Introduction
Engineering Bill of Materials (BOM) management is a critical but often overlooked part of the product development process. An engineering BOM details the parts, components, and assemblies required to manufacture a product. Keeping this BOM up-to-date across the entire product lifecycle can be challenging without the right tools. Integrated design software solutions can streamline engineering BOM creation and management. In this article, we’ll explore the benefits of an integrated approach and how to implement it effectively.
The Challenges of Engineering BOM Management
Traditionally, engineering BOMs have been managed manually in spreadsheets or documents. While simple in concept, this approach introduces major inefficiencies:
- Difficult manual updates - As the design evolves, engineers must manually update BOM information across multiple sources. This is time-consuming, error-prone, and leads to inconsistencies.
- Lack of traceability - With no linkage between the BOM and design files, it's impossible to track BOM changes to design iterations. Engineers can't validate the BOM against the current design.
- Siloed systems - Spreadsheet BOMs are disconnected from downstream manufacturing and purchasing systems. This causes delays for production planning and ramp-up.
- No change management - Without structured change control, there's no record of BOM changes, rationale, and approval over time. Unmanaged changes lead to mistakes and rework.
Clearly, traditional BOM methods are no longer sufficient for today's complex, fast-paced product development. Next generation tools are needed to streamline and automate BOM workflows.
Integrated BOM Software Solutions
Integrated engineering design platforms now provide advanced BOM management capabilities. By connecting BOM data directly to 3D model data, they overcome traditional limitations. Key capabilities include:
Automated BOM Generation
Rather than manually creating BOMs, integrated tools generate them directly from the 3D model. The engineering BOM updates in real-time as the design changes. This automation eliminates manual work and ensures the BOM always reflects the current design.
Bidirectional CAD Integration
Bidirectional synchronization maintains associations between BOM lines and specific 3D components. Updates flow in both directions. When an engineer alters the CAD model, the connected BOM updates automatically. Changes to the BOM also propagate back to the source model. This closed-loop process reduces errors and rework caused by manual BOM management.
Robust BOM Configuration
Sophisticated configuration tools allow engineers to readily tailor the BOM's structure, columns, sorting, grouping, filters, and output formats. This flexibility caters to the needs of design, manufacturing, purchasing, and other stakeholders. Role-based views provide each group with a customized BOM perspective.
End-to-End Change Management
Full change management capability traces all BOM changes, including date, user, rationale, and approval status. This audit trail meets compliance requirements and provides process control. Automated change notifications alert impacted users across departments.
Seamless Integration with Downstream Systems
APIs, batch imports, and other tools integrate the engineering BOM with downstream manufacturing, ERP, MRP, and supply chain systems. This connectivity closes gaps that hinder production planning, procurement, and new product introduction.
Best Practices for Implementation
To maximize benefits, organizations should follow best practices when deploying integrated engineering software and connecting it with their BOM process:
Choose Solutions that Support Standards
To ease integration with suppliers and other enterprise systems, select tools that comply with standards like ISO 10303 STEP and IPC-2581. This enables cleaner data exchange and avoids using proprietary CAD formats.
Define a Consistent BOM Structure
BOM configurations should be consistent across programs to reduce training needs and support easier reporting. Gather input from all departments to build consensus for BOM columns, sorting, grouping, templates, etc.
Implement Robust Change Management
Utilize the software's built-in change management capabilities. Document all changes, capture approval with electronic workflow, and implement notifications/alerts to improve visibility.
Integrate with ERP, MRP, and Supply Chain Systems
Leverage APIs and batch export/import to connect the engineering BOM with downstream systems. Schedule frequent automated data exchanges to keep systems in sync.
Provide Access to All Stakeholders
Extend secure BOM viewing and/or editing access to all departments involved in product design, sourcing, planning, production, and delivery. Desktop and mobile apps make access easy.
Train an Administrator
Appoint a trained administrator responsible for configuring BOM templates, workflows, user roles, integrations, and other global settings. They'll serve as the first point of support for users.
Conduct User Training
Train all users on BOM access, navigation, configurations, change order workflow, integrations, and release processes. Documentation and videos can support onboarding.
Linking the Engineering BOM to CAD
One of the most powerful advantages of integrated software is bidirectional linkage between the engineering BOM and CAD data. This connectivity provides immense efficiency gains compared to manual BOM creation. Here are some of the key benefits:
- Automatic BOM updates - When engineers modify the 3D model, associated BOM data updates automatically to reflect the change. No manual manipulation needed.
- Validity checking - Engineers can instantly cross-check the BOM against CAD models to validate accuracy. Missing or incorrect BOM items are flagged.
- Design reuse - Leveraging existing CAD models to seed new designs updates linked BOM data automatically for quick reuse.
- Change Impact Analysis - When proposed CAD changes affect the BOM, it's simple to assess downstream impact on materials, tooling, processes, cost, schedules, etc.
- Efficient collaboration - With linked data, design and manufacturing teams maintain a "single source of truth" to prevent misalignment.
- Traceability - Bidirectional linkage provides full traceability from BOM to CAD entities and vice versa throughout the development lifecycle.
Unifying CAD and BOM with a Master Model
Rather than external file-based CAD references, leading systems incorporate a Master Model concept. This unified data model integrates both design geometry and BOM data, including parts lists, materials, specs, etc. Key benefits include:
- Single integrated model combining both CAD and BOM data avoids maintaining separate references. This converged master model powers many downstream use cases.
- Persistent associations between BOM items and CAD geometry are inherent in the master model rather than external mappings. These robust links persist regardless of model changes.
- Seamless user experience for both CAD and BOM functions. Moving between tools feels like a unified environment rather than switching contexts.
- Multi-CAD support allows consolidating design data from various CAD formats into the unified master model. This facilitates collaboration across disciplines while maintaining links.
- Cleaner data exchange via master model-based formats. No loss of intelligent BOM-to-CAD linkage when sharing design data with suppliers compared to using basic CAD file exchange.
Automating the Linking Process
Manually creating and maintaining associations between CAD geometry and BOM items is inefficient and error-prone. Automated linking streamlines the process:
- CAD feature recognition automatically identifies CAD model features like bolts, fasteners, machined parts, stock raw material, and standard components.
- Intelligent mapping links recognized CAD features to corresponding BOM items based on properties like part number, material, size, etc. Advanced algorithms also learn designers' preferences.
- User overrides allow engineers to review automated mappings and modify them as needed. Bulk editing tools make quick work of updates.
- Incremental updates maintain existing links while adapting to design changes. Only affected associations get remapped based on change recognition.
Automated BOM-to-CAD linking removes duplication, enables validation, and allows engineers to focus on design rather than administrative data tasks.
Facilitating Collaboration Across Disciplines
For complex products, engineers across disciplines like electrical, mechanical, software must collaborate on integrated designs. Facilitating this presents challenges including:
- Mismatched CAD tools used in different disciplines make data exchange difficult
- Context gets lost when exporting/importing CAD data between tools
- No common BOM across disciplines leads to gaps and misalignment
- Hard to visualize interactions between electrical, mechanical, and software components
- Difficult to assess multi-discipline change impacts
By consolidating multi-CAD design data and integrating cross-discipline BOMs, integrated software addresses these challenges:
Unified Design Environment
All engineers access a shared design environment removing exchange barriers between CAD tools. Multi-CAD data consolidates into a unified "master model" retaining native representations.users don't have to change tools.
Shared BOM
A common engineering BOM spans mechanical, electrical, and other disciplines for complete visibility. Automated links between master model CAD data and BOM enables validity checks.
Visualization and Clash Detection
Engineers easily visualize the integrated design in 3D to spot interferences between components. Automated clash detection tools flag issues early when easier to address.
Change Management
Collaboration features like comments and task assignments facilitate cross-discipline change processes. Dashboards and reports provide insight into change impacts across electrical, mechanical, software, etc.
Seamless External Sharing
The master model integrates externally with partners and suppliers, retaining intelligent BOM-CAD linkages. This facilitates collaboration while protecting IP.
With an integrated approach, engineers gain efficiency, prevent redundancies, and reduce mistakes that result from fragmented tools and data.
Optimizing BOM Configurations
Engineering BOMs must satisfy a variety of downstream consumers who need different perspectives on product design data. Manufacturing may want a BOM optimized for fabrication and assembly planning. Purchasing may want a BOM structured for procuring parts and materials from supply chain vendors.
By offering robust configuration options, integrated engineering software allows tailoring BOMs to meet the needs of specific user groups:
Custom Columns and Properties
Columns can be added or removed to include the data attributes most relevant for target users like cost, lead times, life cycle status, custom properties, etc.
Sorting and Grouping
BOM lines can be sorted and grouped/collapsed in different ways for each target user. Sort by part type for manufacturing or supplier for purchasing. Group components by assemblies and hide low-levels.
Filtering
Apply filters to show only BOM lines relevant to specific users, hiding unnecessary clutter. Filter by supplier, part type, lifecycle state, custom property like "electrical" vs "mechanical", etc.
Templates
Store column layouts, sorting, grouping, filtering and other "views" as templates to consistently apply or share with other users. Switch templates for tailored views.
Role-Based Access
Leverage role-based security to provide tailored BOM application experiences and data access for different user types via permissions and configurations.
Report Output
Generate production-ready BOM reports in PDF or Excel formats for downstream handoff tailored to the needs of manufacturing, purchasing, subcontractors, etc.
With robust configurability, integrated BOM solutions allow optimizing engineering data to streamline handoff to other departments and processes. Consistent templates ensure users always get the right view.
Linking the Engineering BOM to Downstream Systems
A key benefit of integrated engineering software is the ability to connect engineering BOMs upstream with manufacturing, ERP, MRP and supply chain systems downstream. This connectivity closes gaps that hinder production planning, procurement, and new product introduction. Here are some ways to achieve it:
Two-Way CAD Integrations
Bidirectional CAD integrations avoid disruptive manual handoffs from engineering to manufacturing. Native CAD data used for production remains linked with engineering master data.
Automated ERP/MRP Exchange
Schedule periodic automated BOM data imports/exports between engineering and ERP/MRP systems. This keeps both systems closely in sync as designs evolve.
Web Services, APIs and Batch Processing
Leverage integration methods like web services, REST APIs and batch import/export to connect the engineering environment with external systems.
Integrated Change Processes
Share engineering change orders with manufacturing and purchasing to assess downstream impacts. Automate manufacturing change orders back to engineering for closed-loop change management.
Role-Based Access
Provide manufacturing, purchasing and other users access to engineering BOM data via desktop or mobile apps. Secure role-based permissions prevent unauthorized changes.
Digital Thread Dashboard
Consolidate engineering, manufacturing, and purchasing data in a single view to monitor product lifecycle health from design through production.
With end-to-end connectivity, organizations reduce delays getting designs to production. Automated propagation of BOM changes dramatically accelerates new product introduction.
Gaining Control with Engineering Change Management
During development, engineering BOMs undergo constant change. Lacking process control, these changes create confusion, lead to errors, and impede production readiness. Robust change management capabilities are essential for managing fluid BOMs. Key features include:
Associative Change Requests
Changes requests associate with specific BOM objects like parts for contextual clarity. Details like affected designs solidify the scope.
Change Documentation
Require documentation for every change like rationale, implementation notes, impact assessment, and approval notes. Built-in templates streamline documentation.
Automated Notifications
Automated emails inform affected users and departments about pending changes. This minimizes surprise, facilitates review, and enables collaboration.
Digital Approval Workflow
Online approval workflows route changes through proper authority channels for faster sign-off. Electronic signatures ensure accountability.
Seamless Implementation
Accepted changes integrate seamlessly into the BOM upon approval. Automated backup of pre-change BOM state enables rollback if needed.
Comprehensive Audit Trail
Every BOM change includes date/time stamp, user, old and new values, discussion threads, and electronic approval signatures for complete traceability.
Dashboards and Reports
Interactive graphs highlight BOM change trends. Reports document approved changes and associated discussion threads for archival purposes.
Integrated ECM Systems
Optionally integrate with enterprise content management systems for deep archival capabilities, version control and advanced searching of all change artifacts.
Implementing robust change management from the start helps maintain order as complexity increases. The real-time change insight reduces downstream surprises that delay production readiness.
Accelerating New Product Introduction
For manufactured goods, the transition from design to production is rife with challenges. BOM errors, unmanaged changes, lack of alignment with suppliers, and other issues result in delays getting new products to market. Integrated software addresses these barriers:
- Validated BOMs - Automatic CAD-BOM linking enables continuous design-to-BOM validation to prevent errors that delay manufacturing release.
- Early Supplier Integration - Share BOM data with suppliers early for collaborative design and planning via secure access to engineering environment.
- Digital Thread Visibility - Consolidated analytics across engineering, manufacturing, purchasing provides visibility to accelerate new product introduction.
- Automated Production Release - Electronically sign-off on designs and auto-send release packages to manufacturing including BOMs, CAD data, and documentation.
- Managed Changes - Conduct engineering changes through requirements-to-production via structured change processes to minimize downstream disruption.
- Production Feedback Loop - Receive manufacturing change requests back into the engineering environment for assessment and action.
- Post-Release Audits - Compare BOM data pre- and post-release to validate accuracy, prevent escapes, and identify process improvements.
By connecting disparate downstream systems earlier in the lifecycle, organizations remove handoff gaps. This accelerated feedback loop gets high-quality products to market faster.
Conclusion
Engineering BOMs are a critical backbone of product development and manufacturing. Manual disconnected BOM processes cause significant problems with accuracy, timeliness, traceability and new product introduction.
Next generation integrated software provides automation, change control, collaboration, and connectivity to streamline engineering BOM workflows. Transitioning away from traditional fragmented and error-prone BOM methods towards an integrated platform approach can significantly improve engineering efficiency and product quality.
The key is unifying BOM data with mechanical, electrical and software design information in a single environment. This breaks down silos to give all stakeholders the contextual visibility required to make informed decisions. By implementing robust configuration, collaboration and change management capabilities, engineering teams reduce mistakes and speed manufacturing readiness.
Frequently Asked Questions
What are some key capabilities to look for in integrated engineering software?
Some core capabilities that enable more automated, connected BOM workflows include:
- Bidirectional CAD integrations to link BOM with design models
- Automated BOM generation from CAD models
- Robust configuration tools for tailored BOM views
- Change management with approvals, notifications, and audit trail
- APIs and batch integrations with downstream manufacturing systems
- Consolidated environment for multi-CAD and multi-discipline collaboration
How does integrating the engineering BOM help manufacturing?
Upstream integration of the engineering BOM provides manufacturing teams earlier visibility into emerging designs. This allows parallel planning vs. sequential handoff. Instant propagation of BOM changes also reduces delays and errors getting data to production systems.
What training is required to leverage integrated BOM tools effectively?
Users should undergo both general new software training as well as tailored instruction for specific roles like design, manufacturing planning, purchasing, etc. For administrators, additional training on configuration, integration setup, security policies, and change management workflows ensures optimal leverage.
How can we convince engineering teams to adopt new integrated tools after years of spreadsheet BOMs?
Highlight specific pain points engineers experience today like manual entry, validation difficulties, lack of change control, and collaboration barriers. Connect improvements directly to their day-to-day challenges. Phase in the rollout and gather feedback to drive adoption.
How can we ensure consistency of BOM configuration across programs?
Develop a set of standard templates codifying best practice configurations to reuse across programs. Store these centrally for easy distribution and updating. Implement administrator review processes for new configurations and changes.
