Presentation on MUL Bill of Material (BOM) by EN8
Nov 16, 2015
Presentation on MUL Bill of Material (BOM) by EN8
EN8
Agenda Bill of Material ? Purpose of BOM. What does BOM contains ? How does Engg. Information Flow? Preparation of New BOM. Screen Shots of BOM. Model code ? Part Number ? BOM Maintenance. Logics followed for BOM updation. Block -Variant (EBOM) ECN process.
EN8
Bill of Material ?
BOM is a hierarchical representation of parts and their attributes for a model .BOM is of 2 types:
a) EBOM Engg. BOM b) PBOM Production BOMEach Model spec has one BOM .BOM is uniquely identified by a Model code .(8 digit code)
EN8
Differences b/w EBOM & PBOM
EBOM based on block & variant concept.In EBOM part has linkages with Drwgs.EBOM is used for localization process (LP,LAR,ECP,ECR,etc.)
PBOM is based on Reference No.PBOM contains Part classification (local,KD),shop codes,station no.,usage conditions,etc.PBOM is used for running MRP & consumption booking.Inventory Mgmt. Is done through PBOM.Cost control is done through PBOM.
EN8
Purpose of BOM
Managing Product design changes (ECN)
Standard qty requirement as per design .
Material Resource Planning / DI system
Scheduling of Parts (SOB information is not stored in BOM )
Receipt of Material
Issue of material to vendor for further processing.
EN8
Purpose of BOM contd.Consumption booking.
To facilitates Spare Parts needs.
Models Costing ( Price information is not stored in BOM ) .
Inventory Management.
EN8
What does BOM contain?BOM basically contains three main information related to parts : Design Information
Procurement Information
System Information
EN8
Engg Information flowJapan IndiaTechnical part list Drawings /Data Paper Dwg Scan Images Satellllite link for UG,
Catia, SCAD etc)ECN Standards (SES, SIS, JIS etc)Color list KD Partlist /SCAN
EN8
Engg Information flowJapan IndiaLocalisation Plan (LP)Localisation Approval Request(LAR)Local -KD ClassificationECR,EI,ECP,NEC,Vendor Drawings,Draft TPL (Paper)
EN8
Preparation of EBOM SMC TPL(xls)(Block and Variant)Loading in PDM (Block-VR Product structure for SMC and MUL configuration) New Model/ Family Maruti Part number for local parts and supplier relationParts classificication( Make or Buy)(Local/KD)Identification of Common /uncommon parts Creation of MUL Model codesLinking of Block-VR to MUL Models Creation of MUL specific blocksCreation of Vehicle FamilyLoading ofSMC Drawings EBOM Ready EBOM release to PPCModification of EBOM through ECN Life Cycle
EN8
Snap shots of EBOM View
EN8
Engg BOM(Based on Block and Variant concept)
EN8
Engg BOM(Based on Block and Variant concept)
EN8
Integration of Engg and Production BOMProduction BOM product structure is reference number based and has non-uniform product structure to fulfillMUL specific requirements. CMS - Link between EBOM and PBOM for partlist updation through ECN system
EN8
EN8
Model Code
MES N 2004
Basic vehicle code
Selection Code
Sub Model Code
Variant Code
Specification Code
Alphabet
Numeral
1
2
4
5
6
7
8
3
EN8
Model Code explanation
C
R
4
H
S
7
0
0
Car (M800)
RHD (M/T)
4 Door
Heater
Standard
NCR Model
For Domestic Mkt (India)
SMC Model Coding
AlphabetNumeral12456783YProduct ClassificationY- 4 WheelerDestinationBasic Series CodeMinor ChangeSpec Code** 1. Body style, Seating Capacity 2. T/M , Strg Handle Position 3. Grade etc. Body type Code
EN8
Part Number coding
Basic NumberModel type Number Hyphen (- for KD , M for Local, N for other than SMC import, E -KD Part with extra processingType number (Source)Design Change NumberColor code , etc
EN8
Standard part : No Part DrawingCommonly used in Many products e.g. Fasteners. Part number for standard items starts with 01-08 (first two digit of Part number)
18Standardized part identification n umberUnique number by the typeNominal size,strength classification etcSurface treatment 0
EN8
Semi standard parts : Non standard parts ,designed specially for specific purposes. Part number for semi standard items begins with 09 . These items are also called 09 series parts .09Semi standard part identification numberUnique number by the typeNominal size(main characteristic)Registration number (001-999)
EN8
Regular parts: General design parts other than standard and non standard parts. Part number starts with 1 onwards . Starting digit specifies whether part is for Engine, Electrical, Suspension, body or Interior.Functional Classification numberDetailing numberModel Type numberType numberDesign change orderColor identification numberBasic Number
EN8
Structure of basic part number
Large classification1- Engine, 2-T/M 3-Electrical 4-Suspension 5- brake6- white body 7 Equipment(under cabin) 8- door seats 9 Etc (A/c) , 0- Fastners or bearings Part (0 is not assigned at fifth place )Comp ( less than 9 parts) --0 at fifth placeComp (more than 9 parts) - 0 at fourth place
EN8
Design of a particular spec is represented as Product Structure in BOM .Parent - Child relationship. (Reference number )Design information is stored in following attributesPart number (00000M00000-000)Part Name (Description of item)Qty. ( Qty required / reference )ECN numberOptional (Y / N )
Design information
EN8
Product Structure
EN8
1.bin
BOM Maintenance BOM is a dynamic database which is regularly updated to give the latest status as on a particular day or a period.Parts detail is changed and maintained in BOM by ECN Process.ECN are issued by SMC as well as MUL .Localization of Parts (Deletion Proposal)BOM feedback system
Contd.
EN8
ENGINEERING BOM( Block-Variant)
EN8
88.bin
BLOCK CODE
EN8
Large Block
A
B
C
D
E
F
G
H
J
K
L
M
P
R
S
T
C
Engine
Engine
Auxiliary
Transmission
Engine
Electric
Body
Electric
( Frame )
Suspension
Brake
White Body
( E Pump )
( R Body )
Equipment
Special Equipment
Unite Body
Separate Frame
Cabover
Engineering Change Process
EN8
RequestEngg raisesECRPESCEngg/En8SMC/VENDORECNPPC/MCDENGGDistributionBOMECN WORK FLOW(Actual ECN)
EN8
ECN Work Flow
EN8
ECN
&C&"Arial,Bold"&14Simplefied flow chart for Formal SMC ECN life cycle
&R&D&T
SMC ECN
EN8
CD ROM
Loading in PDM SMC ECN acceptance life cycle
Engg to accept / Not to adopt SMC ECN
Create ECR/ECN
Raise NEC to SMC
Not to be adopted
e.g. R04-0001
PE
SC
For concurrence
Engg 1-5
Conversion to ECN
e.g. N04-0001
File Transfer to CMS system
PDM system
( Change Management system )
PPC to assign final implementation date after checking inventory
Updation of Production BOM and information to all concerned
Engg identifies Distribution list e.g. PPC, SC, PE, Service, Spares, QA etc
File Transfer to PDM system
Updation of EBOM
PDM sends E-mail as per distribution list
system mail to all concerned
CMS System
Regulatory ECN , date of implemenation decided by Engg
Homologation check done by EN8
PDM
System
CMS
system
3 CD-Roms are received monthly
CAD data
&C&"Arial,Bold"&18CAD Data Flow Chart (YN4)
&R&D&T
SMC
SMC DataExchange Server
NAS data server
EN8Carry out revision control
EN8untar & unzipdata
MUL dataExchange server
SMC-Advisor
All concerned departments
EN8Make dataavailable
Design gr.(comp. owner)Approve
Data
FTP download/Thru CD's/CDR
upload data
request(as per format)
information
data
EN8
EN8Data List is maintained at \\multad\smc cad dataFormal data : YN4 UG Foraml Data.xls
All in the factory can see the list
Advance ECN Flow Chart
Advance ECN mail
Advance ECN mail
Advance ECN mail
&C&"Arial,Bold"&18&UADVANCE ECN FLOW CHART (YN4)
&R&D&T
SMC
SMC Advisor (Engg)
EN8
Parts Inspection
Production Engg
EN1-EN5
Central data at multad server with hyperlinks
Vendor
Supply Chain
Advance information
Dicussion wth Engg
Email from Neni
Advance UG Data (CS, CJ ), B sheets , Drawings, Excel file on CD ROM ( weekly)
SMC Advisor(Engg)
EN8
UG / SCAD data loading in CAD server
B-Sheets data stored in Multad Server
Information to Engg and PE
Email to Engg on B sheets Data
EN4-EN5 request through Notes system to SMC for Cad data
System accepts the request
System loads the requested data to FTP server
Download through FTP server by MUL
Notes system for CS-CJ
TPL information
Receipt of SMC TPL
Weekly difference list is prepared by EN8
Model K development status reporting
&C&"Arial,Bold"&16Processing of SMC TPL at MUL
&R&D&T
SMC sends TPL(YN4) on weekly basis on CDROM
SMC Advisor (Engg)
EN8 receives email of TPL ( STD, DX,Super Dx)
TPL is stored in MULTAD server (monthwise)multad\yn4_ref\TPL
multad\yn4_ref\TPL\Apr'04
Access to Engg and PI
Week 1TPL ( std, Dx, Sup Dx)
Week 2TPL ( std, Dx, Sup Dx)
Difference list
E-mail of difference list to Engg 1-5 and PI
EN8 block coordinator update the Engg Matrix file
Difference list are stored in MULTAD server
TPL STD,DX, SUP DX
EN1-MATRIX
EN2-MATRIX
EN3-MATRIX
EN4-MATRIX
EN5-MATRIX
Splitting TPL in five files as per blocks with addition of Sequence number
Updation of additional data for reporting.Formal Dwg, Cad data,Ref Dwg ,Local/KD, Classification, RFQ, LOC, Common, Exclusive, Functional, Vendor, Tool Maker, Material, Remarks , CAD data requirement, Notes system file name , Sample submission (T0, final), Spec mtg etc
Engg updates the local/kd, classification vendor etc for records marked as MOD or ADD.
Old records -->marked as DEL,New records--> ADD,Modified records--> MOD ,Qty-change---> Qty_Change
EN1-MATRIX
EN2-MATRIX
EN3-MATRIX
EN4-MATRIX
EN5-MATRIX
Reporting for Model K development status review
PI has read only access to this data base
EN8 block coordinator updates the SMC Enfiguration in PDM
ECN system in PDM Its an Electronic ECN (no Paper copy) .Concurrence and approval is through work flow as per ECN Life Cycle.ECNs can be tracked very efficiently.Concurrence bottlenecks can be easily identified and resolved .
EN8
THANKS
EN8