Example 3.3 Bill of Material with Scrap Factor Information

As in the introductory example described in the section Getting Started: BOM Procedure, this example uses two data files, PMaster3 and ParComp3, as input data sets for the BOM procedure. The PMaster3 data set, shown in Output 3.3.1, lists the part master records for all items of the ABC Lamp Company. The Part and Desc variables contain the part number and description, respectively. The Unit and LeadTime variables contain the unit of measure and lead time information for the item identified by the Part variable. The ParComp3 data set (shown in Output 3.3.2) lists all product structure records in the company. The Parent and the Component variables contain the part numbers for the parent item and the component, respectively. The QtyPer, Fscrap, and LTOff variables contain the quantity per assembly, scrap factor, and lead-time offset information, respectively, for the relationship identified by the Parent and Component variables. The SDate and EDate variables are the start and end dates for the bill of material effectivity dates. The effectivity dates are used to determine when a component is active as a part of the bill of material. In this example, item '1700' uses component '2200' until the end of the 7th of April, 2001. Starting on April 8, 2001, item '1700' uses component '2210' instead. Refer to Landvater and Gray (1989) for more information about bill of material effectivity dates.

Output 3.3.1 Part Master Data Set (PMaster3)
ABC Lamp Company
 
Part Master Records

Part Desc Unit LeadTime
1100 Finished shaft Each 2
1200 6-Diameter steel plate Each 3
1300 Hub Each 2
1400 1/4-20 Screw Each 1
1500 Steel holder Each 2
1600 One-way socket Each 2
1700 Wiring assembly Each 1
2100 3/8 Steel tubing Inches 3
2200 16-Gauge lamp cord Feet 2
2210 14-Gauge lamp cord Feet 2
2300 Standard plug terminal Each 1
A100 Socket assembly Each 1
B100 Base assembly Each 1
LA01 Lamp LA Each 2
S100 Black shade Each 2

Output 3.3.2 Product Structure Data Set (ParComp3)
ABC Lamp Company
 
Product structure Records

Parent Component QtyPer Fscrap LTOff SDate EDate
LA01 B100 1 . . . .
  S100 1 . . . .
  A100 1 . 2 . .
B100 1100 1 . . . .
  1200 1 . . . .
  1300 1 . 1 . .
  1400 4 . 3 . .
A100 1500 1 . . . .
  1600 1 . . . .
  1700 1 . . . .
1100 2100 26 0.2 . . .
1500 1400 2 . . . .
1700 2200 12 0.1 . . 07APR2001
  2210 12 0.1 . 08APR2001 .
  2300 1 . . . .

The following code invokes PROC BOM to produce the indented bill of material and the summarized parts list.

  /* Create the indented BOM with lead time */
proc bom data=ParComp3 pmdata=PMaster3 
         out=IndBOM3 summaryout=SumBOM3; 
   structure / part=Part 
               leadtime=LeadTime 
               parent=Parent
               component=Component
               quantity=QtyPer
               factor=Fscrap
               offset=LTOff
               id=(Desc Unit)
               rid=(SDate EDate); 
run;

The indented bill of material in Output 3.3.3 is similar to the one displayed in Output 3.2.2, with additional fields for scrap factor, lead-time offset, total offset, and the start and end effectivity dates. The values of scrap factor, lead-time offset and the effectivity dates are carried from the product structure input data set shown in Output 3.3.2. The value of the total offset (denoted by the Tot_Off variable) is determined by the procedure as the total lead-time offset accumulated from the end item identified by the _Prod_ variable to the item identified by the _Part_ variable. In addition, the value of the quantity per product (denoted by the Qty_Prod variable) for each record of this indented bill of material has been increased by the scrap factor to account for anticipated loss within the manufacture of the product 'LA01'. See the section Indented BOM Data Set for information about determining the quantity per product when scrap factor is in effect.

Output 3.3.3 Indented Bill of Material with Scrap Factor (IndBOM3)
ABC Lamp Company
 
Indented Bill of Material, Part LA01

Obs _Level_ _Parent_ _Part_ Desc QtyPer Fscrap Qty_Prod Unit LeadTime Tot_Lead LTOff Tot_Off SDate EDate _Prod_
1 0   LA01 Lamp LA . . 1 Each 2 2 . 0 . . LA01
2 1 LA01 B100 Base assembly 1 0.0 1 Each 1 3 0 0 . . LA01
3 2 B100 1100 Finished shaft 1 0.0 1 Each 2 5 0 0 . . LA01
4 3 1100 2100 3/8 Steel tubing 26 0.2 26 Inches 3 8 0 0 . . LA01
5 2 B100 1200 6-Diameter steel plate 1 0.0 1 Each 3 6 0 0 . . LA01
6 2 B100 1300 Hub 1 0.0 1 Each 2 5 1 1 . . LA01
7 2 B100 1400 1/4-20 Screw 4 0.0 4 Each 1 4 3 3 . . LA01
8 1 LA01 S100 Black shade 1 0.0 1 Each 2 4 0 0 . . LA01
9 1 LA01 A100 Socket assembly 1 0.0 1 Each 1 3 2 2 . . LA01
10 2 A100 1500 Steel holder 1 0.0 1 Each 2 5 0 2 . . LA01
11 3 1500 1400 1/4-20 Screw 2 0.0 2 Each 1 6 0 2 . . LA01
12 2 A100 1600 One-way socket 1 0.0 1 Each 2 5 0 2 . . LA01
13 2 A100 1700 Wiring assembly 1 0.0 1 Each 1 4 0 2 . . LA01
14 3 1700 2200 16-Gauge lamp cord 12 0.1 12 Feet 2 6 0 2 . 07APR2001 LA01
15 3 1700 2210 14-Gauge lamp cord 12 0.1 12 Feet 2 6 0 2 08APR2001 . LA01
16 3 1700 2300 Standard plug terminal 1 0.0 1 Each 1 5 0 2 . . LA01

The summarized parts list, which has been sorted by the _Part_ variable, is displayed in Output 3.3.4. Comparing it with the summarized parts list displayed in Output 3.1.3, you can see the impact of scrap factor on the gross requirement (and hence, the net requirement). Moreover, the summarized parts list data set shown in Output 3.3.4 contains a record for each of the items '2200' and '2210', and the gross requirements of these two items are not affected by the bill of material effectivity dates.

Output 3.3.4 Summarized Parts List (SumBOM3)
ABC Lamp Company
 
Summarized Parts List, Period 3

_Part_ Low_Code Gros_Req On_Hand Net_Req LeadTime Desc Unit
1100 2 1.0 0 1.0 2 Finished shaft Each
1200 2 1.0 0 1.0 3 6-Diameter steel plate Each
1300 2 1.0 0 1.0 2 Hub Each
1400 3 6.0 0 6.0 1 1/4-20 Screw Each
1500 2 1.0 0 1.0 2 Steel holder Each
1600 2 1.0 0 1.0 2 One-way socket Each
1700 2 1.0 0 1.0 1 Wiring assembly Each
2100 3 31.2 0 31.2 3 3/8 Steel tubing Inches
2200 3 13.2 0 13.2 2 16-Gauge lamp cord Feet
2210 3 13.2 0 13.2 2 14-Gauge lamp cord Feet
2300 3 1.0 0 1.0 1 Standard plug terminal Each
A100 1 1.0 0 1.0 1 Socket assembly Each
B100 1 1.0 0 1.0 1 Base assembly Each
LA01 0 1.0 0 1.0 2 Lamp LA Each
S100 1 1.0 0 1.0 2 Black shade Each