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Product Structure

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This function is applied to create Product structure data to define the Bills of Material.

In order to access certain areas of this function, (specifically related to project specific bills of material, contract/project substitutes and the mapping of a project work breakdown structure into the BOM hardware structure) module licensing is required for Project Specific Baselines and Contract Management in addition to the required user access profile.

Module licenses valid for your Company can be viewed via the function "Module Licensing".

The structure defines the required material, components, shop floor consumables, technical specifications and other utilized items such as manuals, tools and equipment required to manufacture a product.

The Bills of material can be for actual engineering assemblies and parts, as well as for phantom parts, planning bills for options or sales forecasting, or maintenance- and upgrade kits.

 

Prior to creating the Product structure to define Parent/component relationships and related meta data, the Part master records for the items must be defined.

Part master data can be created for any item, whether for finished goods, raw material, components, specifications, documentation, consumable items, tools, machines, assets or any other item that needs to be identified with a unique part number. These will include part numbers for phantom parts, planning bills, modular bills and maintenance kits. The part master contains all related Engineering-, manufacturing-, maintenance/repair, inventory planning- and financial data.

 

The Product structure detail can be systematically completed as the engineering design of an item and its phase in the development life cycle progresses.

The parts can originally be created with minimal data, and this applies the Bill of material as well.

 

Systematically, the routing steps to define the manufacturing process can be added and mapped in the Bill of material, as can maintenance data for maintenance significant items and addition data for yield and scrap attrition, offset lead-times and part substitution rules.

The functionality provides for a single integrated routing definition for both "manufacturing" and "maintenance" scenarios.

Via the Bill of material and the association of BOM-items with specific manufacturing and repair operations, visibility is provided of all associated facilities, skills and resources (documentation, tools, machines, sundry consumables and others) applied in the manufacturing process.

Back-flushing rules for labour report back and post deduction of inventory balances are fully integrated with the product design and manufacturing tasks defined in the routing.

Comprehensive functionality is included for routing steps performed externally by Suppliers.

 

The functionality extends to the point where Contract specific Bills of material can be created, associated with contract specific part substitution rules and contract requirements for quality, documentation, packaging, preservation and marking.

As an alternative to implementing engineering changes effective from specified dates, functionality is provided to implement such changes from a specified contract/project end-item serial number, thus eliminating all the factors that traditionally interfere with correctly timing the implementation and thus minimizing obsolescence.

 

Once the structure has been extended from a basic engineering design to one that incorporates and reflects the manufacturing and repair process and the planning data for all related parts have been specified,  the real-time navigation tools provides for critical path  lead-time analysis and past, present and future views of the product base line.

 

Although the Product structure is created level by level, functions such as Product Structure Navigation allows multiple options to explode/implode multiple levels of the structure.

The function Deliver to operation maintenance also allows a multi-level view and maintenance for the linking of Bill of material items to specific manufacturing and/or maintenance operations.

 

The Structure Maintenance tab is applied to specify the Parent/component relationships and to add or remove items from the structure.  A project specific BOM can only be created from the standard BOM, and can thus only exist if created from the standard BOM.

 

The Engineering & Manufacturing Data tab is used to define the basic engineering data on the Link, such as Quantity Per, Drawing Annotation, Effective Status of the Link and the Effectivity Date.  It is also used to define manufacturing data to associate material/ components or sub assemblies to specific manufacturing operations with offset lead times and scrap percentages where applicable.

 

The L.S.A. Data is used to define Logistic Support Analysis and product Maintenance Data. This includes mapping of BOM-items to specific repair or maintenance operations, repair scrap- and failure allocation percentages and identification of Illustrated parts catalogues. Via this tab an item-link is also identified as the item being consumed or utilized only and whether it is a standard- or "as needed" replacement when the parent part is maintained. It also provides settings to specify whether extra material (for spillage, chuck allowance and others) or QA pieces (to demonstrate that manufacturing processes are under control by manufacturing additional pieces for QA purposes) are required (also see tab "QA and extra pieces").

 

The Positioning tab is used to identify the various positions (drawing annotations) for components with a qty per > 0.

If a component is installed in different positions on the parent part, the related position and qty per for the position can be specified.

 

The Std Substitutes tab is used to identify all alternate parts (substitutes) that can be applied where shortages exist for the selected component/material part. These substitutes are application sensitive and not universal.

If a Copper washer of the same size is specified as an alternate for a Steel washer, the alternate Copper washer would thus only be valid as a substitute when the selected parent part is manufactured.

Also see Project Substitutes.

 

The Projects tab is applied to access the 2 sub tabs where contract and project rules can be specified for substitution and for mapping the project WBS to the hardware structure.

 

The Project Substitutes tab is used to identify all alternate parts (substitutes) that can be applied where shortages exist for the selected component/material part on orders related to a specific customer contract or project. It is thus possible to allow either none, or only some of the alternate parts defined via the Substitutes tab for a specific contract or project. (i.e. only those that would be acceptable to the customer).

Items that can normally, from a form, fit and function perspective act as a substitute, may not be acceptable for certain contracts due to its surface treatment, marking or other factors.

Also see Substitutes.

 

The Project WBS Nodes tab is used to map the work breakdown structure (WBS) of a Project into the hardware breakdown structure of the Bill of material.

This enables MRP to suggested the correct WBS-element when stock replenishment orders are suggested and correctly identifies the element in the WBS of which the budget is to be consumed when manufacturing or purchasing a specific item in the BOM.

 

The QA and extra pieces tab is applied where extra material (for spillage, chuck allowance and others) or QA pieces (to demonstrate that manufacturing processes are under control by manufacturing additional pieces for quality assurance purposes). The tab can be accessed if a component with type of link "E" or "Q" is selected and the tab is then applied to specify the calculation method for such extra pieces or QA pieces.

 

The creation or maintenance of product structures can be Change Control protected.

This can vary from "No" control, to limited or detailed levels of control where approved Change Proposals are required to execute changes to the BOM.

The settings ECP Control Product Structure on System Configuration and

The settings for the product code of the Parent part being maintained as defined on Product Master governs the level of control.

 

The function allows the user a variety of modes to add and maintain the Product structure:

 

How to link a single component to a parent

How to same-as copy a product breakdown structure

How to replace a component with another component based on a where used

How to delete a component from the structure

How to associate a component part with a maintenance task

How to associate a component part with a manufacturing operation

 

On this tab the following fields can be viewed:

hmtoggle_plus1Structure Maintenance

hmtoggle_plus1Engineering & Manufacturing Data

hmtoggle_plus1Positioning Function

hmtoggle_plus1L.S.A. Data

hmtoggle_plus1Std Substitutes