Presentation on

MUL Bill of Material

(BOM)
by 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.

03/31/15

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 BOM
Each Model spec has one BOM .
BOM is uniquely identified by a Model code
.(8 digit code)
03/31/15

EN8

Differences b/w EBOM & PBOM

1. EBOM based on block &
variant concept.

1. PBOM is based on Reference

No.

2. In EBOM part has linkages

with Drwgs.

2. PBOM contains Part

classification (local,KD),shop
codes,station no.,usage
conditions,etc.

3. EBOM is used for

localization process
(LP,LAR,ECP,ECR,etc.)

3. PBOM is used for running

MRP & consumption booking.
4. Inventory Mgmt. Is done
through PBOM.

03/31/15

5. Cost control is done through

PBOM.
EN8
4

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.

03/31/15

EN8

Purpose of BOM
contd.

Consumption booking.
To facilitates Spare Parts needs.

Models Costing ( Price information is not stored in

BOM ) .

Inventory Management.
03/31/15

EN8

What does BOM contain?

BOM basically contains three main
information related to parts :
Design Information
Procurement Information
System Information
03/31/15

EN8

Engg Information flow

India

Japan

Technical 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
03/31/15

EN8

Engg Information flow

India

Japan

Localisation Plan (LP)

Localisation Approval
Request(LAR)
Local -KD Classification
ECR,
EI,
ECP,
NEC,
Vendor Drawings,
Draft TPL (Paper)
03/31/15

EN8

Preparation of EBOM

New Model/ Family

Parts classificication
( Make or Buy)
(Local/KD)

SMC TPL(xls)
(Block and Variant)
Maruti Part number
for local parts and
supplier relation
Creation of
MUL
Model codes

EBOM release
to PPC

Creation of
Vehicle
Family

Creation of
MUL
specific
blocks

03/31/15

Identification of
Common
/uncommon parts
Loading in PDM (Block-VR
Product structure for SMC
and MUL configuration)

Linking of
Block-VR to
MUL Models

Loading of
SMC
Drawings

Modification of EBOM through

ECN Life Cycle

EN8

EBOM
Ready

10

Snap shots of EBOM View

03/31/15

EN8

11

Engg BOM
(Based on Block and Variant concept)

CA010-10
SMC
Model

CB200-01

YM111B2AP74

CG200-01

Model
Family

CS200-02

YM1

Maruti
Model

MS200-03

BR4BS600
BR4HS512

03/31/15

Maruti Blocks introduced

for MUL specific
requirements

EN8

12

Engg BOM
(Based on Block and Variant concept)

Block-Variant
(CA010-10)
SMC
Product
Structure

SMC Part Numbers

arranged as per Parent
-Child relationship

03/31/15

MUL
Link based on Block-Variant Product
Structure

Product structure contains

both SMC Part Numbers as
well as MUL Part Numbers
arranged as per Parent Child
EN8
13
relationship

Integration of Engg and

Production BOM
Production BOM product structure is reference number
based and has non-uniform product structure to fulfill
MUL specific requirements.
Engg BOM
(PDM)
Engg
responsibility

Production BOM
CL03

CMS
PPC responsibility

PPC
responsibility

CMS - Link between EBOM and PBOM for partlist updation

03/31/15
through ECN system

EN8

14

Model Code
MES N 2004
1

Specification Code

Basic
vehicle code

Variant Code
Sub Model Code

Alphabet

Selection Code

Numeral

03/31/15

EN8

15

Model Code explanation

C

4 H

0
For
Domestic
Mkt ( India)

Car (M800)

NCR Model
RHD (M/T)

4 Door

03/31/15

Standard
Heater

EN8

16

SMC Model Coding

Y

8
Destination

Minor Change
Basic Series
Code

Body type Code

Product Classification
Y- 4 Wheeler
Numeral
Alphabet

Spec Code*

* 1. Body style, Seating Capacity

2. T/M , Strg Handle Position
3. Grade etc.

Part Number coding

Color code ,
etc

Basic
Number

Design Change
Number
Hyphen (- for KD , M
for Local, N for other
than SMC import, E -KD
Part with extra
processing

Type number (Source)

Model type
Number

Standard part : No Part Drawing

Commonly used in Many products e.g. Fasteners. Part
number for standard items starts with 01-08 (first two
digit of Part number)
0

1
8
Unique number
by the type
Standardized part
identification n umber

Surface treatment
Nominal size,strength
classification etc

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 .
0

9
Registration number
(001-999)
Unique number
by the type
Semi standard part
identification number

Nominal size
(main characteristic)

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.
Basic Number

Design change order

Type number
Model Type number
Detailing number
Functional Classification
number

Color identification
number

Structure of basic part number

Part (0 is not assigned at fifth place )

Comp ( less than 9 parts) --0 at fifth place
Comp (more than 9 parts) - 0 at fourth place

Large classification

1- Engine, 2-T/M 3-Electrical 4-Suspension 5- brake

6- white body 7 Equipment(under cabin) 8- door seats
9 Etc (A/c) , 0- Fastners or bearings

Design information
Design of a particular spec is represented as
Product Structure in BOM .
Parent - Child relationship. (Reference number )

Design information is stored in following

attributes

Part number (00000M00000-000)

Part Name (Description of item)
Qty.
( Qty required / reference )
ECN number
Optional (Y / N )
03/31/15

EN8

23

Product Structure
R e f e re e n c e n u m b e r
E n g in e a s s y

P is to n
P lu g

B lo c k C o m p C y lin d e r
C ra n k b e a rin g

03/31/15

001

C y lin d e r B lo c k
assy

C y lin d e r H e a d

T ra n s m is s io n

C a p C ra n k B rg

B o lt c ra n k b rg C a p

P is to n rin g s

B o lt c ra n k B e a rin g

P is to n R in g s 1

P is to n rin g 2 n d

0 0 1 -0 0 1
-

EN8

0 0 1 -0 0 1 -0 0 1

R in g , P is to n o il

0 0 1 -0 0 1 -0 0 1
-0 1 0 -

24

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
03/31/15

EN8

25
Contd.

ENGINEERING BOM
( Block-Variant)

P A R T L IS T
M1
M O DEL TYPE

CA
LAR G E BLO C K
E N G IN E
CA010
CYL. HEAD

CA020
CYL. HEAD CO VER

10
V A R IA N T
S E L E C T IO N 1

20
V A R IA N T
S E L E C T IO N 2

PART ASSY

PART ASSY

PART COM P
P A R T (A ) P A R T (B )

PART

P A R T (A )

CB
LAR G E BLO CK
E N G IN E A U X IL L A R Y

P A R T (B )

M2

M3

CC
LARG E BLO CK
T /M
CA480

P A R T (C )

P A R T (C )

03/31/15

EN8

26

BLOCK CODE
Large
Block

E n g in e
EA nu gxiilni ae r y
T r a n sm i s si o n
EE nl e gcti nr ei c
BE ol e dcty r i c
( F ra m e )
S u sp e n si o n
B r a ke
U n it e B o d y
SF re a p ma re a t e
C a b o ve r
(E Pum p )
(R Body )
E q u ip m e n t

White Body

D IA G R A M
J im n y 1 9 8 4 m o d e l

( COVER )

E n g in e

( INDEX )

C y lin d e r H e a d

H ead C over

E n g in e
A u x ilia r ie s
S p a r k P lu g

T r a n s m is s io n

E n g i n e E l e c t r i c a ls

Block

C yB l ilno dc ek r

Level - 1 Parts

P a rt-A ( A s s y )
( MAIN SHEET )

P a rt-B ( C o m p )

03/31/15

P a rt-F

Level - 2 Parts

EN8

27

Large
Block

Engineering
Change
Process

ECN WORK FLOW(Actual ECN)

SMC/VENDOR

Request

Distribution

Engg
raises
ECR
ENGG

PE
SC

Engg
/En8

PPC/
MCD

ECN

EN8

29

BOM
03/31/15

ECN Work Flow

Homologation check
done by EN8

P
D
M

S
y
s
t
e
m

SMC ECN

CD ROM
3 CDRoms are
received
monthly

EN8

Loading in PDM SMC

ECN acceptance life
cycle

Engg to accept /
Not to adopt
SMC ECN

Create
ECR/ECN

Not to be adopted

PE
e.g. R04-0001

Engg identifies
Distribution list
e.g. PPC, SC, PE,
Service, Spares, QA etc

Raise NEC
to SMC

Engg 1-5
SC

For concurrence
Regulatory ECN , date of
implemenation decided by
Engg

Conversion
to ECN

Updation of
EBOM
PDM sends E-mail as
per distribution list

e.g. N04-0001

File Transfer to PDM system

PDM system
CMS System

C
M
S

File Transfer to CMS system

( Change Management system )

Updation of
Production BOM
and information to
all concerned

system mail to all

concerned

s
y
s
t
e
m

03/31/15

EN8

PPC to assign final

implementation date
after checking
inventory

30

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 .

03/31/15

EN8

31

THANKS

03/31/15

EN8

32