Bill of Materials Revision Lines

Bill of materials revision lines are input/output lines of the bill of materials revision. The information regarding the finished products and semi finished products to be produced from the bill of materials lines, and the materials to be used to produce them are recorded by specifying the line type.

The main output line is applied to the material produced using the defined bill of materials. The first line of the bill of materials is automatically generated by the LOGO application. The line type and material code of this line cannot be changed. Other information such as quantity to be produced, Unit used and operations is also specified on the fields of the line.

Bills of materials of product classes can be applied either to all the materials within the class or only a part of them. In this case, the materials to be produced and their quantities are recorded using "Apply Distribution Template" or Material Table options depending on the material class type selected in the bill of materials line.

The information about the materials used as input or output in production is recorded on the bill of materials lines. The number of lines is unlimited. The first bill of materials line of product type is automatically generated by the LOGO application.
The fields and functions of the Bills of Materials are:

Line Type: Indicates the line type of the bill of materials. The line type options are:

• Product
• Input
• Pseudo Semi Product
• Co Product
• By-Product

Recorded information varies depending on the line type.
Type: Indicates the finished product type to be obtained from production in the output lines of Co Product and By Product type. This field contains two options:

• Material
• Material Class

The type of the co product or by product produced with the same bill of materials can be material, material class (general) or material class (with table). The details of material class (general) and material class (with table) type products are recorded using the Material Class Detail Lines and Material Table option of right mouse button menu.

Material Code / Material Description: The code and description of the input to be used in production or the product to be obtained.

Quantity Formula: This field is used to specify the input quantities to be used in production in the input lines of the BOM, and the product quantity to be produced in the output lines of the BOM. The quantity can be given as a fixed value, or entered using a formula. The formula is defined using defined parameters along with arithmetical and logical operators. In addition to existing system parameters, specific constants defined for the company can also be used for formula generation.

Formulas are also used in the detail lines of material class type output lines. The quantity calculated using the formula entered in the quantity formula field is recorded on the quantity field of the BOM line. Direct data entry or modification of the calculated quantity is not allowed in the quantity field. The value is recorded on the quantity formula field even if the quantity is a fixed value.

Quantity: The input/output quantity calculated using the formula entered in the Quantity Formula field is displayed on this field.

Unit: Indicates the Unit with which the inputs to be used in production and the outputs will be processed.

Material Code / Description Used in Formula: The code and description of the material to which the parameters such as product quantity, width and size used in the formula to determine the input and output line quantity.

Variant Formula: In case the processed material in line is configurable, this formula field is used to indicate the necessary material quantity to obtain output materials in input lines and to indicate material quantity to be produced in output lines.
In variant formula field, main product characteristics and input material characteristics are matched with each other.
There are two kinds of usage.

Input Material Code.Characteristic Code = Main Product Code.Characteristic Code
This kind of usage means that input characteristic value will be main product's characteristic value.
A second usage:

In this kind of usage, the condition is used together with variant option. This kind of usage means, when main product's characteristic value is X, the variant will be used that its input characteristic value is Y.

Variant Condition: In case the processed material in line is configurable, this field is used to specify the condition for the material that will be used in production or that will be produced. Using the formula/condition window fields the necessary conditions are defined for the material to be produced.

Operation Code / Operation Description: These fields are used to specify the operation to which the input and output lines of the BOM are related. The operations of the route selected in the BOM revision are listed by clicking on "..." icon, and the appropriate operation is selected.

Same input material can be selected in different lines, and be connected to separate operations. However, the same output material cannot be selected in different lines, and can be connected to one operation only.

Affects Operation Time: The workstations where each operation will be performed are determined by checking minimum quantity, maximum quantity and start date in the requirement lines while the related operation is defined. If "Affects Operation Time" box is checked for any of the materials used in the operation as input or output, the minimum quantity and maximum quantity checks are performed according to the quantity of the material. If more than one material is selected for the same operation (work order), the check is performed without processing Units depending on the quantity of all materials.

This field is checked if the material contained in the input and output fields affect the workstation and the operation batch quantity of the workstation. The operation time is calculated according to the selection made on this field. The quantity to be used as the production quantity in the time calculation formula is equal to the quantity of materials specified as "affects operation time" in the BOM.

If the user checks more than one material for the same operation, the quantities of all materials are included in the formula as the production quantity. The user can directly enter the operation time.

Scrap Rate: This field is used to record the scrap quantity of the material used in the input lines. The scrap rate is entered as percentage.

Scrap Calculate: This field is used to specify the scrap calculation method if scrap is specified for production. This field contains the following options:

• Net
• Gross (by Usage Quantity)
• Gross (by Total Quantity)

When Net is selected, the material quantity entered in the quantity field is assumed to be the actual quantity, and the scrap rate is added to this quantity. Usage quantity and scrap quantity are added, and then subtracted from inventory.
When Gross (by Usage Quantity) is selected, scrap quantity is calculated by applying the scrap rate to the usage quantity entered in the quantity field.

Example:

Quantity = 100
Assumed that Scrap Rate = 20

When Gross (by Usage Quantity) is selected, and usage quantity is assumed to be X, scrap quantity is 0,2X. Using X+0,2X=100 equation, X is calculated as 83,333333, and the scrap quantity as 16.66667.

When Gross (by Total Quantity) is selected, the scrap quantity is calculated using the quantity entered in the line. The scrap quantity is calculated as 100*0.2=20, and the usage quantity as 100-20=80.

Scalable: Used to determine the proportion between the output to be produced and the quantities of materials to be used in production.

This field is used to specify the quantity condition.

When Scalable is checked, the material quantity to be used in production is calculated by processing materials used for Unit output and the quantity to be produced.

If Scalable option is not checked, the quantity entered in the input material lines is used to produce the quantity of goods entered in the output lines.

Alternative Material Usage: Indicates whether or not an alternative will be used instead of the material displayed on the line. This field contains the following options:

• Do Not Use Alternative
• Use Only One Type of Material
• Use Only One Type of Alternative
• All

When "Do Not Use Alternative" is selected, alternative materials are not used even if the material is depleted during production.

When "Use Only One Type of Material" is selected, only one of the alternatives is used. If the quantity of material used as input is not sufficient, the alternative material to be used must meet the amount necessary for production in whole.

When "Use Only One Type of Alternative" is selected, only one of the alternatives is used. An appropriate alternative material is selected by priority, start date, end date, minimum quantity and maximum quantity from among the alternatives that meet the necessary quantity.

The quantity of alternative material to be used in production is calculated according to the factor or divisor relation specified in the Alternatives tab of the material.

When the alternative material quantity is checked in the LOGO application, the consignments received specified in the BOM input lines and the selections made in the material withdrawal from different warehouses parameters specified in the production order gain importance. 

When "All" is selected, the alternative materials are used to close the gap when the input material quantity is insufficient. The difference between this option and "Use Only One Type of Alternative" is that only the missing quantity is produced using the alternatives.

Using Consignment: This field is checked if the consignment material on hand is required to be used in production.

Conditioning Material Code / Description: When Material Class is selected as product or co product, this field is used to specify the output for which the material in the line will be used in production.

Bill of Materials Code / Bill of Materials Description: The code and description of the bill of materials used in production. Data can be entered into these fields when Semi Finished Product or Pseudo Semi Finished Product is selected as line type.

Revision Code / Revision Description: The code and description of the route used in production. Data can be entered into these fields when Semi Finished Product or Pseudo Semi Finished Product is selected as line type.

Engineering: This field is used to specify whether or not the BOM line will be affected by engineering changes. If the box is checked, line information can be changed through engineering changes. If the box is not checked, line information cannot be changed through engineering changes.

Production: This field is used to specify whether or not the BOM line will be affected by BOM Update transaction. If the box is checked, line information can be changed through the update transaction. If the box is not checked, line information cannot be changed through the update transaction.

Production Status: Only Output type line information can be entered into this field. The product specified in the line can be produced always or when required. There are two options:

• When Required
• Always

Costing: Indicates whether or not a material in the bill of materials or production order will affect the total cost amount during the planned/actual cost calculation transaction. This option can be used in Product, Co Product and By-Product line types.

Cost Rate: The field used to record the cost rate in Product, Co Product and By-Product bill of materials lines. The cost rate affecting the related output is entered into each line.

Standard Cost Usage: Indicates that the standard cost will be used for output cost calculation. When the box is checked, cost is not assigned using Planned / Actual Cost Calculation option; the standard costs of outputs are used.

When the production order cost is calculated, the cost factor of the outputs for which the Standard Cost Usage field is checked is not processed. In this case, first the standard costs of checked outputs are subtracted from the total production order cost, and then the costs are distributed to other outputs by cost factors.

Costs, calculated using Planned / Actual Cost Calculation option, are inserted into the Planned/Actual Input From Production slips.
Line Aux. Code: The aux. code and description of the BOM line. Used to classify bill of materials lines.

Attention: The input and output quantities of the bill of materials are calculated by the LOGO application by processing the specified formulas and constants. Data cannot be entered directly into the quantity field.

Formula usage is applied to all line types of the BOM. The quantity is also calculated according to the formula in the detail lines of the outputs of material class (with table) and material class (general) type.

Line Comment: The field used to enter explanatory information belonging to bill of material.

Overlapping Among Routes:

In production orders that related to each other, to be able to calculate well-planned durations, the data of overlapping among the routes are specified in bill of material lines. The feasibility of defining overlapping among routes, as well as it is defined among operations, will provide obtaining well-planned durations when MPS and MPR is used.

The overlapping data is recorded by the bill of material lines of semi finished good and finished good type materials. The fields concerning overlapping are:
Overlapping Type: Used to determine the overlapping type among the routes. This field contains the following options:

• Production Orders
• Work Orders

The overlapping is considered basis on Production Order or Work Order according to the selection here.

Overlapping Method: In related production orders, it indicates how the overlapping among the routes will be considered. It contains the following options:

• After Started
• Before Finished

When After Started is selected, the overlapping value indicates how much time it will take to start main production after the input's production has been started.

When Before Finished is selected, the overlapping value indicates when the main product production will start, before the input material's production has been finished.

Overlapping Type: Used to determine the overlapping type among the routes. It contains the following options:

• Duration
• Quantity
• Rate

Overlapping Value: According to the selection in overlapping type field (Duration, Quantity or Rate), this field is used to determine the overlapping value. When overlapping type is determined as "Duration", its unit is determined by "Overlapping Unit" field. When it is "Quantity", line unit is the overlapping unit. When overlapping type is determined as "Rate", this field's value should not be over 100.

Overlapping Unit: When overlapping type is selected as "duration", its unit is determined by Overlapping Unit field. Contains, Day, Hour, Minute and Second values.

Example:

According to the values above, after 3 hours of YM.001 production beginning, MM.001 production is started.

It means that MM.001 production starts 3 hours before YM.001 production has been finished.

When 10% of YM.001 production is completed MM.001 production is started.

When 90% of YM.001 production is completed MM.001 production is started.

Material Procurement
When material procurement is done through production order, if there is an available input material of semi finished good type in related production order, material procurement proposals are calculated according to the overlapping info of the bill of material of the finished good.

Semi finished good's production start date is determined according to the recorded production order.
Overlapping data is only considered when material procurement is started through only a single production order. In "Batch Material Procurement" operation, these overlapping values are omitted.

Example:

In the event of YM.001 operation party is 1 and operation duration is 1 hour and if MM.001 production has been started at 15:00, production start hour of YM.001 is 12:00.
12:00 15:00

Warehouses

In bill of materials lines input and output warehouses can be specified separately. So, it is possible to deliver raw materials to be used in production from more than one warehouse. The input warehouse to be used for material delivery and output warehouse is specified in Workstation definitions. The warehouses specified in workstation record are transferred to production order lines automatically as default and can be changed by uses if it is necessary.

In production orders, instead of warehouses selected in workstation, the warehouses selected in BOM lines are considered. The warehouses specified in BOM are used in all material delivery transactions.