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Bills of Material Demo
This demo is one example of how to manage your Supply Chain using SAS Software. It is a client-server application driven from your desktop and running at SAS Institute in Cary, NC. The graphs and reports in the demo have not been saved but are calculated on demand. This means that they change dynamically as the data used to calculate them change.
The Bills of Material (BOM) demo composes, displays, explores, and outputs several different types of bills of material. A bill of material for an item is a list of all parts, ingredients, or materials needed to create one unit of that item. A bill of material may detail only the components directly used in the item or it may cover multiple levels of manufacturing or assembly, listing subcomponents of major components, parts of subcomponents, raw materials for parts, and so on. The BOM demo supports several different types of bills of material, providing valuable and diverse views of product makeup and part/component/material usage. It also reports on upcoming shortages and identifies the shortage status of critical parts and components.
Note: In this discussion "item" is defined as in the APICS Dictionary: "any unique manufactured or purchased part, material, intermediate, subassembly, or product." Customarily there is a bill of material for each item, regardless of whether the item is a finished product, a subassembly, or a component that contains other parts.
Planning effectively for the production and delivery of finished goods requires answers to a number of critical questions, including:
Businesses must confront and answer these questions in order to track the status of production, assess order status, and plan for future production.
The Part Master file includes, for each item:
The Parent-Component Structure data describes each parent-component relationship:
The Planned Orders data describes each planned order:
Several different types of bills of material are produced.
For the entire product line or company:
Summarized Parts List across all planned orders, listing all parts, assemblies, and end items involved. The following is listed for each item:
Indented BOM for end items only, describing all parts used in the item and, for each part, listing:
For any selected item:
Single-level BOM for each item, describing all parts used directly in its production:
Indented BOM for each item, describing all parts used in the item and, for each part, listing:
Summarized BOM for each item, describing all the parts and their total quantity required in the item. For each component the summarized BOM lists:
Gross requirements summary for each item, listing the quantities of all components needed to produce the required quantity of the item and listing, for each:
Single-level where-used report for each item, listing the parent items using it and, for each parent item, listing:
Indented where-used report for each item, tracing its use through the indented bill of material. This report lists the item and steps through each higher-level component or assembly using the item until a final product is reached. At each level, for the current part or assembly this report lists:
Summarized where-used report for each item, listing every parent item using it. For each parent item, the report lists:
For each planned order:
The BOM demo also reports on anticipated part shortages and analyzes the critical path for each planned order (recall that each planned order specifies a quantity of a final product and a due date):
Rough-cut shortage analysis report describes the shortages related to the planned order. This report is structured according to the product's bill of material, and for the final product and each sub-assembly or component lists:
Items with positive Variance will not be available in the desired quantity when needed, and hence have shortage or schedule problems. There might be many items with such problems, but typically only a few affect the release dates for the planned orders.
You can evaluate the impact of the Variance value for item by comparing it to the two reported slack values. If Variance does not exceed Slack to Next Assembly then availability for the item will not delay production of the listed parent component. If Variance does not exceed Slack to Final Product then availability for the item will not delay release of the order.
The items controlling their parent items' availability are those items with a zero value for Slack to Next Assembly; these are referred to as "pacing items." Every subassembly has its own pacing item. Items with a zero value for Slack to Final Product are said to be "critical."
This report is termed a "rough-cut" because it does not account for on-hand stock of any items and assumes that procurement and production begins on the user-specified start date.
Critical path identification produces the same report as the rough-cut shortage analysis, but only reports on the final product and on those items for which Slack Time to Final Product is zero. These are the items on the critical path for production of the planned order; any delay in their availability will delay release of the order. The critical items are the items that delay product availability, and often merit special attention and expedited scheduling.
Material Requirement/Availability Schedule is a Gantt chart, a time-scaled graphical depiction of the schedule for a planned order. The schedules for all items needed to fulfill the order are displayed hierarchically, with critical items depicted in red and all others depicted in green schedule bars. Schedule bars indicate the start and finish of production or procurement for each item, and indicate any slack time that exists. Links between the schedule bars indicate the hierarchical relationships between the items. Milestone markers indicate the Need Date and Promised Date for each item, and a vertical line indicates the Due Date for the order.
This demo requires Internet Explorer (version 5.0 or later).