Presentation on MUL Bill of Material (BOM) by EN8

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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.

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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)

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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.

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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.

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Purpose of BOM contd.Consumption booking.

To facilitates Spare Parts needs.

Models Costing ( Price information is not stored in BOM ) .

Inventory Management.

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What does BOM contain?BOM basically contains three main information related to parts : Design Information

Procurement Information

System Information

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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

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Engg Information flowJapan IndiaLocalisation Plan (LP)Localisation Approval Request(LAR)Local -KD ClassificationECR,EI,ECP,NEC,Vendor Drawings,Draft TPL (Paper)

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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

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Snap shots of EBOM View

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Engg BOM(Based on Block and Variant concept)

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Engg BOM(Based on Block and Variant concept)

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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

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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

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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

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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

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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

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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)

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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

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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

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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

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Product Structure

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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.

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ENGINEERING BOM( Block-Variant)

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88.bin

BLOCK CODE

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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

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RequestEngg raisesECRPESCEngg/En8SMC/VENDORECNPPC/MCDENGGDistributionBOMECN WORK FLOW(Actual ECN)

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ECN Work Flow

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ECN

&C&"Arial,Bold"&14Simplefied flow chart for Formal SMC ECN life cycle

&R&D&T

SMC ECN

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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

E-mail

Data

FTP download/Thru CD's/CDR

upload data

request(as per format)

information

data

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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)

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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)

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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 .

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THANKS

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