Manufacturing Bill of Materials for Configurable Products in Time-phased MRP-controlled Manufacturing Planning & Control -Systems
Mellanen, Atte (2016)
2016
Tuotantotalouden koulutusohjelma
Talouden ja rakentamisen tiedekunta - Faculty of Business and Built Environment
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Hyväksymispäivämäärä
2016-10-05
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201609204520
https://urn.fi/URN:NBN:fi:tty-201609204520
Tiivistelmä
The importance of product structures in production and production management has increased as the importance of product customization has increased. This research is focusing on manufacturing’s needs for BOM structures for complex and highly configurable products in time-phased MRP-controlled manufacturing environment by focusing on a case company in an elevator-escalator business. The problem with the product structures is that they are barely used in the production apart from the material requirements planning. The main reason for that is that the factories do not have separated manufacturing BOMs and the engineering structure does not support manufacturing well enough. In case a factory has separated manufacturing BOMs, they do not support the changing operative environment at the case company.
The target is to clarify what kind of BOM structure would support production and sourcing at the case company, and what requirements time-phased MRP-controlled manufacturing environment and complex and highly configurable products set for manufacturing bill of materials. The results are based on the interviews with 22 professionals from the production and the material management from ten case factories. Based on these interviews, product structure recommendations are created for the different case company’s system module categories as a starting point for the detail planning of product structures.
The research indicates that the needs for product structures in manufacturing vary a lot depending on the product complexity, manufacturing environment as well as the culture. Especially sourcing and production processes and the degree of customization affect the BOMs. In addition, IT-systems like MES have an influence on the BOMs. Despite from the different needs for BOMs, flat BOMs are seen insufficient, while multi-level BOMs are seen as an ideal option in production. Furthermore, fixed BOMs are seen problematic too. Configurable BOMs support production better when the product is complex. Fixed BOMs are working only if the product variety is small. The number of production orders per sales order item varies and is directly dependable on the manufacturing processes and the challenges in operations management caused by the product complexity. For that reason, the number of production orders per sales order items should always be factory based. The advantages and disadvantages of the global aspect as well as whether the structure should be the same in engineering and manufacturing vary depending on the point of view. In general, it can be said that the engineering structure should be global and the manufacturing structure should be local in case it is needed. However, the complexity of the product structures and its effect on operations must always be kept in mind when designing bill of materials.
The target is to clarify what kind of BOM structure would support production and sourcing at the case company, and what requirements time-phased MRP-controlled manufacturing environment and complex and highly configurable products set for manufacturing bill of materials. The results are based on the interviews with 22 professionals from the production and the material management from ten case factories. Based on these interviews, product structure recommendations are created for the different case company’s system module categories as a starting point for the detail planning of product structures.
The research indicates that the needs for product structures in manufacturing vary a lot depending on the product complexity, manufacturing environment as well as the culture. Especially sourcing and production processes and the degree of customization affect the BOMs. In addition, IT-systems like MES have an influence on the BOMs. Despite from the different needs for BOMs, flat BOMs are seen insufficient, while multi-level BOMs are seen as an ideal option in production. Furthermore, fixed BOMs are seen problematic too. Configurable BOMs support production better when the product is complex. Fixed BOMs are working only if the product variety is small. The number of production orders per sales order item varies and is directly dependable on the manufacturing processes and the challenges in operations management caused by the product complexity. For that reason, the number of production orders per sales order items should always be factory based. The advantages and disadvantages of the global aspect as well as whether the structure should be the same in engineering and manufacturing vary depending on the point of view. In general, it can be said that the engineering structure should be global and the manufacturing structure should be local in case it is needed. However, the complexity of the product structures and its effect on operations must always be kept in mind when designing bill of materials.