCESS". Once the kit status has been changed to "Kit in Process" the parts now become a kit shortage, and the system will calculate from the WO due date or production lead time and NOT from the production offset.

Enter Effectivity Date for the line item to be used in the BOM.

(Note: Prior to Effectivity Date or after Obsolete Date, the line item will not appear on the Current BOM view nor will it appear on a Pick List to Kit the Assembly.)

Edit the "Used in Kit" by selecting Y (Yes) for Used in Kit unless the item is not to be issued when a kit is pulled. Select P (Phantom) to cause a Make subassembly to be treated as a Phantom when kitted. Select N (No) if the item is provided to the Line by some other means than kitting.  (Note: Chemicals and adhesives are typical not-kitted items that are referenced on the BOM for costing or specification but issued to the production floor on a bulk replenishment basis.)

If you depress the AVL & Reference Designator tab the Ref designators can be edited manually in the table OR Enter the Prefix letter, Start No and End No and click on the Calculate button to auto-number.  Here is where you will also check the approved AVL's and uncheck the AVL's that are NOT approved for this BOM.  NOTE:  If "GENR" is approved on the BOM MRP will consider any inventory for that part even if the AVL is NOT approved on the BOM.  When adding new AVL's to the item master, if you do not want the BOM's automatically updated be sure that the "Disable Automatic BOM AVL update" is Enabled.  See article #1477  for more information.

You may also Add or Delete Alternate Parts by depressing the Add or Delete button near the Alternate Parts to select alternative part numbers for the Line Item currently being edited in the BOM. This table is in the BOM screen because alternate part usage is always dependent upon the application and hence is BOM specific. (Note: Use the Quantity Info screen and AVL window to show alternate manufacturers; the alternate part window is only for items with a different internal part number (such as faster or tighter tolerance parts) that can be used on a temporary deviation when there is no choice.)

Within the Bill of Material module the users have the option to mark each item loaded to the BOM as Used in Kit Y, N or F. 

Y = Yes, this part is used in the Kit and will be considered fro MRP demands and appear within the Kitting module Qty Pick screen.  Once the parts have been issued to the kit  the system will automatically decrement it from inventory upon WO complete. 

N = No, this part is NOT used in the kit, but it will be considered by MRP for demands but will NOT appear in the Kit module Qty Pick screen.  This item will still be displayed on the Kit Pick Worksheet but it will have the “N” next to the item so users will know that it is not used in the kit.  Example:  you would use this option for Documentation.  NOTE:   Keep in mind that this item will be picked by the users on the floor but it will not be relieved from inventory in any way through the Kitting module. Users have to go make and manually adjust the inventory qty’s for this type of item.

MRP includes items with "N" flag in "used in kit" for Purchase Order Actions. The flag does not mean don't buy it, but instead, it means don't kit it. The part is still needed, or it wouldn't be on the BOM. Or the quantity would be zero. This feature is usually used by Users who have bulk stock on the floor, and the assemblers pull the parts out of floor stock.  But there still remains the requirement to get the parts in house so they can be put into floor stock.

F = Floor, this would be used for an item that is not kept in the Stock room but is physically stored out on the Floor in production.  “F” items will also be considered by MRP for demands, but will NOT be displayed on Kit Module Qty Pick Screen or the Shortage report.  This item will still be displayed on the Kit Pick Worksheet but it will have the “F” next to the item to indicate to the users that it is located on the Floor.  NOTE:  Keep in mind that this item will be picked by the users on the floor but it will not be relieved from inventory in any way through the Kitting module.  Users have to go make and manually adjust the inventory qty’s for this type of item.

Within the Bill of Material Module you will see a Setup Scrap check box and a Standard Build field.  If you wish for the setup scrap qty’s to be included in the Kitting and MRP calculations,  Standard Cost Adjustments, etc. . . you need to make sure that the BOM has the Setup Scrp box marked.  Then upon checking this box the system will default in the Standard Build qty to 1 (just because it can not be blank)  It is recommend that you change the Standard Build qty to the desired average build qty for the product (the Standard Build will affect how the system will calculate Standard Cost Adjustments, etc. . . within the system)

To display or print a Report for a BOM, first find the BOM. (See Article #571).

1. To access the reports, depress the Print action button at the top of the screen.  The report screen will appear.

2.  Select the output you desire by selecting one of the output radial selections at the top left of the screen, Screen, Printer, XL File, TXT File, or PDF.

3.  Highlight the report desired and click on the option tab.  (The BOM reports will indicate in the Source column if the item is setup as Make/Buy or Make/Phantom, along with Consigned or Buy).

BILL OF MATERIAL WITH REFERENCE DESIGNATORS

For the BOM with Reference Designators report check if you would like the BOM Notes to be displayed on the report.   Depress the OK button.

The following is printed

BILL OF MATERIAL BY PART NUMBERS

BILL OF MATERIAL BY ITEM NUMBERS

Check the boxes if you want the BOM item notes list and/or the BOM notes to be displayed on the report. Depress Ok.

The following report will print:

 

BILL OF MATERIAL WITH STANDARD COST

Choose By Item #, By Part #, or Descending Extended Cost from the Detail Report. Depress Ok.

Note: This report takes into consideration the Std Bld Qty when calculating the setup scrap.  You might find the cost calculated in SFT is different from the calculation shown on this report due to,  that if the part UOM is "EACH" and the part has scrap % the code will round it up to next inter number.

 

a)  For the PHANTOM parts in this report the standard cost calculated is based on their components (SUM of component's qty * component standard cost).  Once the standard cost is calculated for the PHANTOM part, the report will treat the PHANTOM part as a single entity on the top assembly BOM and proceed as it was a BUY part with the std cost already entered.

b)  If one of the component parts is a MAKE (not MAKE_BUY) and HAVE components assigned to it, the report will NOT show std cost of the parts itself, it will only show std cost of its subcomponents.
c)  If one of the component parts is a MAKE (not MAKE_BUY) and does NOT HAVE parts assigned to it the report will show std cost of the part itself.

d)  If one of the component part is a MAKE and MAKE_BUY the report will show price for the part itself and will show 0.00 costs for the subcomponents.

e)  If one of the component part is a MAKE and a Phantom/Make the report will NOT display the std price for this part because the report will show the cost of this parts components.

 

Note:  This report will only display the costs for ACTIVE parts and subassemblies as of the date of the report and will NOT include any parts that may have been identified as inactive either in the item master or in the obsolete date of the part on the BOM.

 

The values displayed should be in sync with the Cost Roll Up values.   The following may be why the Standard Cost Roll is different from the Cost BOM Reports.

a)    On the costed BOM Report for a Make/Buy assembly we display the value of the BOM in the costed report, but that total is NOT used in subsequent rollups to higher levels only the standard cost is.  

b)    In Kit Default Setup , user can "Exclude Scrap and Setup Scrap"  in Kitting, MRP, and Cost Rollup, and this will override the "Setup Stcrp" box in the BOM.      Therefore, if user checks "Setup Stcrp" checkbox along with a Standard Bld qty in BOM header, but has the checkbox checked in Kit Default Setup to "Exclude Scrap and Setup Scrap" for Cost Roll, the Cost Roll will NOT calculate the Setup Scrap cost, but this report will always calculate the Setup Scrap cost and this will cause unfavorable Configuration Variances.   For further detail on how Excluding Scrap and Setup Scrap values will affect the variances see Articles #3067, #3053, and #3320 . 

 

The following report will print:  This report ALWAYS includes ALL the parts (including the items flagged as "N" for Used in kit) 

 

 

BILL OF MATERIAL LEAD TIME REPORT

Choose By Lead Time, or By Part # from the Detail Report. Check Ok. The BOM with Lead Time report will add the lead time of the parent part into the lead time field.  So if you have a child part with a Purchase lead time of 30 days, and a parent part with a lead time of 1 day for Kitting and 3 days for Production, the lead time of the child part will be 1+3+30 = 34.

The following report will print:

 

BILL OF MATERIAL, INDENTED WITH WORK CENTER 

BILL OF MATERIAL, OUTDENTED WHERE USED

Select the Inventory Type by choosing the radial.  Enter the Internal Part Number and Rev.  Check the box if you want the  BOM items that are expired or not effective yet to be displayed on the report.

The following report will print:

BILL OF MATERIAL WITH ALTERNATE PART NUMBERS

BILL OF MATERIALS WITH REFERENCE DESIGNATORS & AVL

Check the boxes if you want the BOM item notes list and/or BOM notes to be displayed on the report.    The AVL Order Pref Code will be displayed in front of the Mfgr and Mfgr PN information.   For further detail on exporting to XL format see Article #3319 .

The following report will print:

TOP ASSEMBLY PART USAGE

Select the Product number and applicable revision. Select the quantity by toggling on the up and down arrows. Choose between All Current Components, Used in Kit Components Only and Not used in kit Components by clicking on the desired radial. Choose between Group by Component/Work Center and Show with Parent Assembly by clicking on the desired radial.  Depress Ok.

The following report is printed:

COSTED TOP ASSEMBLY PART USAGE

Select the Product number and applicable revision. Select the quantity by toggling on the up and down arrows. Choose between All Current Components, Used in Kit Components Only and Not used in kit Components by clicking on the desired radial. Choose between Group by Component/Work Center and Show with Parent Assembly by clicking on the desired radial.  Depress Ok.

The following report will print: