Detailed Design Package

Module 2A Bill of Materials and Bill of Process

Motivation
Why is this module important?

 Even the simplest products are typically complex in structure

 If bill of materials (BOM), bill of process (BOP), and engineering
drawings are not crystal clear to the innovator and the
manufacturer, it can result wasted money and/or products that
are improperly constructed
 It’s crucial to know the answers to:
—What and how many components form the product?
—What are the steps/sequence for fabricating the product?
—How can the product continue to be produced effectively as its
complexity increases?

2
Module Outline

 Learning objectives
 Product hierarchy, bill of materials (BOM)
 Process planning, routing sheet, bill of process (BOP)
 Engineering drawing:
—Component level
—Assembly level
—Interpreting engineering drawings

 Case studies

3
Learning Objectives

 LO1: Identify product hierarchy and assembly plan

 LO2: Develop appropriate process plan for components
 LO3: Assess engineering drawings for components

4
What This Module Addresses

 The relationship between BOM, BOP, and engineering drawings

 Basic terminology of BOM, BOP, and engineering drawings
 Some existing online tools to assist in creating a BOM and a BOP
 How to manage BOM generation for complex products

5
BOP, BOM, And Drawings
How they all relate

Engineering and
Assembly
Drawing

Bill of Process Bill of Materials

(BOP) (BOM)

These 3 blocks must be considered

simultaneously!
6
BOP, BOM, And Drawings
How they all relate

Engineering and
Assembly
Drawing

Bill of Process Bill of Materials

(BOP) (BOM)

Engineering and assembly drawing provides:

 Visual representation of product and components
 Fit, tolerances, and assembly specifications
7
BOP, BOM, And Drawings
How they all relate

Engineering and
Assembly
Drawing

Bill of Process Bill of Materials

(BOP) (BOM)

Bill of process (BOP) addresses:

 Processes that produce the product and their sequence
 Specifications and parameters of each process step
8
BOP, BOM, And Drawings
How they all relate

Engineering and
Assembly
Drawing

Bill of Process Bill of Materials

(BOP) (BOM)

Bill of materials (BOM) addresses:

 Components forming the product
 Production time per component
9
Bill Of Materials
Basics

 Bill of materials (BOM): Lists quantities of components,

ingredients, and materials required to make a product
 Integrates product hierarchy through parent/child delineation
Levels of a product:
 Parent: End item (or final product)
 Children: Raw materials, components, and sub-assemblies
Demand may depend on product levels:
 Parent: Independent demand (external to the system)
 Children: Dependent demand (internal to the system)—Demand
for an item depends on the demand for items ”higher up” on the
the BOM
10
Bill Of Materials
Example - Product hierarchy
Laptop Parent
(end item)

Processor Keyboard Monitor

Quantity: 1 Quantity: 1 Quantity: 1
Lead Time: 3 weeks Lead Time: 2 weeks Lead Time: 2 weeks
Children

Casing Keys
Quantity: 1 Quantity: 104
Lead Time: 2 days Lead Time: 1 week

Raw Materials
The BOM provides information about:
 Relationship between items at different levels
 Quantity of each item
 Lead Time of each item 11
Bill Of Materials
BOM generation components

Low-level coding (LLC):

 A number that identifies the lowest level at which a specific item
exists in the BOM
 Allows for easily computing the requirements of an item existing
at different levels of the BOM
BOM processor:
 Essential component in most commercial packages; maintains
the BOM and automatically assigns LLCs
 Is essential for products with large BOMs (e.g., automobiles with
approximately 30,000 components)

12
 Bill Of Materials
Example – Lower level coding
A Level

Parent
0

B C
Level
Quantity: 1 Quantity: 1 1
Lead Time: 1 week Lead Time: 2 days

F E D

Children
Level
Quantity: 1 Quantity: 1 Quantity: 1 2
Lead Time: 4 days Lead Time: 2 days Lead Time: 6 days

G H G Level
Quantity: 2 Quantity: 1 Quantity: 1 3
Lead Time: 5 days Lead Time: 5 days Lead Time: 5 days

 Item G can be coded as Level 2 (under B) or Level 3 (under E)

 LLC convention has it coded as Level 3 13
Bill Of Materials Tools

Online BOM tools:

 Build and generate BOMs in a standard user-friendly
environment
 Scan the BOM for duplicates or redundant parts
 Generate BOM graphical representations
 Enable collaboration across an organization
Examples: Dragon Standard BOM is a free chrome extension for
creating BOMs. Commercial solutions include Arena Solutions’
Product Lifecycle Management (PLM), Mouser Electronics’ Forte,
and IQMS Enterprise Resource Planning (ERP) software.

14
Bill Of Materials
Example – BOM software

15
Process Planning
Basics

 Process planning is typically documented on a routing sheet,

also known as a bill of process (BOP)
Process planning organizes these production-related elements:
 Methods of production
 Tooling
 Fixtures
 Machinery
 Sequence of operations
 Processing time of operations
 Assembly methods

16
Process Planning
Key considerations

Factors to be considered during process planning:

 Dimensions/size
 Surface finish
 Geometric shape
 Tolerance
 Material being processed
 Product value and urgency
 Manufacturing capabilities and resources available

17
 Process Planning
Example

Source: https://www.slideshare.net/GuhanM/process-planning-34794073
18
Engineering Drawings
Example - Component level

 Represent 3D objects in 2D by projecting the object’s shape onto

a plane

19
Engineering Drawings
Example – Internal features

 Represent internal features of components using sectional views

 This is important to distinguish between hollow components and
solid components
3D view of
a
component

Indicates where
the section was
taken

Corresponding
sectional view
(demonstrating
internal features)
20
Engineering Drawings
Dimensional tolerances

Dimensional tolerances:
 Defined as the allowable errors on a specific dimension
 Typically expressed as a range of values (i.e., the diameter of a
hole is expressed as “3.5 inches ± 0.02,” which means that the
hole is acceptable as long as its actual manufactured diameter is
between 3.48 and 3.52 inches in diameter)

21
 Engineering Drawings
Introduction to dimensional tolerances

 Representing dimensional tolerances on a component’s drawing

+0.2
40 -0.1 mm 40 0.1 mm

40.2
39.9 mm

More detailed examples here -

https://www.nmri.go.jp/eng/khirata/metalwork/basic/accuracy/index_e.html 22
Engineering Drawings
Geometric tolerances

Geometric tolerances:
 Defined as the allowable errors on shapes, locations, and profiles
(as opposed to size or dimensional tolerances)
 Specified on engineering drawings as a box with a leader
connected to the feature of interest

23
Engineering Drawings
Main types of geometric tolerances

24
 Engineering Drawings
Example - Geometric tolerances

 This feature control

frame is read as: "The
specified feature must
lie perpendicular
within a tolerance
zone of 0.05 diameter
at the maximum
material condition,
with respect to datum
axis C
 In other words, this places a limit on the amount of variation in
perpendicularity between the feature axis and the datum axis.
In a drawing, this feature control frame would accompany
dimensional tolerances that control the feature size and
position 25
Source: https://www.joshuanava.biz/engineering-4/geometric-tolerancing.html
 Engineering Drawings
Example – Flatness geometric tolerance

Engineering drawing indicating

desired flatness outcome

Tolerance
Parallel Zone
planes

Translates
into <0.001

Manufactured product within

specifications of the engineering drawing

26
Engineering Drawings
How to interpret them

Information on an engineering drawing or “blueprint”:

 Title
 Version
 Material
 Projection type
 Units
 Scale
 Other (i.e., assembly instructions, intellectual property,
tolerances)

27
Engineering Drawings
Example - Interpreting the blueprint

28
Engineering Drawings
Example – Assemblies

 Assembly drawings are engineering drawing representations of

the BOM

Enlarged on next slide

29
Engineering Drawings
Example – Assemblies (cont.)

30
BOP Assembly Map
Example 1 - Initial waste pipe bracket

X2

Lower Screw flip

Clamp

X2 X2 X2 X2 X2

scale Scribe Measure Mark Measure Mark Pipe Pipe Clamp PreAsm cdi Upper Angle Washer Nut Driver cdi Wrench
Loc Loc Clamp Clamp

X2 X2 X2 X2 X2 X2 X2

tighten Scribe Mark Driver Loosen Rem Rem cdi Rem Rem Rem Rem Unclamp Rem Drill Drill Cleco Cleco
tool Loc Screws Clamp Nuts Wshrs Angle Upr Pipe Pipe Motor Pilot Pliers
Clamp
X2 X2 X2 X2 X2 X2 X2

Insert Pipe Clamp Cleco Insert Harness Clamp Clamp clamp Drill Drill Drill Drill Cleco Cleco New Remove Drill
Cleco Angle Cleco Cleco Angle Cleco Motor Pilot Motor Full Pliers Clecos Clecos Motor

X2 X2 X 16 X8 X8 X8

Drill Cleco unclamp Rem Rem Debur Debur Solvent Rag Wipe Get Inspect Alodine Prime
Full Plier Harness Pipe Tool Inspector Holes
Ang Ang
31
BOP Assembly Map
Example 2

32
BOP Assembly Map
Example 3 – Car Assembly Line

33
Engineering Drawing
Example

34
Bill Of Materials
Example – BOM on an engineering drawing

35
BOP, BOM, And Drawings
Example

1. Bearing Mounting
Pad

2. Motor Mounting
Pad
8. Motor Mounting
Pad
3. Main Frame

4. Angle Mounting
Base Plate Assembly
Brackets

These items correspond to

5. Cross Supports
the line number in the BOM
on previous slide 36
 BOM/BOP
Case study 1 – LED light bulb

Background:
 Hyperion is developing a LED bulb that will replace the
conventional high-intensity discharge (HID), metal halide, and
high-pressure sodium bulbs used in ornamental sidewalk lamps.
The bulb referred to here as the B1 has developed through two
major iterations, the B1-a and the B1-b, with numerous
development iterations between the versions

Note: Throughout the Build4Scale modules, we’ll include product

case studies that illustrate what one company experienced as they
were developing their products. We have changed the company
name and anonymized their product, but we hope that their
experience will help you avoid the pitfalls they encountered and
shed light on the lessons they learned along the way.
37
Bill Of Materials
Case study 1 – LED light bulb (cont.)

 Using the BOM, Hyperion was able to identify which

components would provide the most overall value for product
cost reduction and design optimization.
 Instead of looking at every single component in the BOM,
Hyperion was able to focus its attention on a few components
that would greatly affect cost and time
 In this case, the BOM was used to identify component hierarchy
based on the function, materials, and cost of production
 Hyperion was able to clearly identify the fan assembly as a prime
target for cost reduction with a percentage of total cost at scale
of 43.2%

38
Bill Of Materials
Case study 1 – LED light bulb (cont.)

Fan Assembly

39
Bill Of Process
Case study 1 – LED light bulb (cont.)

 By coding their production into a running list of processes

(or BOP) and tracking iterations using version control, the
company documented changes in their prototype
production processes to later be carried into a
manufacturing iteration
 The BOP and the BOM are the foundation upon which
further product development can be built from prototype
to manufacturing. They will be a continuous trunk of
information running through all future iterations

40
Manufacturing Process
Case study 1 – LED light bulb (cont.)

 As the team began production of the lamp end cap, the

quantity of production began to dictate the manufacturing
process
 The decision came down to the manufacturing process that
had the lowest cost
 Initial prototyping was completed at the Los Angeles
Advanced Cleantech Incubator (LACI) Prototyping Center to
allow for rapid iteration development

41
Manufacturing Process
Case study 1 – LED light bulb (cont.)

 As the demonstration sites were coming online, Hyperion

moved production to a silicon mold cast contractor to
handle the increased quantities
Number of Parts Manufacturing Production
Needed Process Site
Prototyping
1-100 3D Printing
Center
Silicon Mold
50-500 Contractor
Casting

2,000-10,000 Injection Molding Contractor

42
Scale-Up Effects On BOM/BOP
Tradeoffs

So many tradeoffs—how do you evaluate?

Material tradeoffs:
 Different materials require different tools and production
processes, each with their own trade-offs
 Reduced cost of materials may mean higher per-piece price with
volume if the new material requires a more expensive
production process
 More robust materials may require larger investment in tooling
and capital equipment
 Lighter weight does not necessarily mean less material

See Module 3B for more details on material selection

43
Scale-Up Effects On BOM/BOP
Tradeoffs (cont.)

Manufacturing process tradeoffs:

 Lower volumes require different manufacturing process to
control tooling and capital equipment investments
 Switch to high volume with less takt time process may require
major investment in capital equipment but lower per-piece price
over time

See Module 3C for more details on manufacturing processes

44
Material Selection
Case study 2 - Outdoor LED retrofit bulb

2. Summarize and prioritize the

functional needs based on the
operating environment (ideally
quantify needs):
— a. Structurally strong
Fan Center
— b. Operate at high heat
Body Support (500 – 700 °C)
— c. Cost effective
1. Determine the 3. Explore your material options
operating environment: based on availability, general
Industrial/power plants—the cost, weight, manufacturability,
lamp would experience high etc. Determine options to be:
temperatures and vibration — Polycarbonate
— Stainless Steel
45
 Material Selection
Case study 2 - Outdoor LED retrofit bulb (cont.)

4. With material selection 5. Final decision: Because of the

narrowed down evaluate each unique operating conditions, we
based on three criteria in step 2 preferred stainless steel

Key determining factors are circled below:

Material Operating T (°C) Strength Weight Cost
Polycarbonate 100 Lower Lighter Lower
Stainless steel 800 Higher Heavier Higher

 Stainless steel - Not as  Polycarbonate - Attractive

attractive because of higher because it's lower in weight
cost and weight but still and cost but these are
preferred due to strength and secondary factors
operation in heat 46
Scale-Up Effects On BOM/BOP

Material Low Volume Medium Volume High Volume

Lowest per-piece cost,
Higher per-piece cost, Lower per-piece cost,
Higher capital equipment,
Low-cost tooling Higher tooling cost
tooling cost
Machine from Billet, Soft Tooling Hard Tooling
Metal Additive Mfg (Casting) (Stamping Die, Extrusion)
Machine from Billet, Rotational Molding, Blow Injection Molding,
Plastic Additive Mfg Molding, Thermoforming Extrusion, Pultrusion
Injection Molding,
Hand Layup, RTM, VARTM,
Composite Additive Mfg Compression Molding
Pultrusion, Filament
Winding

 The use of materials and manufacturing process is not only

dictated by volume but also by tolerance requirements and
design priorities
Note: Definition of processes found on the next page

See Module 3B and 3C for more details 47

Scale-Up Effects On BOM/BOP
Description of Molding Methods

 Resin transfer molding (RTM) is an increasingly common form of molding,

using liquid composite https://www.azom.com/article.aspx?ArticleID=8620
 Vacuum Assisted Resin Transfer Molding (VARTM) or Vacuum
Injected Molding (VIM) is a closed mold, out of autoclave (OOA) composite
manufacturing process
https://en.wikipedia.org/wiki/Vacuum_assisted_resin_transfer_molding
 Pultrusion is a continuous process for manufacture of composite
materials with constant cross-section https://en.wikipedia.org/wiki/Pultrusion
 Hand lay-up is a molding process where fiber reinforcements are placed
by hand then wet with resin http://www.coremt.com/processes/hand-lay-up/
 Compression molding is a forming process in which a plastic material is placed
directly into a heated metal mold, then is softened by the heat, and forced to
conform to the shape of the mold as the mold closes once molding is
completed excess flash are removed, in-order to get best finish
https://en.wikipedia.org/wiki/Compression_molding

48
Scale-Up Effects On BOM/BOP
Key considerations

Controlling variability in BOM and BOP:

 Adds to cost, complexity
 Impacts quality control, inventory readiness, parts tracking,
supplier contracts
Parts planning:
 Consider a parts tracking system (for inventory ordering/control
and quality traceability)
 Highly recommend a plan for each part!
Process documentation:
 Work flow process mapping (value stream mapping)
 ISO process documentation
49
Scale-Up Effects On BOM/BOP
Summary

50
Resources

 General molding resource guide

http://www.plasticmoulding.ca/techniques/compression_moulding.htm

51
List Of Terms
In glossary

 BOM – Bill of Materials is a list of the raw materials, sub-assemblies, intermediate assemblies, sub-components, parts
and the quantities of each needed to manufacture an end product.
 BOP – Bill of Process is a best practices template for production comprised of detailed plans explaining the
manufacturing processes for a particular product. Within these plans resides in-depth information on machinery, plant
resources, equipment layout, configurations, tools, and instructions.
 Engineering Drawings are a type of technical drawing is used to fully and clearly define requirements for engineered
items.
 Assembly Drawings show how different parts go together, identify those parts by number, and have a parts list,
 Routing Sheet in a manufacturing or production unit defines the exact process by which a product is to be
manufactured or a service is to be delivered.
 Product Hierarchy is the decomposition of a product showing the relationship between parts. This is used in
conjunction with the BOM which additionally shows all critical product information including lists the raw materials,
assemblies, components, parts and the quantities of each needed to manufacture a product.
 LLC - Low-Level Coding refers to the lowest level code of the item used in BOM. The low level code is registered to
each item, and is used to perform a level-by-level explosion.
 BOM Processor is data management system that organizes the specifications of product assemblies and structures
used in manufacturing and related industries. Essential component in most commercial software packages; maintains
the BOM and automatically assigns Lowest-Level Coding (LLCs) — The BOM processor is essential for products with
large BOMs (e.g., automobiles include approximately 30,000 components)
 Process Planning is a plan of how your parts will be produced, what machines to use and in what order, to achieve the
correct tolerances etc. It involves strategic decisions and careful analysis with production engineers and expertise in
order to plan and adapt the production of every single component.

52
List Of Terms
In glossary (cont.)

 Orthographic Projection is a means of representing three-dimensional objects in two dimensions.

 Dimensional Tolerances is the permissible limit or limits of variation in: a physical dimension; a measured value
or physical property of a material, manufactured object, system, or service; other measured values (such as
temperature, humidity, etc.); in engineering and safety, a physical distance or space (tolerance); in mechanical
engineering the space (such as between a bolt and a nut or a hole, etc.)
 Component Level Design involves the selection, maintenance, design and construction of smaller parts for a larger
machine/assembly. This includes selecting, qualifying, approving, documentation, and managing the purchasing of
components and direct material required to produce an end product.
 Component engineering also involves product lifecycle management plan when a component is going to be obsolete or
to analyze the form–fit–functionality changes in the component.
 Geometric Tolerances (GD&T) is a system for defining and communicating engineering tolerances. It uses a symbolic
language on engineering drawings and computer-generated three-dimensional solid models that explicitly describes
nominal geometry and its allowable variation.
 Material Properties is an intensive, often quantitative, property of some material
 Mechanical Properties is the response of the material to force and load.
 Physical Properties is any property that is measurable, whose value describes a state of a physical system. Physical
properties are often referred to as observables.
 Thermal Properties is the reaction of the material in the presence of heat or cold.
 Electrical Properties is the ability of a material to transmit, store, or impede electricity.
 Optical Properties is the ability of the material to transmit, reflect, or absorb light.
 Environmental Properties are the ability of the material to maintain performance in its application environment.

53
List Of Terms
In glossary (cont.)

 Hardness is the resistance of a material to indentation.

 Young's Modulus also known as the elastic modulus, is a measure of the stiffness of a solid material.
 Stainless Steel is a steel alloy with a minimum of 10.5% chromium content by mass. Stainless steel is notable for its
corrosion resistance, and it is widely used for food handling and cutlery among many other applications.
 Polycarbonates are a group of thermoplastic polymers containing carbonate groups in their chemical structures.
Polycarbonates used in engineering are strong, tough materials, and some grades are optically transparent.
 Resin Transfer Moulding (RTM) is an increasingly common form of molding, using liquid composites.
 Vacuum Assisted Resin Transfer Molding (VARTM) is a closed mold, out of autoclave (OOA) composite manufacturing
process.
 Pultrusion is a continuous process for manufacture of composite materials with constant cross-section.
 Hand lay-Up is a molding process where fiber reinforcements are placed by hand then wet with resin.
 Compression Molding is a method of molding in which the molding material, generally preheated, is first placed in an
open, heated mould cavity.

54