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Is your Bill of Materials really accurate?

 
The Bill of Materials (BoM) forms the foundation of the production process. Maintaining its accuracy in environments where production plans shift frequently, and procurement conditions fluctuate is challenging, to say the least. Many organizations have grown used to working with outdated practices and underestimating the risks that unreliable data can pose.

One of those practices is overwriting the previous BoM structure with a new one, making it impossible to trace the specific component that caused a defect in production. Another one is updating the BoM manually, increasing the risk of prototype parts being accidentally mixed into regular production. Situations like these are essentially ticking time bombs.

These problems do not come from lack of attention. They come from systems that were not built for the pace of modern manufacturing. Depending on constantly overwriting the same Bill of Materials is no longer enough. It is time to recognize the limits of past practices and move to a system capable of properly controlling and tracking information as it evolves.
 
 

Turning the Bill of Materials into a strategic asset

 
So how do you stop the problems that keep resurfacing and turn your Bill of Materials into something your organization can rely on? One viable solution is the next generation Bill of Materials provided by Beas Manufacturing, the manufacturing add-on for SAP Business One. (For reference, see the article on the Bill of Materials in SAP Business One here.)
Instead of just listing components, the system keeps track of how the product evolves over time, with built-in version control.

In the screenshot shown above is an example of a Bill of Materials in Beas Manufacturing. Within a single product, in this case, a shelf, multiple specifications can coexist, with Version 1 representing the red shelf and Version 2 representing the blue shelf. Since the product structure is visualized in a hierarchical format, even highly complex, multilevel products can be understood at a glance.
 
 

3 control mechanisms to prevent errors on the shop floor

 
How does BoM version control capability affect operations on the shop floor? We want to introduce 3 control mechanisms that can significantly improve your data accuracy and provide strong operational support.

1. Multi-version control: Multiple versions of a single product can be maintained in parallel. This reduces the need to search for historical data and enables an effective response to defect analysis and repeat orders, thereby improving overall quality assurance.
2. Validity period control: The system automatically switches to the appropriate version based on its defined effective dates. This removes the need for manual updates at changeover times and prevents input errors associated with manual processing, enabling a fully calendar-driven operation.
3. Status control: Usable versions for sales orders, purchase orders and other documents are restricted according to each version’s status. This prevents inconsistencies such as issuing orders for incomplete or invalid versions of products and establishes a shop floor environment in which errors are eliminated through systematic controls.

 
 

Reliable information drives quality manufacturing

 
When this kind of system becomes the standard across an organization, it can bring clarity and order to the shop floor. Departments no longer need to rush around trying to handle each change. Employees are freed from the frustration of searching for missing information or worrying about mistakes, reclaiming the time needed to pursue high quality manufacturing. Reliable information becomes a source of confidence, and smooth collaboration across departments takes shape naturally.

Beas Manufacturing delivers value that goes far beyond simply providing a software solution. It circulates vital information throughout the factory in real-time, enabling all departments to work with greater ease. Dependable data becomes the basis that supports the company’s ability to grow.
 
If you are interested in learning more about how Bill of Materials and its version management work in Beas Manufacturing, please feel free to contact us.