untitled

Size: px

Start display at page:

Download "untitled"

송현 난
5 years ago
Views:

1 2007 PLM Best Practice Conference 조선산업의 BOM 구조와종류소개 , ( ) jh_lee@inha.ac.kr,kyungho@inha.ac.kr Page 1

2 Contents I. II. BOM III. BOM IV. BOM V. BOM Page 2

3 Product: Material( ) (CAD, BOM),,, Process: Material Flow (BOP, WBS),,, BOM:,,, Resource: Machine (BOR, OBS),, Page 3

4 Product, Process, Resource, BOM and Routing PRODUCT PROCESS RESOURCE [ ] HP, CPC/PDM Page 4

5 BOM [ : mysap PLM] Page 5

6 BOM Usage Project Organization Project Mile stone Activity Page 6

7 Data Interface between PDM and ERP CONFIGURATION Config. Item Effectivity Options Eng. Chge EBOM Mockup Assembly Plan MBOM Part12-V1 Part1-V1 Part4-V1 Part3-V1 Part5-V1 Part5-V1 Part1-V1 Part2-V1 MSA1 MSA2 MSA2-V1 MSA1-V1 Part2-V1 Part1-V1 Part5-V1 Downstream ERP Product Doc. BOM Assy Plan Doc. BOM Book-V1 Book-V1 Chapt1-V1 Chapt2V1 Chapt1-V1 Chapt2V1 Parg1-V1 Parg2-V1 Parg1-V1 Parg2-V1 Page 7

8 BOM Engineering To Order:, Plant, Construction = ( ) Make To Stock :,, = Assemble To Order: DELL Computer = +, Make To Order:,,, Page 8

9 BOM (Modular BOM) Modular BOM product product product part part part Limited Number of Items Made from Many Intermediate Items or Components Ex) Ship Building Many Items Made from a Smaller Number of Intermediate Items or Sets of Components Ex) Motor Engineering Many Items Made from Limited Number of Components Ex) Steel, Chemicals Page 9

10 Contents I. II. BOM III. BOM IV. BOM V. Page 10

11 BOM (Bill Of Material) APICS (American Production and Inventory Control Society) Item: Any unique manufactured or purchased part, material, intermediate, subassembly, or product BOM: A listing of all the subassemblies, intermediates, parts and raw materials that go into a parent assembly showing the quantity of each required to make an assembly BOM (Bill of Material) (Item) (Item) BOM Item (relationship) Product Structure, Bill of Material, Part List BOM,. Page 11

12 BOM example Bicycle Wheels My Bicycle Rear Wheel Front Wheel Q=2 Q=24 Q=2 Q=2 Q=48 Q=24 Tire Hub Rim Spoke #Rear Chain Wheel Page 12

13 What s Your Motivation of BOM? 1. Traditional BOM (Make To Stock) 2. MPS (Demand Management) 3. Product Structure, Option/variant Item master Traditional BOM Modular BOM ATO, MTO 4. MRP Super BOM + Variant BOM Material Plan 5. Lead time Page 13

14 Contents I. II. BOM III. BOM IV. BOM V. BOM Page 14

15 BOM BOM Engineering BOM Manufacturing BOM / BOM Planning BOM Others Modular BOM Percentage BOM ( Ratio BOM ) Super Common BOM (Super BOM in APICS Dictionary) Inverted BOM Family BOM Add/Delete BOM Generic BOM Page 15

16 BOM MTS ATO MTO ETO BOM BOM Planning BOM Project BOM Project BOM Page 16

17 BOM ( /2000) Information BOM Planning BOM Manufacturing BOM Indented BOM E-BOM Where Used BOM Price/Cost BOM M-BOM Matrix BOM Summarized BOM Common Parts BOM Super BOM Modular BOM Aggregate BOM As-Built Configured BOM Customer Order Configured BOM Frozen BOM Page 17

18 BOM A. / 1) Engineering BOM, BOM BOM. (Functional Sub-Systems). 2) Manufacturing BOM BOM, BOM. / (Assemble Groups). 3) Planning BOM BOM. (MPS) (Material planning), BOM. BOM. 4) Others BOM. ). Page 18

19 BOM Planning BOM Modular BOM BOM (management), BOM. (Option), [BALC1992], [ 1996], [BERT2000] : Module. Percentage BOM ( Ratio BOM ) cf) Super BOM Super Common BOM (Super BOM in APICS Dictionary) Inverted BOM Family BOM Add/Delete BOM cf ) Generic BOM, Generative BOM Processing System Page 19

20 BOM B. (Life Cycle) 1) As Designed (develop) BOM., Engineering BOM. 2) As Planned BOM. (Prototype). 3) As Built (Produce) BOM., Manufacturing BOM. 4) As Maintained (Service) BOM. (Service Part) (Warrantee Service) BOM. Page 20

21 Engineering BOM, Manufacturing BOM EBOM (Engineering BOM) (Function) EBOM CAD S/W: (Assembly Product) A, (Product Configuration) Manufacturing BOM BOM MRP BOM MBOM VS EBOM E-BOM Item Page 21

22 Planning BOM (PBOM) PBOM (Planning BOM) (Production Planning) (Master Production Scheduling), Planning BOM Planning BOM (1) Modular BOM (2) Percentage BOM (3) Super Common BOM (Super BOM in APICS Dictionary) (4) Inverted BOM (5) Family BOM (6) Add/Delete BOM Page 22

23 Modular BOM PBOM ATO (Assemble-To-Order) Option. (Manufacturing Strategy) - ATO. Variant, Feature/Option, Product Configuration. Page 23

24 Modular BOM PBOM ) Engine: 1800cc, 2000cc Audio:, Graphic Equalizer, CD ABS, Air bag:, + TCS (Tracking Control System) Seat:, Color: 10 : Option BOM Variant BOM Option BOM Configuration Management Page 24

25 Modular BOM PBOM Option BOM BOM? ) A 3, B 10, C 5, D 5, E 10 >> 3 * 10 * 5 * 5 * 10 = 7500 BOM,, = 33 BOM Modular BOM (Common Parts) Modular BOM, BOM Master Production Scheduling Option, (Final Product) 7500, 33 Common Parts (MTS, ATO, MTO) Make-To-Stock Assemble-To-Order, Make-To-Order Page 25

26 Modular BOM ( Feature, Option and Variant ) Frame: F53, F57, F60, F65 : MR, MT, WR, WT : C, T 4x4x2= 32 Page 26

27 Percentage BOM PBOM, BOM. (1) Color TV 14, 15, 17 Color TV 20%, 30%, 50% Percentage BOM. (2) Modular BOM VS Percentage BOM Option BOM 1800cc 60%, 2000cc 40%, 30%, Graphic Equalizer 30%, CD Player 50% MPS(Master Production Scheduling) : Percentage BOM Page 27

28 Percentage BOM PBOM 1 ) Process Industry 2 ) Module cf ) Super BOM Car Family qty/parent=0.3 qty/parent=0.3 qty/parent=0.3 qty/parent=0.1 Sonata Avante Accent Tiburon * source : [Mather 87] Page 28

29 Super BOM ( Feature, Option ) (Demand Management) Planning Group : Percentage BOM : Super BOM Make To Stock Super BOM. Option Page 29

30 Super BOM ( : Demand Management) F53-MR-C 0.3x0.4x0.7= % Super BOM Modular BOM Page 30

31 Inverted BOM Inverted BOM BOM BOM: / Tree, TOP-DOWN Package Percentage BOM. : BOM (Parent Child Relationship), Parent Item Child Item : ( )., BOM Inverted BOM Page 31

32 Inverted BOM Magnetic tape jumbo roll qty/parent = 0.3 qty/parent = 0.1 qty/parent = 0.2 Reel Packaging Kit - 600ft Reel Packaging Kit - 800ft Reel Packaging Kit ft * source : [Mather 87] Page 32

33 Family BOM (?) Family BOM ( ). Common BOM A Kind of Planning BOM A Kind of Phantom BOM It groups Common Components for a product or family of products into One BOM, Grouping. BOM,. Page 33

34 BOM Multilevel BOM BOM Display BOM Parent Child, Child Child ( ) BOM BOM Single level BOM Multi level BOM Single Where Used BOM Multi Where Used BOM Indented BOM BOM Multilevel BOM Parent Child BOM Page 34

35 BOM Bill Of Activity (WBS) Bill Of Process (BOP) BOM Routing,, /NC / Bill Of Resource (BOR),, Shop, Workstation Page 35

36 CEM Code BOM BOM BOM. C: parent/child E: E-BOM M:M-BOM Page 36

37 1 st Step: Traditional BOM 2 nd Step: Modular BOM BOM 3 rd Step: Family BOM Modular BOM 4 th Step: Generic BOM 5 th Step: Variant BOM, Option BOM Generic BOM Variant Option Option BOM (mandatory, substitute,...) Page 37

38 Modularization Non Modular 제품사양별독립된 BOM 존재 설계변경불가 생산계획불가 Modular: Variant/Option, Product configuration 모듈구성 : 제품에들어가는부품의사용형태분석 Modular BOM 은 Planning BOM의로서만의미를가짐 Product Structure 정보가없음, 따라서 Product Structure를표현할수있는 BOM 정의가추가되어야함. 사양이많이증가할경우에는구현이어려움 조선, Plant와같이복잡한사양을갖는 ETO에적용하기위해서는변화가필요함. Page 38

39 Product Configuration Management Product Group Ship Specification Feature Option Item Assembly Sub Assembly Part Page 39

40 Contents I. II. BOM III. BOM IV. BOM V. BOM Page 40

41 E-BOM, M-BOM Page 41

42 E-BOM, M-BOM Page 42

43 E-BOM Page 43

44 M-BOM Page 44

45 Carpet Cleaner Part No Page 45

46 Indented BOM (Part #6221) Page 46

47 Where Used- Single Level Page 47

48 Where used Multi Level (Part # 4209) Page 48

49 Product Configuration : Feature & Option, Variant Page 49

50 Page 50

51 Page 51

52 Bottom up View Page 52

53 Contents I. II. BOM III. BOM IV. BOM V. BOM Page 53

0) Pre-Contractual Hull form General Arrangement Naval Architect Analysis Cost Estimate [FROM

Preliminary Structural Layout Compartment and Zoning Pre. weight estimates 2.

54 0) Pre-Contractual Hull form General Arrangement Naval Architect Analysis Cost Estimate [FROM Dassault Systemes] 3) Detail Steel Design Finalize design per block Minor stiffeners, shell plates, end-cuts, slots Weld & paint 2.a) Functional Design Primary Steelwork Through whole ship FEM Analysis 1) Concept Design Preliminary Structural Layout Compartment and Zoning Pre. weight estimates 2.b) Work Preparation Build Strategy Assembly hierarchy Welding procedures Interim Product 4) Deliverables extraction Manufacturing Data Assembly drawings Bill of Materials Fixture Tooling / Lofting

a) Functional Design P&I/HVAC Diagrams Systems Runs Equipment Layout 4) Deliverables extraction Piping ISOMETRIC Piece Drawings Assembly

55 0) Pre-Contractual Flow Diagrams General Arrangement Propulsion Systems Cost Estimate [FROM Dassault Systemes] 3) Detail Design Piping Spec-modeling HVAC and Raceway placement Structural Foundation Pipe Hangers and Penetration design 2.a) Functional Design P&I/HVAC Diagrams Systems Runs Equipment Layout 4) Deliverables extraction Piping ISOMETRIC Piece Drawings Assembly drawings Bill of Materials Loop Diagrams 1) Concept Design Space Claim Flow Diagram Run Ways allocation Cost Estimate 2.b) Work Preparation Build Strategy Assembly hierarchy Spool Definition

56 Process [FROM TRIBON] Page 56

57 BOM [Modified from Dassault Systemes] Hull Structure Arrangement Fluidic Electrical Conceptual Naval Arch Hull form Gen. Arrang Preliminary Estimates EBOM (MML_ Space Reservation Equipment Layout Refined Estimates Process Flow Fiagram Process Simulation Cableway Reservation Functional Hull Structures Functional Design EBOM Piping & Instrumentation Diagram HVAC Schematics EBOM Piping & Instrumentation Diagram Flow Analysis HVAC Schematics Air Flow Analysis Cable Block Diagram ISOMETRIC Diagtrams Deck Plans One Line Diagram Electrical Analysis EBOM Detail Hull Structures Detail Design Mechancal Design (nonstandard) Piping Hangers H VAC Cableway Definition Hangers Build Strategy FEM) Mass Prop. Piping Stress H VAC Stress Cable Routing Manufact. & Const. Manufacturing Data (NC) MBOM Assembly Drawings Tooling/Lofting MBOM Drawings Piping Isometrics Piping Spools HVAC Drawings HVAC Flat Wrap Cable Lists BOM From/to Lists Cable Lengths/Size MBOM MBOM Page 57

58 BOM ( ) Inquiry / POS /Maker Maker DWG / S/C BOM G/A M/A BOM(MML) Key Plan(Midship S., T.BHD) Key Plan(Con-Pro/Shell Exp.) Acc. Plan( ) ( ) M/A( ) P&ID( ) P&ID( ) P&ID( ) DHI 3D Modeling C/A( ) P/A( ) Steel Outfitting Arr t( ) Wiring Diagram( ) EBOM BLK BOM G/A of Electric Equip.( ) BOM POR Rev A / ( ) EBOM Pipe List Valve List Inst. List Equip. List H/P Rev 0 NC Data Hole Plan MFG( )INST( ) H/P MFG( )INST( ) MFG( )INST( ) MFG( ) BOM H/P MFG( )INST( ) BOM BOM PML BOM PML BOM PML Page 58

59 Structure Model Equip. Page 59

60 E-BOM Page 60

61 Structure Design Page 61

62 E-BOM & M-BOM E-BOM Page 62

63 E-BOM (Block BOM) < Parts List > Page 63

64 Page 64

65 BOM Page 65

66 E-BOM (MML) 1 Rule A Rule B Rule C 2 Rule D Rule E Rule F MASTER BOM Option A Option B Option C Option D BOM 1 BOM 2 Option E Option A Option A Rules Option C Option B Validation Check BOM Option D Option D Page 66

67 E-BOM (MML) Configuration Editor Master Option Master BOM Page 67

68 Engine Room Piping Hull Piping Accom.. Piping Piece List Cutting Plan Page 68

69 Piece List Piece Drawing Weight List Material List Page 69

70 Pipe Support Seat Page 70

71 Why BOM? What BOM? ATO, ETO, MTO, MTS (P,P,R,S/C) BOM Modular BOM? Project BOM? Page 71

72 Bill Of Material Accuracy Accuracy: 98~100%. MRP 98%. Exception Message BOM! 1. Team Meeting 2. Sampling WOD 3. Manufacturing & Disassemble 4. Greatest Experts Page 72

73 Jerry Clement, Adndy Coldrick and John Sari, Manufacturing data Structures, John Wiley & Sons, Inc. 1992,,,2003 [ 97], BOM, 1997, [ 97], Web-based BOM, 1997, / 97, pp [ 96], Family BOM, 1996, / 96, pp [ 96], BOM BOM, 1996, 96, pp [ 96], Modular BOM,1996,, Multi Views BOM,, 1998 August-Wilhelm Scheer, Business Process Engineering - Reference Models for Industrial Enterprises,, Springer-Verlag K. J. Balcerak et al., Structuring Modular Bills of Material with Usage Pattern analysis, IJPR, 1992, Vol. 30, No 2 YunKung Chung et al., A Conceptual Structure and Issues for an Object-oriented Bill of materials Data Model, Computers ind Engng, 1994, Vol. 26, No 2 Jerry Clement et al. Manufacturing Data Structures, 1992, Oliver Wight Publications Michael Cunningham et al., A Decision Support Tool for Planning Bill-of-material, Production planning and control, 1996, Vol. 7, No 3 Hal Mather, Bills of Material, 1988, Dogwood Publishing Company, BOM BOM,,,, Page 73

<4D F736F F F696E74202D20B0F8B0B3BABB202D20C1B6BCB1BBEABEF7B0FA20C0DAB5BFC2F720BBEABEF7C0C720504C4D20C6AFBCBA20BAF1B1B32E

<4D F736F F F696E74202D20B0F8B0B3BABB202D20C1B6BCB1BBEABEF7B0FA20C0DAB5BFC2F720BBEABEF7C0C720504C4D20C6AFBCBA20BAF1B1B32E 조선산업과자동차산업의 PLM 특성비교 2008. 7. 10 이장현, 이경호 ( 인하대학교 ), 서흥원 ( 대우조선해양 ( 주 )) 목차 PLM 의정의 조선과타산업의설계특성 PLM 도입배경의차이점 PLM 구축범위의차이 인하대학교선박해양공학과 2 PLM 의정의 다양한의견 References 外 10 여권의 PLM 도서 外수백건의문서및 PLM 기술자료, 논문 인하대학교선박해양공학과