Menu Path: Manufacturing Module Setup Bill of Material Maintenance
Define and maintain bills of material for products.
Use Bill of Material Maintenance to define and maintain a bill of material for a specific product based on a single or all locations. Use this window to enter all of the necessary components and information necessary to build a product. A bill of material can only be set up for products marked with a Replenishment Path - Build. After a bill of material is defined as active, work orders can be created for the manufactured product.
You can also import bills of material in Bill of Material Import.
Bill of Material Maintenance is divided into multiple tabs that include fields of related information. The following table lists the purpose of each tab.
Tab |
Description |
This tab allows you to set general settings for the bill of material, such as the status and associated project number. |
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This tab allows you to define the operations and work centers (or work center groups if the bill of material is for all locations) required to create the finished product for the bill of material. This tab is not available for kits. Note You must define an operation on this tab before you can assign components, cost categories, and instructions for the operation on the other tabs. |
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This tab allows you to define the component products (raw materials) used for each operation to manufacture the finished product for the bill of material. |
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This tab allows you to define the cost categories to track labor and other costs associated with each operation for the bill of material. This tab is not available for fixed kits. |
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This tab allows you to set up step-by-step instructions for each operation that users can print during the manufacturing process. You can also attach a file with detailed information to each step. |
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This tab displays component and cost totals for the bill of material. |
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This tab allows you to view detailed component information for manufactured components used for multiple-level bills of material. Example Product A is manufactured from two components, Product B and Product C. Product B is also manufactured from two components, Product D and Product E. The bill of material for Product A is a multiple-level bill of material because it is built from manufactured components. |
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This tab displays information for all versions and revisions for the bill of material. |
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This tab allows you to select options for outputting a bill of material summary report. |
Button |
Description |
Exit |
Click this button to close the Bill of Material Maintenance window. |
New |
Click this button to create a new bill of material for the selected product. If a bill of material exists for a product for a different location and you click this button, the Question dialog box appears and asks if you want to copy the existing bill of material. If you click the Yes button, the Bill of Material Copy Selection window appears and allows you to select the bill of material from which you want to copy data. If a bill of material exists for a product for the selected location and you click this button, the Question dialog box appears and asks if you want to create a new version of the bill of material. Click the Yes button to create a new version of the bill of material or click the No button to update the existing version of the bill of material. |
Update |
Click this button to update the selected bill of material for the selected product. If the bill of material is active, the Question dialog box appears and asks if you want to update the revision number of the bill of material. If you click the Yes button, the revision number is increased by one. If you click the No button, and active work orders exist for the bill of material, another Question dialog box appears and informs you that to update the bill of material, you must increment the revision number. Click the OK button to increase the revision number by one. |
Delete |
Click this button to delete the selected bill of material for the selected product. |
Copy |
Click this button to copy the selected bill of material for the selected product to a new bill of material for a different product in the same location (or all locations). You cannot change the location or type for the copied bill of material, but you can change all other information for the bill of material. |
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Click this button to output a bill of material summary report for the selected bill of material using the options selected on the Print Options tab. |
OK |
Click this button to accept an action. This button is only available after you click the New, Update, or Delete button in the ribbon. If you are updating a bill of material for a fixed kit, and changing the components or component quantities, the Question dialog box appears and asks if you want to update existing orders for the fixed kits. If you click the Yes button, unpicked order line items are updated based on the new bill of material. |
Cancel |
Click this button to cancel an action. This button is only available after you click the New, Update, or Delete button in the ribbon. |
Expand All |
Click this button to display components of all components of the bill of material on the Multi-Level tab. This button is only available if you click the Multi-Level tab. |
Expand None |
Click this button to hide components of all components of the bill of material on the Multi-Level tab. This button is only available if you click the Multi-Level tab. |
New Routing |
Click this button to create a new version of the selected bill of material. If you click this button, the new version is not the primary routing by default. |
Notes |
Click this button to display Notes Entry, which allows you to view and enter notes for a selected bill of material. |
Attachments |
Click this button to display Attachment Entry, which allows you to view and enter attachments for a selected bill of material. |
Detailed Information |
Click this button to display detailed information for a selected component on the Components tab. If the bill of material is for a specific location and the component is not manufactured, click this button to display Product Location Maintenance, which allows you to view and edit product/location information for the component. Note If you are not authorized to use Product Location Maintenance, Product Location Inquiry appears instead, and allows you to view product/location information for the component. If the bill of material is not for a specific location and the component is not manufactured, click this button to display Product Maintenance, which allows you to view and edit information for the component. Note If you are not authorized to use Product Maintenance, Product Inquiry appears instead, and allows you to view product information for the component. If the component is manufactured, click this button to display Bill of Material Maintenance, which allows you to view and edit the bill of material for the component. Note If the bill of material is for a specific location and the component is manufactured only in a different specific location, Product Location Maintenance appears instead. If the component is a bill of material group, click this button to display Bill of Material Group Maintenance, which allows you to view products in the bill of material group. |
Update Revisions |
Click this button to display Bill of Materials Revision / Version Update, which allows you to view build information for the selected bill of material and change the active version/revision. |
Field or Button |
Description |
Enter a product code for which you want to view or set up a bill of material, or click the Lookup button to select a product code. This is the product you want to build. Products are defined and maintained in Product Maintenance. |
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Click this button to display Product Prompting, which allows you to enter a product code by element. |
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Click this button to select a product for which a bill of material has already been set up. |
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Enter a product name for which you want to view or set up a bill of material, or click the Lookup button to select a product name. This is the product you want to build. Products are defined and maintained in Product Maintenance. |
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Select this check box to set up a bill of material for all locations. If this check box is selected, the product must be set up for each location in which it will be manufactured with the replenishment path - build. |
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Enter a location prefix or name for which the product will be built, or click one of the Lookup buttons to select a location prefix or name. These fields are only enabled if you clear the All check box. Locations are physical warehouses defined in Location Maintenance. |
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This field displays the version number for the bill of material. |
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This field displays the revision number of the bill of material. The revision number allows you to track changes to the bill of material. This works in conjunction with the bill of material statuses (planning, active, or retired). As the bill of material status changes or any part of the bill of material is updated in the active status, a message appears asking if the revision number should be increased by one. This simply implies that each time an adjustment is made, you have the option of increasing the revision to the bill of material by one number. Increasing the revisions provides a historical record of the bill of material and is useful for inquiring on previous revisions. |
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Click this button to select a version and revision of a bill of material. |
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This field displays the sum of the cost of all components for the bill of material. |
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These fields display the total cost for the bill of material, which is equal to the amounts in the Lines Total and Cost Category Total fields, and the currency for the bill of material. The currency is the currency for the location, or if the bill of material is for all locations, the currency for the functional ledger. |
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This field displays the sum of the cost for all cost categories for the bill of material. |
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These fields display the total cost per stocking unit of measure. |
Field or Button |
Description |
The selected radio button indicates the type of bill of material. One of the following is selected automatically based on the selected product:
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Select whether the bill of material is for an express work order or a work order. Select Work Order if you want to:
Select Express Work Order if all components are stored in backflush bins. These radio buttons are only available if the Work Order radio button is selected for the Type option. |
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Select the status of the bill of material. You can select one of the following:
The status defaults to Active. Note You can only create a work order in Work Order Create or Work Order Maintenance if Active is selected for the status. |
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Enter a description of the bill of material. |
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Enter a unit of measure for the bill of material, or click the Lookup button to select a unit of measure. |
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Enter a project number for the bill of material, or click the Lookup button to select a project number. General ledger projects are defined in Project Maintenance, and are used to track expenses against a general ledger account. |
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Enter the backorder release priority for the bill of material. The backorder release priority ranges from 0 to 999, 0 being the lowest and 999 being the highest. Any backordered work orders for the defined bill of material product are released in Work Order Allocate based on the priority that is assigned for the product. For example, if two separate work orders that contain similar component products are on backorder due to insufficient inventory, the product that was assigned the higher backorder release priority is released first. |
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Select this check box if the version/revision of the bill of material is the primary routing that is used by default when a work order is created for the product. This check box is only enabled if the Work Order radio button is selected. |
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This check box is selected if the version/revision of the bill of material is active, and can be used to create a work order for the product. |
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Select this check box to allow additional cost categories to be added to work orders for the bill of material. |
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Select this check box to allow additional components to be added to work orders for the bill of material. |
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Select this check box to allow the manufactured good to be broken down to the component products. |
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Select this check box if you are using cartonization and you want all components of a fixed kit to be placed in a single carton. If you select this check box, the system will recommend packing in the smallest carton that can fit all the kit components. This check box is only enabled for fixed kits. For information on setting up cartons, see Shipping Carton Maintenance. For more information on cartonization, see Cartonization FAQ. |
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Select one of the following options to control whether quantities greater than the quantity ordered can be confirmed during work order confirmation:
The selected option defaults from Manufacturing Control Maintenance. |
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Enter the percentage that users can confirm during work order confirmation greater than the quantity ordered on the work order. Example If you enter 10 for this field, and a work order is created for 20 units of product A, 22 units of product A can be confirmed during work order confirmation. This field defaults from the percentage entered in Manufacturing Control Maintenance. This field is only enabled if you select the Percent Overage radio button. |
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Select an option to indicate how to handle work orders for the bill of material if the cost variance is too much based on the percentages entered in the Upper Bound % and Lower Bound % fields. You can select one of the following options:
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Enter the lower cost variance percentage limit for work orders for the bill of material. If the estimated cost for manufacturing the product is less than this percentage of the cost variance comparison value, the work order is either placed on cost variance hold or a warning is displayed. This field is only enabled if you select the Manufacturing Control, Hold, or Warning radio button. Note The value that is compared to the estimated cost for the cost variance comparison is set up in Manufacturing Control Maintenance. Example The system is set up to use List Price 1 for cost variance comparisons and Hold is selected for the Cost Variance Option. You enter -50 in this field for a product with a list price of 10. If the estimated cost of the product for a work order is less than 5, the work order is put on cost variance hold. NOTE If this field is left at 0, the default lower bound percentage is used, which is set up in Manufacturing Control Maintenance. |
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Enter the upper cost variance percentage limit for work orders for the bill of material. If the estimated cost for manufacturing the product is greater than this percentage of the cost variance comparison value, the work order is either placed on cost variance hold or a warning is displayed. This field is only enabled if you select the Manufacturing Control, Hold, or Warning radio button. Note The value that is compared to the estimated cost for the cost variance comparison is set up in Manufacturing Control Maintenance. Example The system is set up to use List Price 1 for cost variance comparisons and Hold is selected for the Cost Variance Option. You enter -20 in this field for a product with a list price of 10. If the estimated cost of the product for a work order is greater than 8, the work order is put on cost variance hold. NOTE If this field is left at 0, the default upper bound percentage is used, which is set up in Manufacturing Control Maintenance. |
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Enter the quantity of the manufactured good to produce for the bill of material. This quantity is used as a multiplier for totals. |
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This field displays the estimated production time for the building of the product. Click the Lookup button to select whether the production time is in hours, minutes, or seconds. The estimated production time is the time it takes to complete the manufacturing of the number of units of the finished product entered in the Quantity for Totals field. The production time is calculated based on the times required for the cost categories for the bill of material. |
Note This tab is not available for bills of material used for phantom assemblies, fixed kits, or configuration kits.
Field or Button |
Description |
Enter an operation code for an operation that must be performed for the bill of material, or click the Lookup button to select an operation code. For information on setting up operations, see Operation Maintenance. |
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Enter an operation name for an operation that must be performed for the bill of material, or click the Lookup button to select an operation name. For information on setting up operations, see Operation Maintenance. |
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If the bill of material is for a specific location, enter the work center code for the work center in which the operation will be performed, or click the Lookup button to select a work center code. For information on setting up work centers, see Work Center Maintenance. If the bill of material is for all locations, enter the work center group code for the work center group that includes the work centers in which the operation will be performed, or click the Lookup button to select a work center group code. For information on setting up work center groups, see Work Center Group Maintenance. |
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If the bill of material is for a specific location, enter the work center name for the work center in which the operation will be performed, or click the Lookup button to select a work center name. For information on setting up work centers, see Work Center Maintenance. If the bill of material is for all locations, enter the work center group name for the work center group that includes the work centers in which the operation will be performed, or click the Lookup button to select a work center group name. For information on setting up work center groups, see Work Center Group Maintenance. |
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Click this button to add the operation for the operation code entered in the Operation Code field to the Operations grid. |
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Click this button to remove the selected operation in the Operations grid. |
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This grid displays operation information for the selected bill of material. You can select an operation, and then click the up and down arrow button to the right of the grid to change the order of operations. |
Field or Button |
Description |
This grid displays all operations for the bill of material routing. You can set up the operations on the Routing tab. Select an operation to view or edit the components for the operation. |
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Enter a component product code, or click the Lookup button to select a product code. Component products are items or parts that make up a product to be built or become a manufactured good. Component products are tracked by product, location, and bin. Components can also be tracked by lot, but can only be tracked by serial number for fixed kits. Manufactured products can be tracked by lot or serial number. Component products are picked primarily from the primary work order bin. If this bin is empty and the Must Use Primary Work Order Bin check box is cleared, the software looks at other bins to allocate products for a work order. Note You can use the same product code for the component and the finished good if you want to create a bill of material for rework. However, if you do this, be careful to track the location of the product carefully so that you can determine which bins contain the reworked inventory and which contain the inventory that has yet to be reworked. |
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Click this button to display Product Prompting, which allows you to enter a product code by element. |
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Enter the quantity of the component product required to build the manufactured good. |
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This field displays the smallest product unit of measure for the component product. |
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Click this button to add the component product to the Components grid. |
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Enter the component product name, or click the Lookup button to select a product name. Component products are items or parts that make up a product to be built or become a finished good. Component products are tracked by product, location, and bin. Components can also be tracked by lot, but can only be tracked by serial number for fixed kits. Manufactured products can be tracked by lot or serial number. Component products are picked primarily from the primary work order bin. If this bin is empty and the Must Use Primary Work Order Bin check box is cleared, the software looks at other bins to allocate products for a work order. Note You can use the same product code for the component and the finished good if you want to create a bill of material for rework. However, if you do this, be careful to track the location of the product carefully so that you can determine which bins contain the reworked inventory and which contain the inventory that has yet to be reworked. |
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Enter a scrap factor percentage for the component. This is the excess quantity of the component that is typically scrapped during the manufacturing process, and for which material must be issued. Example A bill of material is set up to require 10 feet of component A with a scrap factor of 10. This indicates that 11 feet of component A are required to manufacture the finished product. |
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Click this button to clear the fields related to the component product. |
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Enter a sequence number for the component product. You can use this number to sort products in the Components grid. |
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Click this button to display Bill of Material Group Maintenance, which allows you to enter, edit, or view bill of material groups for configuration kits. This button is only enabled for configuration kits. |
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Select this check box to allow a substitute component product to be used for building the manufactured product. |
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Select this check box to allow the quantity of the component to be changed for the building of the manufactured product. |
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Click this button to delete the selected product in the Components grid. |
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Select this check box if you only want allocations for material issues to come from the primary work order bin. If this check box is cleared, product is first allocated from the primary work order bin, and if additional quantities are required, other bins are used for allocation. This check box is only enabled if the All and Must Backflush check boxes are cleared, and if the bill of material is not for a fixed kit. |
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Enter the primary bin that is used to allocate the component for material issues, or click the Lookup button to select the bin. If the Must Use Primary Work Order Bin check box is selected, products can be only allocated from this bin. If the check box is cleared, product is first allocated from this bin, and if it is not available, then other bins are used for allocation. This field is only enabled if the All and Must Backflush check boxes are cleared. Note The primary work order bin can also be set up for products/locations in Product Location Maintenance and for work centers in Work Center Maintenance. The primary work order bin for the bill of material overrides the primary work order bin for the work center and the product/location. |
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Select this check box if the component must be issued from a backflush bin for the selected operation. This check box is only enabled if the All and Must Use Primary Work Order Bin check boxes are cleared, the bill of material is not for a fixed kit, and you do not enter a bin in the Primary Work Order Bin field. |
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Enter the backflush bin for the component, or click the Lookup button to select the backflush bin. The backflush bin is used when inventory is not allocated until it is used (and confirmed in Work Order Confirm). You can require a product/location or bill of material component to be taken from the backflush bin. This field is only enabled if you select the Must Backflush check box. |
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This grid displays component products and bill of material groups used for the selected operation. If you are creating or editing a bill of material, double-click a product to edit component information for it, or double-click a bill of material group to display Bill of Material Group Maintenance, which allows you to enter, edit, or view products in the bill of material group. If you are viewing a bill of material, double-click a component to display detailed information, as follows:
Note If you are not authorized to use Product Location Maintenance, Product Location Inquiry appears instead, and allows you to view product/location information for the component.
Note If you are not authorized to use Product Maintenance, Product Inquiry appears instead, and allows you to view product information for the component.
Note If the bill of material is for a specific location and the component is manufactured only in a different specific location, Product Location Maintenance appears instead.
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Note Cost categories set up for operations override cost categories set up for work centers or work center groups.
Field or Button |
Description |
This grid displays all operations for the bill of material routing. You can set up the operations on the Routing tab. Select an operation to view or edit the cost categories for the operation. |
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Enter a cost category code that you want to associate with the operation, or click the Lookup button to select a cost category code. You can only enter or select a cost category code that is set up for the location for the bill of material. |
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Enter a cost category name that you want to associate with the work center, or click the Lookup button to select a cost category name. You can only enter or select a cost category name that is set up for the location for the bill of material. |
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Enter a sequence number to indicate the order in which work for the cost category is performed. Example If work for three cost categories is performed for the operation, you can enter 10 for the cost category performed first, 20 for the cost category performed second, and 30 for the cost category performed last. |
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Select this check box if the cost category is used to calculate the operation times and expected finish dates for work orders. This check box is selected by default if the cost category is set up to be included in total work time. |
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Select this check box if you want to override the default time for the cost category. This check box is cleared by default. |
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These fields displays the time and unit of time (seconds, minutes, or hours) for the selected cost category. The time type (Per Unit or Fixed) is also displayed to indicate whether the time is the overall time it takes to complete work for the operation or the time for each unit of product worked on for the operation. If you select the Override check box to the left of these fields, you can enter the time it takes for work for the cost category to be performed in the displayed unit of time. |
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This field displays one of the following cost types for the selected cost category:
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Select this check box if you want to override the default cost category multiplier for the operation. This check box is cleared by default. This check box is only available if the selected cost category's cost type is Per Unit. |
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This field displays the multiplier for the cost category if the cost is for a subunit of a product. Example The cost category is for painting legs of a chair. Enter 4 as the multiplier if all 4 legs are always painted. This value is used as the product quantity ordered for the service product purchase order for outside processing. If you select the Override check box to the left of this field, you can change the multiplier for the cost category and operation. This field is only available if the selected cost category's cost type is Per Unit. |
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Select this check box if you want to override the default cost category labor rate for the operation. This check box is cleared by default, and is only enabled for internal processing work centers. |
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These fields display the labor rate, rate currency, and cost type for the selected cost category. If you select the Override check box to the left of these fields, you can change the labor rate for the operation. |
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Select this check box if you want to override the default cost category overhead rate for the operation. This check box is cleared by default, and only enabled for internal processing work centers. |
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These fields display the overhead rate and rate currency for the selected cost category. If you select the Override check box to the left of these fields, you can change the overhead rate for the operation. |
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Enter the product code of the service product associated with the cost category, or click the Lookup button to select a service product code. This is typically entered for outside processing to indicate that product that is added to the automatically generated purchase order. This field is only enabled for external processing work centers. |
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Enter the product name of the service product associated with the cost category, or click the Lookup button to select a service product name. This is typically entered for outside processing to indicate that product that is added to the automatically generated purchase order. This field defaults to the service product name associated with the cost category. This field is only enabled for external processing work centers. |
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Enter the purchase class to use for the automatically generated purchase order if the cost category is used for outside processing, or click the Lookup button to select the purchase class. This field defaults to the purchase class associated with the cost category. This field is only enabled for external processing work centers. |
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Click this button to enter the cost category for the selected operation of the bill of material. |
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Click this button to clear the fields related to the cost category. |
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Click this button to remove the selected cost category in the Cost Categories grid from the bill of material. |
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This grid displays cost categories for the selected operation. Double-click a cost category to edit information for it. |
Field or Button |
Description |
This grid displays all operations for the bill of material routing. You can set up the operations on the Routing tab. Select an operation to view or edit the instructions for the operation. |
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This field displays the selected instruction number or the next undefined instruction number. |
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Select this check box to print the instruction on the pick demand. This check box is only available for fixed kit bills of material. |
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Select this check box to print the instruction on the pack list. This check box is only available for fixed kit bills of material. |
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Enter a folder path and file name for a file related to the instruction for the building of the finished product, or click the Lookup button to navigate to and select a file. |
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Select this check box to print the file entered in the File Name field when issuing materials. |
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Enter the instruction step for building the selected product. |
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Click this button to add the entered instruction step to the Instructions grid. |
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Click this button to clear the instruction entered in the Instruction field for a new instruction or cancel the editing of an existing instruction. |
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This grid displays all instructions for building the selected product. Instructions should be followed by the users responsible for the actual construction of a finished good. Double-click an instruction to edit it. Select an instruction and click the up or down arrow buttons to reorder the instructions. Example If instruction #3 is intended to be the first instruction, select instruction #3 and click the up arrow twice until it becomes instruction #1. |
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Click this button to delete the selected instruction line in the Instructions grid. |
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Click this button to display the file associated with the selected instruction in the Instructions grid. |
Field or Button |
Description |
This grid displays summary information for the selected bill of material. |
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This grid displays component products used for the selected bill of material. |
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This grid displays labor, overhead, and other costs for the selected bill of material. |
Field or Button |
Description |
This grid displays component products used for the selected bill of material. Select the check box in the Expanded column to view components required to manufacture each component (if any exist). You can also click the Expand All button in the ribbon to view the components of all components. Double-click a manufactured component to display Bill of Material Maintenance, which allows you to view the bill of material for the product. Double-click a component product that is not manufactured to display Product Location Maintenance (or Product Maintenance if the bill of material is for all locations), which allows you to view and edit detailed product information. If you are not authorized to use Product Location Maintenance or Product Maintenance, Product Location Inquiry or Product Inquiry appears instead, and allows you to view product information. |
Field or Button |
Description |
This grid displays all versions and revisions for the selected bill of material, and allows you to see which is the primary routing. If you are in Inquiry mode, you can double-click a version/revision to select it. |
Field or Button |
Description |
Select one of the following output options:
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Save Report File |
Select this check box to save the Crystal Reports report (.rpt) file for the report to the folder entered in the Report Working Directory field for your user ID in User Profile Maintenance. You can use the report file to customize the report. For more information, see Crystal Reports FAQ. This check box is only available if you select the Screen radio button. |
Save Access Database File |
Select this check box to save the Access database (.mdb) file for the report to the folder entered in the Report Working Directory field for your user ID in User Profile Maintenance. You can use the Access database file to customize the report. For more information, see Crystal Reports FAQ. This check box is only available if you select the Screen radio button. |
Output File Type |
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Specify File Name |
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Output Directory |
Enter the location for the output report, or click the Lookup button to navigate to and select a location. This field is only available if the Specify File Name check box is cleared. |
Output File Name |
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Excel Format Name |
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Format Maintenance |
Click this button to display Excel Format Maintenance, which allows you to set up Excel formats. This button is only available if you select the Excel radio button. |
Save As Type |
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Include header |
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Delimiter |
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Enclosing Character |
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Printer |
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Subject |
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Report File Prefix |
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Add Additional Comments |
Select this check box if you want to include additional comments with the emailed report. If you select this check box, the Additional Comments window appears after you click the Print button in the ribbon, and allows you to enter the comments. This check box is only available if you select the Email radio button. |
Print Full Heading on All Pages |
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Print Title Line on All Pages |
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Report Language 1 |
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Report Language 2 |
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Horizontal Shading |
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Collate |
Select this check box to collate the printed copies of the report (if you are printing multiple copies of the report). This check box is cleared by default, and is only enabled if you select the Printer radio button and enter a value greater than 1 in the Number of Copies field. Example You are printing five copies of a 20 page report to distribute to five different people. Leave this check box selected, so that pages 1-20 of the first copy prints, then pages 1-20 of the second copy, etc. If you clear this check box, five copies of page 1 prints, then five copies of page 2, etc. |
Horizontal Shading Color |
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Number of Copies |
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These fields and radio buttons are disabled in this window. |
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This field is disabled in this window. |
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This check box is disabled in this window. |
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This check box is disabled in this window. |
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This check box is disabled in this window. |
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Report Files |
This grid displays report files set up for the report, and is only available if report files are set up for the program in Report File Maintenance. This grid includes the following columns:
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