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BOM

Are you familiar with term “silo”. When it comes to enterprises and large organizations, we often can hear about different silos of information. Here is the definition of information silo as it appears in Wikipedia.

An information silo is a management system incapable of reciprocal operation with other, related information systems. For example, a bank’s management system is considered a silo if it cannot exchange information with other related systems within its own organization, or with the management systems of its customers, vendors, or business partners. “Information silo” is a pejorativeexpression that is useful for describing the absence of operational reciprocity. In Information Technology, the absence of operational reciprocity is between disparate systems also commonly referred to as disparate data systems. Derived variants are “silo thinking”, “silo vision”, and “silo mentality”.

Very often, you can hear about “information silos” in a very negative context. Here are typical reasons why silos are bad – productivity killer, bad information transparency, etc. Recently published by PR Newswire article defines a new term called silo syndrome. Navigate to the following link to read Thousands of Companies Diagnosed with Dreaded ‘Silo Syndrome’. Article defines list of so called “silo syndrome symptoms”:

- An inability to immediately access business information
- Searching for answers but never really finding them
- Problems processing terms like “unstructured content”
- A penchant to unnecessarily flatten relational data
- Inability to join concepts together in real-time
- Needlessly accessing multiple systems for “what” and “why” answers

PLM propaganda very often use the value of PLM in overcoming the problem of organizational silos. Here is one of many marketing examples of PLM value connected to org silos coming from Oracle Agile PLM article on IT Toolbox article.

PLM by definition is concerned with tracking and controlling product-related business processes that span multiple departments across an extended period of time. Each of these departments may utilize differing systems. Tracking a products lifecycle will often present the need to gather and share information with ERP, CRM, inventory, manufacturing, supply chain, logistics and other systems. While some off the shelf integration may be available, current PLM users often find themselves faced with a frustrating level of manual re-entry or poor visibility of information and processes trapped in so-called silos. Overcoming these integration challenges can mean that an organization is liberated to find the true value of PLM: more innovative, market-responsive products, faster-time-to-market, faster time-to-volume, more efficient change management, better customer care, and superior obsolescence strategies. These benefits can be achieved by both process and discrete manufacturers.

The reality of PLM and silos are difficult. The main place where PLM is facing organizational silos is Bill of Materials (BOM) management. For manufacturing organizations, to create and manintain multiple Bill of Materials is a straightforward way to split responsibilities and control. Requirements, Engineering, Manufacturing, Sales, Support, Supply… you name it. Every department and organization is requesting to have “my BOM”, which will allow them to control and manage the information in the way they want. The real challenge come after when people demand PLM system to take care of multiple BOMs and information transformation between these BOM-silos.

What is my conclusion? Today, PLM has a limited success in eliminating organizational silos by introducing support for multiple Bill of Materials. In many situations PLM is not eliminating the needs to re-creating information. The demand of customers is to have sophisticated BOM management tools that allows to maintain multiple BOM silos in organization. In practice, manufacturing organizations are not interested to eliminate BOM silos. People want to keep information silos, but have PLM system that can help them to manage silos. Result is skyrockeing complexity of the PLM systems and implementation. So, do we need to preserve silos? It is a good question you can ask before approaching you next PLM BOM implementation. What is your take? Speak up.

Best, Oleg

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I want to continue my BOM 101 thoughts and speak about working with Bill of Materials during early stages of product development. Engineers are using multiple sources of information to create an initial Bill of Materials. The initial BOM structure can come from CAD system, other BOMs developed earlier and also created from scratch. One of the important steps during this process is to assign Part Numbers as early as possible.

Part Numbers (PN) and development lifecycle process

Initial PN allocation plays a key role in overall product development process. From the moment we assign Part Numbers, the status of product development can be tracked by the Item Lifecycle mechanism. Newly created PN are obviously getting “development” status. However, measurement of time lapsed since PN assignment until Item actually entered into BOM and later until specification document becomes available will allow you to follow process of development on the very early stage.

Par Number and PLM/ERP integration

Part Number assignment requires some degree of system integration. The easiest way to get things done is to manage PN in your PLM systems. However, a reality is different. Very often, item master is managed by ERP system or another data management system. It can be also home grown database that historically keeps record of Item masters and allocate Part numbers. So, to integrate these systems will be extremely important to manage Items lifecycle in the company.

What is my conclusion? It is very important to have item lifecycle started at the very early stage of product development. Unfortunately, very often companies are postponing this step because of the integration complexity. PLM/ERP integration project is starting on the late phase of PDM/PLM implementation. Internal company politics are adding an additional level of complexity  to this decision. It takes weeks or even monts to decide where to manage Item Masters. A significant portion of product cost is defined during early stage of the development. To have early BOM/PN visibility can optimize the process. Just my thoughts…

Best, Oleg

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I’m continue my BOM 101 series of posts. When working on bill of materials, you can often hear about the ability of BOM management software to support so-called “multi-level” BOM. You can search for the definition of multi-level BOM using Google and find many results. I found the following definition of multi-level BOM on Arena website quite balanced. Here is the passage from the Mult-level BOM article:

A multi-level BOM, also referred to as an indented BOM, depicts parent-child relationships and shows the hierarchical structure of assemblies and their related parts and components. A multi-level BOM is essentially a nested list whose parts or items are listed in two or more levels of detail to illustrate multiple assemblies within a product’s BOM. In contrast, a single-level BOM depicts one level of children in an assembly and only the components needed to make that assembly are listed.

In the past, when BOM was managed using paper and spreadsheets, to create multi-level BOM wasn’t a simple task. Computer systems create an opportunity to manage and manipulate easily with multiple levels of BOM. However, the question people are asking usually – how many levels of BOM do we need? This simple question is actually leads to many interesting discussions. From my practice it related to many factors. The most typical are – type of BOM (engineering, manufacturing, support), type of the product, maturity of product development and many others.

I found an interesting writeup about BOM levels in the Frank Watts’ book – Configuration Management Metrics. Navigate to the following link – I was able to access this book fragment using Google Books. Here is an interesting passage:

The tendencies of the companies to create multi-level assembly structures seems to be overwhelming. This analyst has witnessed 11 levels at a couple of companies and had a seminar attendee tell about 16 levels. Many departments wish to add structure for their apparent need and many needs are not in best interest of the company as a whole. Because agreement cannot be reached on one structure, often an “Engineering BOM” and a “Manufacturing BOM” are created. Often a material folks create “Planning BOM”. Many times various department can reach agreement only by adding additional layers to the BOM. 

The following diagram shows the number of levels in BOM correlated to maturity of product development. The analyst believes a better communication can be achieved by creating a BOM with minimum levels of structure.

What is my conclusion? The fact you can create multiple levels of BOM doesn’t mean you need to utilize it at full capacity. Multi-level BOMs are complicated and adding an additional work in the process of changes. How to maintain the right number of BOM levels? I’m interested to learn more about your experience. How many BOM levels do you have in your company ERP/MRP/PDM/PLM system? Speak your mind.

Best, Oleg

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BOM 101: 5 “Don’ts” for Bill of Materials Management

January 21, 2013

BOM is fascinating. After posting 3 Modern BOM Management Challenges a week ago, I keep getting back to Bill of Materials management topic.  If you missed my previous BOM 101 posts, here are links to get up to speed: BOM 101- The four pillars of every BOM management solution, BOM 101- How to optimize Bil [...]

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BOM 101: The four pillars of every BOM management solution

January 17, 2013

I suggest you an experiment. Invite two engineers and ask them to provide a definition for some of PDM/PLM related terms. I’d not be surprised if you will get more than two definitions. It is not unusual to spend lots of time during PLM software implementation meetings to define terms, language and meaning of things. [...]

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Single Bill of Materials in 6 Steps

January 16, 2013

Last week I started the discussion about about modern BOM challenges. That discussion made me think more about the idea of unified and consistent Bill of Materials that can be shared across the company (single BOM). In my view, this is a clear paradigm shift from what we know today as “multiple BOMs”. How to [...]

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BOM 101: How to optimize Bill of Materials

January 14, 2013

Last week, I started the conversation about Bill of Materials and modern challenges. BOM is a heavy topic. Previous blog made me think about few additional things related to BOM management and I decided to share it with you too. One of the concepts I see as important in modern PLM and other enterprise systems [...]

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3 Modern BOM Management Challenges

January 11, 2013

Bill of Materials. Probably the key element in product development and manufacturing. Surprisingly enough, many companies are still struggling with this topic. Bill of Materials drives lots of controversy and discussions. Why it is so important? On a surface you may think BOM is a really simple thing. Just a list of components. However, if [...]

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Why Companies are Not Ready for Single BOM?

December 19, 2012

Bill of Material is one of the fundamental things in engineering, manufacturing and product development. Whatever topic you start discussing, you end up with the discussion about BOM. Wikipedia, actually, provide a decent definition of Bill of Material. Here is the link and quote: A BOM can define products as they are designed (engineering bill [...]

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Multiple BOMs – Why Sync is so hard?

August 30, 2012

Vacation is a great time to work . Finally, you can have time to think about variety of topics that you are missing during your workdays. Here is the one I picked today – multiple bill of materials and synchronization. For those of you in PDM / PLM space even for few years, this topic [...]

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