2007 PLM Best Practice Conference 조선산업의 BOM 구조와종류소개 2007 4 12, ( ) jh_lee@inha.ac.kr,kyungho@inha.ac.kr Page 1
Contents I. II. BOM III. BOM IV. BOM V. BOM Page 2
Product: Material( ) (CAD, BOM),,, Process: Material Flow (BOP, WBS),,, BOM:,,, Resource: Machine (BOR, OBS),, Page 3
Product, Process, Resource, BOM and Routing PRODUCT PROCESS RESOURCE [ ] HP, CPC/PDM Page 4
BOM [ : mysap PLM] Page 5
BOM Usage Project Organization Project Mile stone Activity Page 6
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
BOM Engineering To Order:, Plant, Construction = ( ) Make To Stock :,, = Assemble To Order: DELL Computer = +, Make To Order:,,, Page 8
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
Contents I. II. BOM III. BOM IV. BOM V. Page 10
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
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
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
Contents I. II. BOM III. BOM IV. BOM V. BOM Page 14
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
BOM MTS ATO MTO ETO BOM BOM Planning BOM Project BOM Project BOM Page 16
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
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
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
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
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
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
Modular BOM PBOM ATO (Assemble-To-Order) Option. (Manufacturing Strategy) - ATO. Variant, Feature/Option, Product Configuration. Page 23
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
Modular BOM PBOM Option BOM BOM? ) A 3, B 10, C 5, D 5, E 10 >> 3 * 10 * 5 * 5 * 10 = 7500 BOM,, 3 + 10 + 5 + 5 + 10 = 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
Modular BOM ( Feature, Option and Variant ) Frame: F53, F57, F60, F65 : MR, MT, WR, WT : C, T 4x4x2= 32 Page 26
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
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
Super BOM ( Feature, Option ) (Demand Management) Planning Group : Percentage BOM : Super BOM Make To Stock Super BOM. Option Page 29
Super BOM ( : Demand Management) F53-MR-C 0.3x0.4x0.7=0.084 8.4% Super BOM Modular BOM Page 30
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
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 - 1000ft * source : [Mather 87] Page 32
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
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
BOM Bill Of Activity (WBS) Bill Of Process (BOP) BOM Routing,, /NC / Bill Of Resource (BOR),, Shop, Workstation Page 35
CEM Code BOM BOM BOM. C: parent/child E: E-BOM M:M-BOM Page 36
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
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
Product Configuration Management Product Group Ship Specification Feature Option Item Assembly Sub Assembly Part Page 39
Contents I. II. BOM III. BOM IV. BOM V. BOM Page 40
E-BOM, M-BOM Page 41
E-BOM, M-BOM Page 42
E-BOM Page 43
M-BOM Page 44
Carpet Cleaner Part No. 0123 Page 45
Indented BOM (Part #6221) Page 46
Where Used- Single Level Page 47
Where used Multi Level (Part # 4209) Page 48
Product Configuration : Feature & Option, Variant Page 49
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Bottom up View Page 52
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 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
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
Process [FROM TRIBON] Page 56
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
BOM ( ) Inquiry / -9-8 -7-6 -5-4 -3-2 -1 1-39-38-37-36-35-34-33-32-31-30-29-28-27-26-25-24-23-22-21-20-19-18-17-16-15-14-13-12-11-10-9 -8-7 -6-5 -4-3 -2-1 1 2 3 4 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
Structure Model Equip. Page 59
E-BOM Page 60
Structure Design Page 61
E-BOM & M-BOM E-BOM Page 62
E-BOM (Block BOM) < Parts List > Page 63
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BOM Page 65
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
E-BOM (MML) Configuration Editor Master Option Master BOM Page 67
Engine Room Piping Hull Piping Accom.. Piping Piece List Cutting Plan Page 68
Piece List Piece Drawing Weight List Material List Page 69
Pipe Support Seat Page 70
Why BOM? What BOM? ATO, ETO, MTO, MTS (P,P,R,S/C) BOM Modular BOM? Project BOM? Page 71
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
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. 401-404 [ 96], Family BOM, 1996, / 96, pp. 346-351 [ 96], BOM BOM, 1996, 96, pp. 15-19 [ 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,,,, 2000 http://kmh.yeungnam-c.ac.kr/ 73 Page 73