Your company can never reach its full efficiency potential without the basic infrastructure that makes it all possible. There are two fundamental dimensions to this infrastructure - material, which is defined with bills of material, and labor, which is defined with routings. In this presentation we cover bills of material, which enable you to define the raw materials, components, and subassemblies that comprise the products you make. Bills of material provide all the details needed for cost rollup calculations and job generation, and can be customized as needed for one-off items.
Your manufactured and purchased items are set up here in the Stock Items screen.
Your existing items are displayed on the opening list.
When you click the New button, this screen presents just the required fields, which enables you to rapidly create new items. Here we are creating a manufactured item. And here we are creating a purchased item.
Take note that no GL accounts are specified because all GL posting is controlled by the Account Assignments screen so that your operational people are never exposed to accounting decisions.
For purchased items, allowable suppliers, supplier part numbers, unit of measure conversions, manufacturers, and purchase prices are maintained on this tab.
Default locations and allowable locations are maintained on this tab.
Lot and serial control settings are maintained on this tab.
Multiple documents can be linked to items on this tab, and can also be linked to descriptors, customers, and suppliers and can be automatically retrieved and attached to jobs. Documents can include pictures, drawings, engineering diagrams, process instructions, and manuals. Document linking is vital if you are seeking or wish to maintain ISO-9000 certification.
Manufacturing specifications are entered in the Bills of Material screen. Five bill of material types are offered - BOM, One-Off, Phantom, Batch, and Secondary.
Let's review the standard bill of material type first, which is used for discrete manufacturing where specifications are defined for one unit of the parent product and jobs are run in multiple quantities.
Here on the Revisions tab, you can optionally track engineering changes by revision. Each product has a current revision, which is used for active production, a pending revision for the next version of the product, and archived revisions.
Here we are looking at the Components tab where you specify the raw materials, purchase parts, and subassemblies that comprise the product. Each component is optionally assigned to the routing sequence where it is consumed. The overage percentage provides a safety factor to cover expected scrap. The Speed Entry function enables you to rapidly generate a set of components.
The second BOM type is the One-Off type.
One-off items are generated automatically during quote and sales order entry and represent items that are customized or made on a one-time basis only.
A One-Off bill of material can be entered from scratch or it can be originated from a standard bill of material and then customized as needed for the specific order. When the job is completed and the sales order is closed, the one-off item is automatically inactivated.
The third BOM type is the Phantom type, which is also used for custom manufacturing. A phantom assembly is a make to order subassembly that is never stocked or made on its own job.
Within a One-Off bill of material, phantom parent items are added as components to represent customized product options. At time of job creation, the phantom parent is swapped out by the complete set of phantom assembly components. Therefore, phantom assemblies serve as building clocks that can help you rapidly configure a customized product.
The fourth BOM type is the Batch type, which is used for batch process manufacturing where specifications are entered against a fixed batch size.
Here on the Revisions tab, you define a batch size against each revision.
Here on the Components tab, the usage quantity for each component is the amount that goes into the batch size, which you see here.
The fifth and final BOM type is for Secondary outputs.
Secondary outputs are added to other bills of material here on the Outputs tab. Each job has a primary output, which is the BOM parent, but can also have other outputs. These can be by-products, co-products, usable scrap, or used parts that are derived from disassembly jobs. Each output can be given a Cost Ratio percentage, which is its share of the unit cost.
A variety of tools are provided to help you maintain your bills of material.
Bills of material can be originated from a copy of another bill of material.
New revisions can be originated from current revisions.
The Component Replace screen enables you to mass replace a component across all bills of material where it is used.
The Process replace screen enables you to replace a process across all routing sequences where it is used.
The Change Item ID screen can be used to change a stock item ID number across all associated database tables.
Data Views, inquiries, and reports help you assess your manufacturing specifications.
Here we are looking at the Stock Items data view, within which you can create your own set of customized formats to assess your item specifications.
Two inquiries are available within the Bills of Material screen.
Here we are looking at the Indented View of the item's product structure.
Here we are looking at the same inquiry, in a tree view format.
The Bill of Material Explorer lets you view an item's specifications in a Windows Explorer format.
The Explorer view is in the left panel and the selected item's details are displayed in the right panel.
The Where Used inquiry shows you all the bills of material within which an item is used.
Here is the actual inquiry.
The Multi-Level BOM report gives you an indented view of an item's manufacturing specifications.
Here we are looking at a sample printout.
The Costed BOM report breaks out item costing details within an indented view format.
Here we are looking at a sample printout.
System implementation is greatly facilitated because DBA's data import utility can be used to import the following manufacturing specifications -- stock items, including item categories and locations, item sources, and bills of material.
You export your data into an Excel spreadsheet, and then you edit your data where needed to conform to DBA's requirements.
You then map the DBA fields on this screen to associated spreadsheet columns and then you run the import.
Our data import tools are particularly useful if you create new items and bills of material using a CAD program.
You can import any set of new items and the Stock Item import utility ignores items that already exist and only creates records for new items.
After new items have been created, you can use the Bill of Material import utility to import the new bill of material.
You cannot reach your full efficiency potential without the ability to fully define the material specifications - raw materials, components, and subassemblies, that comprise the products you make. DBA gives you all the tools you need to rapidly and accurately create the bills of material that play such a pivotal role in product costing and job generation.