12.1.1

A Bill of Materials, BOM, can be described as a list of items required to produce a finished assembly or sub-assembly. For example, a bill of materials for a circuit board might consist of resistors, diodes, and the raw circuit board itself. The finished board could in turn be a sub-assembly for a finished product such as the radio BOM shown below.


A Bill of Materials could be called a recipe, formula, cut list, etc. pc/MRP can accept BOMs infinite levels deep. When entering a BOM you must enter the lowest levels first as pc/MRP is always checking if the part or sub-assy exists. In the above example, you would first enter the diode, resistor, and raw board into the part master as parts. Then you would enter the finished circuit board bill of materials listing all of the parts that go into a finished circuit board. You could then enter the radio bill of materials.

pc/MRP uses the BOM files to provide PIC Lists, Where-used Reports, Purchasing Consolidation Reports, Assembly Costs, and to correctly issue and track inventory.

BOMs are not limited to manufacturers, for example, restaurants can correctly track inventory by entering their recipes into pc/MRP's BOM file.

A single level printout of an example BOM is shown below:



An exploded printout includes sub BOM parts and their respective quantities. pc/MRP uses a technique called indenting to help illustrate how the sub assemblies fit together with other sub assemblies to create the final assembly. The same example BOM in an exploded print out is illustrated below:

12.1.2 New BOM (Create A New BOM) By selecting Modules, BOM, and New you can enter a Bill of Materials into the Bill of Materials Database File.

First, you will be asked to enter the new Bill of Materials Number and a BOM Description. Your description should begin with Assy, FG, or WIP to distinguish it as an assembly and not a part. You should choose your wording of the description carefully as good, logical descriptions can improve the usefulness of your alpha numeric part list printouts.

pc/MRP will check if that BOM number already exists in the partmaster and BOM data base files. If pc/MRP finds that number in the part master or BOM data base file it will display an "Already Exists" error message. If this message appears select another BOM number or edit the existing BOM if that is more applicable.

After selecting an acceptable BOM name and entering a BOM description the main BOM creation and editing screen will appear. From this screen you can begin the process of entering parts into your BOM. An example of this screen is provided below.



Take note that the cursor will start by default in the Part Number field. At this time enter the part number of the first part you wish to include in that Bill of Materials. After selecting the part you can select an alternate part by selecting Alternates. (Alternate parts can either be manually entered or automatically updated through using Option 54 in the Settings and Utilities) The part number entered may be for either a part or another BOM. Part or BOM data will automatically be imported from the Inventory DBF into the Part Data fields.

pc/MRP will check if the part or BOM number is a valid number in the part master data base file. If the part or BOM number does not exist in the Inventory DBF it will display a "Does Not Exist" error message. If the part does not exist you can choose to create the part from within the BOM creation and editing screen by selecting Create Part. If you desired to enter an assembly that does not exist you will have to exit this BOM, build the lower level assembly first, than add it to this BOM. All BOMs should be built from their lowest level up.

After entering the desired part or assembly enter the desired quantity of this part or assembly to be added to the BOM. This can be done by entering a number in the Quantity field.

Reference Designators for each part or assembly can also be entered. The Reference Designator field can have an infinite length and can be printed out on Uncosted Single Level Bills of Materials and PIC Lists. It is used by circuit board manufacturers to help assemblers know where to place components on the circuit boards is C1, C2, C3, etc. It can be used by regular manufacturers to list special instructions for assembly, such as, cut 13" long.

In addition to Reference Designators there is a section to enter Comments applicable to the entire BOM. These comments can be entered by selecting Comments. Each BOM can have it's own comments field. The comments field can contain up to 20 lines of routing or assembly instructions for that BOM.

Information about where the added part or assembly is used in addition to this BOM is also available from this screen by selecting BOM or PART under the Where Used heading. Pictures of this part or assembly are also available from this screen by selecting BOM Image or PART Image. For further information about using images see Chapter 4.1.1.

You can add additional parts to this BOM at this time by selecting Add Item. Once again the cursor will begin in the Partnumber field. Simply enter the desired part number, select an alternate if desired, and enter the desired quantity of this part for this level of the BOM. These steps can be repeated for as many parts or assemblies as desired. The Item number heading will automatically increment as additional parts or assemblies are added.

Once you are finished creating this level of the BOM select Finished. If you wish to cancel what you have created select Cancel. To delete a part added to the BOM select Delete. If you wish to edit the quantity of an added part you can sort the data by any of the headings; Item, Type, Part Number, Description, or quantity, and simply change the quantity in the Quantity field. By selecting Revert you can undo the last edit changes made. Revert must be the very next thing used if you wish to undo changes.

The BOM creation screen will accept but not record changes to the Part Data (Use the INVENTORY EDIT PROGRAM, the BOM EDIT BOM NUMBER, or BOM EDIT DESCRIPTION programs as changes for the Part Data are needed.)

To refresh the BOM representative of changes made select Re-load.

Notice that on the botton left of the Part Data section of the Bom Edit screen there is and Ave Cost field. If users click on this the field it will cycle through the average cost, standard cost, and last PO cost.

By selecting Modules and Edit/Delete a BOM Component you can view or edit an existing BOM.
This screen is similar to the new BOM screen. From the BOM edit screen you can edit: Parts, Quantities, Item Numbers, Reference Designators, and Comments. You can view the BOM or Part Image as well as Where Used data and Part Data. The edit screen will accept but not record changes to Part Data (Use the INVENTORY EDIT PROGRAM, the BOM EDIT BOM NUMBER, or BOM EDIT DESCRIPTION programs as changes for the Part Data are needed.)

Unlike the new BOM screen, in the BOM edit/view screen you can step through assembly levels by choosing Step Up or Step Down. As you step through the levels of this BOM you can continue to make changes to this BOM. As mentioned above you can sort the data by any of the BOM Component headings.

To add and additional part or assembly simply select Add Item. To delete a part from the BOM select the part that you wish to delete from the BOM COMPONENTS then select Delete. To create a part from within the BOM engine select Create Part. To change the quantity of an added part or assembly to the BOM simply select the part or assembly from the BOM COMPONENTS and change the number in the Quantity field.

Once you are finished making changes to this BOM select Finished. If you wish to cancel the changes you have made select Cancel. If you have marked one or more records for deletion you must select Modules, BOM, and Remove Marked BOM Records to delete the records from the DBF files.

Note: If the options to: Delete a part, Create Part, and Add Item do not appear you must select Edit under the Action heading when you select which BOM you wish to edit.

To refresh the BOM representative of changes made select Re-load.

Allows you to mark a BOM for deletion. You must remember to run Remove Marked BOM Records to delete the BOM from the DBF files.

Allows you to duplicate a BOM.

Allows you to change a bill of materials number without having to edit every record that contains that bill of material number. pc/MRP also changes the number in the partmaster file.

Allows you to change a bill of materials description without having to edit every record that contains that bill of material description. pc/MRP also changes the description in the partmaster file.

Allows you to print or display BOMs, PIC Lists and Where Used Reports.

See section 15.4.1 to create custom reports.

Selecting a Report Type

To select the report type that you want, place your cursor on the list arrow on the top drop down list box and click. You are then given the following list to chose from:


	Uncosted Single-Level BOM
	Costed Single-Level BOM
	Uncosted Exploded BOM
	Costed Exploded BOM
	All BOMs
	Where Used Reports
	Single-Level Pick List
	Exploded Pick List

The list will look like this:


Select the BOM Number


Next, you would enter in the BOM number that you want printed or displayed where the BOM Number box is.

Select the Number of Assemblies


At the Number of Assemblies box, either type in the number you want or use the spinner button to scroll up and down through the list.

Select Cost Type

Note: This option will only be available when you select a Costed BOM.


Three radio buttons allow you to select which type of costing method is preferable to you. The Average cost will average the total cost. The Standard cost will give you the standard cost. The Last PO cost will give you the cost of the last purchase order.

Select Sort By


Sorting by Part Number will use the part numbers to order the BOMs. Sorting by Root Number will use the root numbers to order the BOMs. Sorting by Item Number will use the item numbers to order the BOMs.

Select Send Report to:


At this option, you can chose to see a display of the report, print it out on either wide or narrow carriage, or send it to a file.

Select Report Type


The Standard report will print/display the way you selected it to be. If you have custom created your reports, then you can print/display them using the Custom report option.


Whenever you run an exploded costed BOM Report, pc/MRP will automatically recalculate the average or standard cost of that BOM and place the new figure in the Partmaster.

The Where Used Report will provide a printout for all parts or for a specified part number. The printout will provide a list of every assembly that uses that part number. It will also note parts that are not used in any assembly. The latter feature is designed to help reduce inventories and inventory write-offs.

PIC Lists are used by stock room personnel to print out the parts required for an assembly or sub-assembly.

An exploded PIC list includes all of parts including parts from sub-assemblies in one consolidated list.

The Reference Designator Fields print out on the wide carriage PIC List, wide carriage Uncosted BOM, and narrow carriage uncosted single level BOM reports.

This option will check your BOM data base file. As a safety precaution make a back up copy of the partmast.dbf and bom.dbf files before running this option. Select, "Compile a list of errors", when prompted. Once you have looked at the error list you can run the report again and select, "Step-through each BOM record with the option to remove it." This program will scan the bom.dbf file and look for the following errors:
• A bom number in the bom.dbf that does not exist in the partmast.dbf
• A part number in the bom.dbf that does not exist in the partmast.dbf
• A bom number in the bom.dbf that contains a part number that is the same as the bom number
• A part number that does not contain a P,A or L in the part_assy field in the partmast.dbf
• A bom number in the partmast.dbf file that does not exist in the bom.dbf file
• It automatically replaces the bom part-assy field with the contents of the partmast.dbf part_assy field.
• A sub bom number found in a bom that does not exist as a bom in the bom.dbf file.
• Once it has finished the above error checking, the program will ask, "Do you wish to check for recursive BOM structures". Answer "Yes", to check for boms that call them selves on levels more than one level deep.
• If you have selected the "Step through and delete option" and have deleted records, answer "Yes" when asked "If you wish to remove the records marked for deletion from disk".
• If any recursive errors were found you must delete the bom record calling the parent bom.

Reindexes the Bill of Materials Index File. pc/MRP automatically updates its index files under normal operation. However, if you ever get a "record out of range" error message or can not find a BOM record, reindexing the partmaster and BOM index files is usually the cure.

12.1.11 Remove Marked BOMs

Removes all bill of materials records marked for deletion from the disk. The records will no longer be recoverable.

If you plan to purchase a sub-assembly from a vendor and not build the subassembly in house, it would be called a phantom BOM. This can be accomplished in pc/MRP by editing the BOM in the Inventory Module and changing the PART/ASSY/LABR field from A to a P. The MRP module would then create action items to buy the sub-assembly from a vendor rather than buying the components and issuing a make for the sub-assembly. However, you would still be able to print this phantom BOM in the BOM module.