Research on Transformation Engineering BOM into Manufacturing BOM Based on BOP
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1 Appled Mechancs and Materals Vols (2008) pp Onlne avalable snce 2007/Dec/06 at wwwscentfcnet (2008) Trans Tech Publcatons, Swtzerland do:104028/wwwscentfcnet/amm Research on Transformaton Engneerng BOM nto Manufacturng BOM Based on BOP HC Xu 1,a, XF Xu 1,b and T He 1,c 1 Sch of Computer Sc & Tech, Harbn Inst of Tech, Harbn , Chna a xhc@hteducn, b xaofe@hteducn, c xuantnghe@hteducn Keywords: Engneerng BOM, Manufacturng BOM, Bll of process Abstract In the producton management as well as n the nformaton technology that supports t, automatcally transformng engneerng BOM(EBOM) nto manufacturng BOM(MBOM) s the key problem of ntegratng product desgn system wth producton plannng system A method of quckly, accurately and automatcally transformng EBOM nto MBOM based on the bll of process(bop) s developed The strct formal defntons of EBOM, MBOM, BOP and the transformaton rules of product structures, lead-tmes and process routnes are presented Based on those, an algorthm of automatcally transformng EBOM nto MBOM s proposed Fnally, a case from practce of ths transformaton method n an electrc machnery manufacturng enterprse ndcates ts effectveness and feasblty Introducton In the producton management as well as n the nformaton technology that supports t, e the MRPII/ERP and CAD/CAPP/PDM software packages, the bll of materal (BOM) s one of the crucal technque data In the whole product lfecycle, a product could have more than one BOM descrbng ts structure from dfferent pont of vew, n whch the engneerng BOM (EBOM) and the manufacturng BOM (MBOM) are the two most mportant ones [1] EBOM normally lsts tems accordng to ther relatonshps wth parent product as represented n assembly drawngs, but ths sn t suffcent to show the groupng of parts at each stage of the producton process nor nclude all of the data needed to support manufacture or procurement Thus, EBOM ust represents the product structure from the engneerng vewpont, not from the manufacturng vewpont, and t can t be drectly used n the manufacturng requrements plannng (MRP) system These requrements may force the arrangement of the product structure to be dfferent n order to assure manufacturablty and need transform EBOM to MBOM MBOM represents the assembly buld-up way a product s manufactured There s a close relatonshp between EBOM and MBOM In practce EBOM s usually produced by CAD system, and MBOM s generated wth human nterventon based on EBOM and complementng some manufacturng nformaton from the bll of process (BOP) But when products comprse a large amount of parts and product structures are complex, to transform between each other s a hard ob Thus a method to quckly, accurately and automatcally transformng EBOM to MBOM s very mportant n the MRPII/ERP system [2] Varous technques have been put forward to solve ths ssue Ou-yang[3] presented a methodology to support the ntegraton of nformaton flow between the applcatons of PDM and MRP A three-level structure ncludng model development, model analyss, system mplementaton and also an approach applyng the concepts of semantc smlarty to fnd the "common" obects used n dfferent busness applcatons were proposed Lu Xaobng[4] presented a method of BOM transformaton based on feature dentfcaton whch keeps the data among BOM vews ntegral, accurate and consstent By ntroducng Process Plannng BOM (PPBOM) and defnng the terms such as successve parts, vrtual parts, mddle parts and ther relevant mappng functons, a mappng model of BOM transformaton was set up and rules for BOM transformaton were stpulated accordng to the parts classfcaton Jang Hu[5] presented to generate MBOM based on process routne and gave a basc convertng process The above methods all emphasze on the product All rghts reserved No part of contents of ths paper may be reproduced or transmtted n any form or by any means wthout the wrtten permsson of TTP, wwwttpnet (ID: , Pennsylvana State Unversty, Unversty Park, Unted States of Amerca-04/06/14,12:50:53)
2 100 e-engneerng & Dgtal Enterprse Technology structures transformaton and neglect the changes of producton lead-tme and process To solve ths problem, ths paper presents a new method to transform EBOM to MBOM based on BOP automatcally Formal Defntons of EBOM, MBOM and BOP BOM s a herarchcal lst of materals (components, subassembles, ngredents) requred to produce a product, showng the quantty of each requred tem Other nformaton such as scrap factors may also be ncluded n the BOM for use n materals plannng and costng[6] Ths paper ust focuses on the product structure and also the lead-tme, assemblng processes data EBOM descrbes the component relatonshp wthn product parts Its formal descrpton s shown as below: Def1 EBOM=(P,R,Q,OR): (1) P s the set of parts, P= { p = 1, 2,, m} (2) R s the set of r( p, p ) ( r for short) r represents composng relatonshp between p and p, e p s a sub-component of p p s called p s father component and p s called p s chld component (3) Q s the set of q( r ) ( q for short) q represents the quantty wthn the relatonshp r, e, n r one father p s composed of chld (4) OR s the set of o ( r ) ( ( ) kl p wth the amount of q okl for short) okl ( ) s an assemblng operaton of p, that means n r, p s assembled on p at the operaton l of the process k of p MBOM descrbes the components relatonshp wthn product parts Its formal descrpton s shown as below: Def 2 MBOM = ( P ', R ', Q ', L) (1) P ' s the set of p ' ( = 1,2,, m ') p ' represents actual parts or phantom parts P ' = PU V, V s the set of phantom parts If p ' P, then then p ' s a phantom part (2) R ' s the set of r '( p ', p ' ) ( r ' for short) ' of p ' p ' s called father part of (3) Q ' s the set of q '( r ' ) ( q ' for short) ' wth the amount of q ' (4) L s the set of lt( p ' ) ( lt for short) beng prepared well or produced well to assemble out one p ' s a actual part, else f p ' V, r means p ' s one of the assemblng parts p ' and p ' s called drect chld part of p ' q means n r ' one p ' s assembled usng lt means the tme from all the drect chld parts of BOP s the combnaton of product process and operaton It descrbes process routnes of parts and fnal product In some large scales enterprses, product process routne s frst dvded nto processes, furthermore processes are dvded nto operatons Its formal descrpton s shown as below: Def3 BOP= ( P ', G, O, T ) (1) G s the set of g g represents process of p ' (2) O s the set of o k ok s the operaton k of process of p ' Usng symbol mn o( p ' ),max o( p ' ) denote the frst and the last operaton of all the operatons of p ' respectvely (3) T s the set of t( o k ) p ' ( t k for short) t k represents the producton tme of o k Formal defntons of EBOM, MBOM and BOP have been gven above Transformaton algorthm proposed below s based on these defntons p ' p '
3 Appled Mechancs and Materals Vols Transformaton Rules and Algorthm Transformaton Rules To transform EBOM to MBOM manly conssts of three aspects: product structure transformaton, BOP modfcaton and product lead-tme recount For the purpose of solvng these three problems, seven transformaton rules are gven below In the aspect of product structure transformaton, the method consders assemblng operatons data and addng phantom parts to EBOM to stretch the structure Fve transformaton rules of assemblng operatons amount countng, and whether addng phantom parts and product structure modfcaton are proposed below Rule1: rule1 s the assemblng operatons amount countng rule If p ' MBOM P ', then fndng k, l from EBOMOR,,let o ( ) EBOM OR The amount of the o ( ) s denoted kl as rc( p ' ), e, the assemblng operatons amount of p ' Completely reduplcate k, l are counted only once The frst and the last assemblng operatons are denoted as mn a( p ' ), max a( p ' ) respectvely Rule2: rule2 s the udgement rule whether parts n MBOM can be nherted from EBOM For p ' MBOM P ', f p ' fulfls one of the two condtons below then t can be nherted from EBOM drectly The two condtons are a) p ' BOP P ', e, p ' hasn t operatons It s a purchase part b) p ' BOP P ', but rc( p ' ) = 0 or rc( p ' ) = 1, e, p ' hasn t assemblng operatons or only has one Rule3: rule3 s the rule whether phantom parts can be nserted nto MBOM and how many should be nserted nto For p ' MBOM P ', f p ' BOP P ' and rc( p ' ) > 1, then phantom parts are requred to be nserted The method of amount countng s: f mn a( p ' ) = mn o( p ' ), then the amount s rc( p ' ) 1, else f mn a( p ' ) mn o( p ' ), then the amount s rc( p ' ) Rule4: rule4 s the rule how phantom parts are nserted and how to adust the relatonshps between phantom parts To p ' accordng wth rule3, f ts assemblng operaton okl ( ) hasn t been dealt wth rule4, then deal wth t as the four condtons below: (1) f o ( ) = mn a( p ' ) and mn a( p ' ) = mn o( p ' ), the operaton s not only the frst kl operaton, but also the frst assemblng operaton, then generate new phantom part kl p ' V to represent the assemblng result, nsert t to MBOM P ' (2) f o ( ) = mn a( p ' ) and mn a( p ' ) mn o( p ' ), the operaton s the frst assemblng kl operaton, but sn t the frst operaton, then generate new phantom part p ', p ' to represent the assemblng results of the operatons before and after ths operaton respectvely Let p ', p ' V, and nsert them nto MBOM P ' and nsert assemblng relatonshp k r ' k nto MBOM R ', meanng that n MBOM R ', p ' k acts as p ' s father part, p ' acts as p ' k s chld part At last, nsert amount q ' k = 1 nto MBOM Q ' (3) If o ( ) mn a( p ' ) and mn a( p ' ) mn o( p ' ) kl, the operaton sn t the frst assemblng operaton and also not the last one, then fndng the phantom part p ' representng the assemblng result of operatons before ths one and generatng new phantom part p ' k to represent assemblng result of ths operaton Let p ' k V and nsert t nto MBOM P ', at the same tme, nsert relatonshp r and amount q ' = 1 nto MBOM R ' and MBOM Q ' respectvely ' k k (4) If o ( ) = max a( p ), the operaton s the last assemblng operaton, then fndng phantom part kl p ' representng the result of operatons before Usng ' result Let p ', p ' V and delete p ' from P, e, to mark p to represent the last assemblng p ' as a phantom part Insert k p '
4 102 e-engneerng & Dgtal Enterprse Technology and p ' nto MBOM P ' and nsert relatonshp r ' and amount q ' = 1 nto MBOM R ' and MBOM Q ' respectvely Rule5: Rule5 s the relatonshps between exstng parts and newly nserted phantom parts To r ' MBOM R ', f p ' V, p ' P, father components are phantoms and chld components are actual parts, then deal them as follows: f k, l,, let o ( ) MBOM OR phantom part ' ' kl, then fnd the p generated accordng to Rule 4 and nsert relatonshp r ' nto MBOM R ', delete r ', nsert q ' ' = q ' nto MBOM Q ' In the modfcaton of BOP, there are rules as follows: Rule6: Rule6 s the rule of BOP modfcaton If p ' P and ' p ' fts to one of the two condtons descrbed n rule 2, then BOP of p ' needn t be modfed Else f p ' P and rc( p ' ) > 1, then modfy all the operatons o k of p ' as follows: (1) f o < max a( p ' ) that s the operaton before the last assemblng operaton, then accordng k to rule4 fnd the generated phantom part for the closest assemblng operaton after from BOP O and nsert o ' k nto BOP O Let t ' k o k, delete o k = tk, delete t k from BOP T and nsert t ' k nto BOP T (2) f ok max a( p ' ) that means o k s the operaton after the last assemblng operaton, then do nothng, these operatons stll belong to p ' The rule 7 s for lead-tme modfcaton Rule7: For p ' MBOM P ', ts lead-tme lt can be counted as below: ts process lead-tme t = tk that means t s the sum of all the operatons lead-tme of p ' s process The k absolute lead-tme of process lead-tme of p ' p, lt = t = tk ' that means k lt s the summaton of all the Transformaton Algorthm A transformaton algorthm s proposed below based on the transformaton rules mentoned above Input: EBOM, BOP Output: MBOM Steps: S1: For the ntaton, t looks on all the elements n EBOM as the ntal elements of MBOM, lettng MBOM = φ, EBOM P MBOM P ', EBOM R MBOM R ', EBOM Q MBOM Q ' S2: For p ' MBOM P ', accordng to rule1 to get the amount of all the parts, the frst and the last assemblng operaton Then accordng to rule2 and rule3 determnes whether t needs nsert phantom parts or not S3: For p ' MBOM P ' accordng to rule3, deal wth all of ts assemblng operatons wth rule4 to nsert phantom parts To modfy the structural and quantty relatonshps between phantom parts and orgnal parts by rule5 n MBOM S4: After the transformaton of product structure, modfy the processes and operatons n BOP accordng to rule6 S5: Recount the product lead-tmes n MBOM wth rule6 S6: over
5 Appled Mechancs and Materals Vols A Practcal Case of the Method In ths part, a case from practce of ths transformaton method n an electrcal machnery manufacturng enterprse s gven to ndcate ts effectveness and feasblty The example product s the bottom rng whch s the key part of an electrc machne The EBOM s shown n Fg1 that descrbes the relatonshp between product and parts The number n the frst bracket besde the part represents the quantty that ts one parent part needs t In the second bracket, the process number and the operaton number are gven n whch chld parts are assembled on parent part For nstance, the part ant-leak rng(2)(1,14) means one bottom wreath comprses two ant-leak wreath, and the two ant-leak wreath are assembled on bottom wreath at the fourteenth operaton of the frst process The MBOM transformed from the EBOM s shown n Fg2 The assemblng process nformaton s enhanced n the MBOM, and the product structure n MBOM accords wth the actual assemblng process Fg1 An example of transformng EBOM to MBOM of the product bottom rng Concluson To solve the problem of automatcally transformng EBOM to MBOM, a method of generatng MBOM based on EBOM and BOP s proposed whch can fulfll the requrements of rapd BOM transformaton n enterprse nformaton system ntegraton, and makes producton plans more effectve and actual In the HEC-CIMSII proect, the method s mplemented n the ntegraton of ERP and PDM system The practcal case ndcates ts effectveness and feasblty References [1] Thomas EVollmann, Wllam LBerry, D Clay Whybark: Manufacturng Plannng and Control Systems Fourth Edton (Tom Casson,1997) [2] Chen ufang: Mechansm manufacturng, Vol41 (2003) No462, pp14-16 [3] C Ou-yang, TA: The Internatonal Journal of Advanced Manufacturng Technology, Vol19 (2004) No2, pp [4] XB Lu, XW Huang, Y Ma and et al: Computer Integrated Manufacturng Systems, Vol8 (2002) No12, pp [5] H Jang: Manufacturng Automatzaton, Vol24 (2002) No7, pp3-6 [6] DC Zhen: Chna Mechansm Proect, Vol14 (2003) No2, pp
6 e-engneerng & Dgtal Enterprse Technology /wwwscentfcnet/AMM10-12 Research on Transformaton Engneerng BOM nto Manufacturng BOM Based on BOP /wwwscentfcnet/AMM
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