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What is a Configurable BOM?

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Configurable BOM Definition

A configurable bill of materials (cBOM) is a versatile, rules-based BOM framework that encompasses all potential components, modules, and alternatives for a product, facilitating the generation of a specific, resolved BOM (variant) according to selections or configuration rules.

Essential elements of a customizable Bill of Materials encompass:

  • Option definitions and variant rules – specifying which parts or modules are optional, which are mutually exclusive, or which depend on certain conditions
  • The master structure, also known as the “super BOM,” is a comprehensive bill of materials (BOM) that includes all possible components, often referred to as a “150% BOM” because it surpasses the requirements of any individual assembly
  • Rules engine/filter logic – the configuration mechanism that assesses selections and either excludes or incorporates components accordingly
  • The resolved BOM output – upon selection of configuration options, the cBOM is refined or converted into a definitive BOM for procurement, manufacturing, or production
  • Modular/hierarchical design – components and subassemblies are organized to facilitate the reuse, interchange, or substitution of modules among variants
  • “Do Not Place” flags / conditional placement – components designated not to be assembled in specific variations (e.g., “DNP,” “NP”)

A configurable BOM is the digital representation of a product family, facilitating the dynamic creation of variant BOMs instead of the laborious management of individual BOMs for each configuration.

Why Configurable BOM Matters for Product & Operations

Many industries, including high-tech and consumer electronics, industrial equipment, medical devices, automotive, telecommunications, and machinery, provide products with various configurable attributes (such as size, color, performance, and optional modules). The use of distinct static BOMs for each configuration becomes impractical. A configurable bill of materials helps:

  • Minimize BOM proliferation – prevents the duplication of analogous BOMs for each product version.
  • Facilitate updates – when a shared component is modified, a single update in the cBOM propagates the change to all variant BOMs
  • Expedite sales-to-manufacture workflow – upon receipt of a sales order with options, the variation BOM is automatically generated and transmitted to manufacturing
  • Minimize mistakes – configuration rules prevent improper combinations and omissions
  • Enhance visibility – analytics and reporting over the full product range (as opposed to individual versions)
  • Facilitate mass customization – enabling product customization while preserving manufacturing efficiency

Without a flexible BOM strategy, administrative burdens, the likelihood of discrepancies, and the intricacies of variant management would escalate significantly as product complexity rises.

Relationship to PLM, QMS, NPI & BOM Management

Configurable BOM in PLM / QMS / Lifecycle Integration

In a PLM environment, the cBOM is generally incorporated within the product master definition, interfacing with engineering, design modifications, versioning, and quality assurance procedures. The rules and configuration logic are versioned, validated, and governed by change management. A QMS overlay ensures auditability about the variation rules or module selections, which is particularly crucial in regulated sectors. The PLM serves as the authoritative system for both the cBOM logic and the finalized variant BOMs.

Configurable Bill of Materials & New Product Introduction / Bill of Materials Management

Configuring the product family is a crucial deliverable during new product introduction (NPI). Establishing the cBOM structure, option regulations, dependence logic, and permissible variation combinations are key components of the planning and design phase. As the product design evolves, the cBOM facilitates the management of numerous pending versions without the need to generate multiple static BOMs. It optimizes BOM management by integrating variation complexity into a singular structured model.

Furthermore, in bill of materials (BOM) management, the configurable bill of materials (cBOM) serves as the definitive source of truth for variation options. Resolved BOMs, or specific configurations, are derived from it. The cBOM guarantees uniformity among variant BOMs, minimizes redundancy, and mitigates discrepancies or version inconsistencies.

FAQs

What distinguishes a changeable BOM from a modular BOM?

A modular bill of materials (BOM) consolidates subassemblies or modules that are reusable across different versions, forming a component of the configuration bill of materials (cBOM) idea. A configurable BOM incorporates rules, logic, and variation dependencies into a modular structure, enabling the dynamic generation of complete variant BOMs.

What constitutes a "resolved BOM" in the context of a changeable BOM?

A resolved BOM is the variant-specific BOM generated by implementing configuration rules on the cBOM. It comprises solely the components required for that specific product variant, extracted from the larger collection.

What is the maximum number of feasible configuration options before a cBOM becomes excessively intricate?

The feasibility is contingent upon the intricacy of the product and the depth of the rules; nonetheless, when the number of variants escalates to hundreds or thousands, managing a static bill of materials (BOM) method becomes untenable. An effectively structured cBOM with robust constraint rules is crucial as the number of variants increases.

In what manner do configuration rules address mutually exclusive or dependent features?

Logic or rules are incorporated into the cBOM, such as “If option A is selected, option B is prohibited” or “If feature X is chosen, component Y must be included and Z excluded.” The rules engine evaluates these dependencies and selectively removes or incorporates components when producing the resolved BOM.

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