Bill of Materials Management (BOM) module is used to display and manage the information about the materials used in production. A bill of materials, which is a list of materials, can be considered as (to be added) a recipe defining the hierarchical structures and quantities of semi-products and/or raw materials required to produce a product. This module allows BOMs to be created, copied, modified and controlled.
BOMs, which are used as reference in the calculation of the semi products and raw material requirements to be determined for Material Requirements Planning module, are also used effectively in processes such as external procurement. In this process, the relevant materials in the BOM can be sent from stock to subcontractors for use.
In conjunction with the Routing Management module, the system creates a production network and displays this network graphically when prompted. Thus, even complex BOMs and routes can be created clearly at different levels. Copying the components of an existing BOM into new BOMs makes workflow easier. Similar materials or structures can be created more easily by referring to the defined BOMs.
The following graph shows the interaction between the Bill of Materials Management and the other modules in the system.
Each BOM created in the Bill of Materials Management Module is valid under the conditions defined for it. For example, the components that make up the product are required to be used according to (depending on) the batch size to which the product is to be produced. Thus, various components can be used for different production batches. Time limits can be made to define the desired structures for specific periods. There may be more than one way of production of a manufactured product within an enterprise. These different types of production can be defined in the system as production alternatives.
The BOM can be used not only for production, but also for sales. The product sets, which are formed by combining more than one product, can be defined as BOMs; They can be sold by entering only the BOM title. Even after the start of production, the relevant BOMs can be changed and these changes can be reflected in open production orders. Thus, product design and production processes can be executed together, if desired.
Audit Down to the Lowest Level
A wide range of configuration options in the BOM Management Module is not limited to only the level of the BOM. In contrast, configurations can be maintained up to each component level. Item types that can be defined freely allow the user to manage each material individually. The components in a BOM that will be used in production and design should have different properties. Thanks to the predefined component properties specified on the module, the separation of these components can be easily done when configuring a BOM. It is possible to define the input quantity for each component. For example, for each X product quantity unit, the Y component quantity unit is required. The units do not have to be the same here. There is also the option to determine the amount of consumption for the components according to the defined formulas. Flexibility in component management also applies to by-products that may occur during production. By-products may be identical or completely different to the product, and cost sharing features can be determined accordingly.
Comprehensible Structure – Easy To Use
Bill of Material Management module is a highly effective tool for working comfortably on complex structures within production. Ergonomic applications with important functions provide ease of use and advantages. Bulk change of components in multiple BOMs or all BOMs, presence of components in all or department specific BOMs, or addition of new components to the desired data records are only a few of these advantages.
The open structure of the ERP system also enables communication with external systems (e.g. a CAD software). Thus, BOMs and even materials can be created and modified in an external system. This interaction is done through the Electronic Data Interchange module.
The Bill of Material Management module, which can be integrated with other processes in the ERP system, plays a key role in basic manufacturing processes with integration to other production modules such as Routing Management and Production Management; It also creates the basis for Material Requirements Planning, Sales Management, Purchase Management, Inventory Management and Standard Cost Management modules.
• Complete integration into production plans and production
• Validations based on time and lot size
• Component-level control
• Expandable BOMs
• Alternative BOMs
• Dismantling (Demontage) BOMs
• Variant Management
• Different measure units
• Determination of quantity based on formulas
• Ergonomic use (Batch updates)
• Sales and procurement BOMs (Product sets)
The steps required to complete production, assembly or disassembly activities and the resources required in these steps are defined on the system with ERP Routing Management (ROU) module.
This module includes information on which operations to perform in which order and which tools and work centers to use in addition to which materials will be used in which operation.
The work centers where the operations within the scope of the Routing Management module are carried out, the machine and personnel capacities in these work centers, the cost/cost types of the machines and the personnel are extremely important in terms of capacity planning and production costs. Working hours and capacity of work centers directly affect the scheduling and cost of production orders. In the module, the factory calendar can be used for all work centers, and the work schedule of each work center can be customized.
The following chart shows the integration of the Routing Management module in the system.
BOM AND VARIANT MANAGEMENT
In the Bill of Material Management module, which can be used in parallel to the Routing Management module, lists of components to be used in production processes are defined. In the route definition, these components and related operations are mutually combined. The detailed planning in the module allows the components to be assigned to the relevant operations. This assignment then forms the foundation of a precise and accurate material requirement planning. Material supply can be planned to take place at the start of production or as a special process. This data is also used in all other stages of production up to purchase.
With the ‘Variant Option Matching’ feature, the operations that should be included in the relevant configuration can be planned in detail depending on the specified characteristics of a material. The production times of these planned operations (Preparation, Machine and Labor) can be determined separately for each Variant Configuration of the product.
WORK FLOW TIME AND SCHEDULING
The operations of each route have a production time planned by the user. In this context, deadlines are planned according to the availability of work centers in production management, material requirements planning and capacity management modules and supply of materials/services. Transition times between operations can be configured with Standby, Move, and Overlap times. All these definitions can be diversified depending on the validity date and the lot sizes. A production order is scheduled based on the operation level and the formulas recorded in the system. The most commonly used production time formulas are presented to the user as a standard, but these formulas can be modified to be specific to the businesses by using the information defined on the operations.
‘Capacity Groups’ can be defined for work centers used in operations. In this way, the Work Centers that do the same work can be grouped and the capacity demands during the operation scheduling can be distributed according to the work centers in the group. This feature allows the operation to be carried out in the fastest way by evaluating the possibility that the operation is done not only in the designated work center but in any work-center included in the group.
CONVENIENCE AND FLEXIBILITY
When a BOM is changed, the relevant route definition for it can also be changed accordingly. Production orders which have not yet been confirmed during this process can also be updated upon request. In the Routing Management module, history of all routes can be kept, and different versions of the route can be stored. Creating alternatives offers a general freedom of choice. In addition, these alternatives allow for a certain amount to be produced on other machines under certain conditions, in connection with particular lot sizes. The module allows easy and flexible management of routes in the system.
Thanks to the integration with the Base Data Management and Bill of Material Management modules, the route information easily generated in the Routing Management module is the main component of the production plans created in the Material Requirements Planning module and the production orders generated in the Production Management module. Scheduling of production plans and orders in the Capacity Management module is done with these data. In addition, quality control plans defined in the Quality Management module can be associated with operations.
The data, which is used as the base data to determine the production costs, is transferred to the Standard Cost Management module and, through production orders, to the Production Costing modules. Route definitions can also be made in relation to (with) Service Management and Maintenance Management modules.
- Base creation for production plans and production orders
- Alternative route management
- Operation matching according to (in line with) product variants
- Configurable operation duration
- Consecutive Loading / Parallel Processing
- Tools and Template Management
- Adding work centers that do the same jobs into a single Capacity Group
- Production formulas specific to enterprises
- Including activity types to cost on demand
- Updating work center calendar based on capacity data