BOMs, routes and resources
The BOM tells the system what to consume, the route tells it how and where. Most production questions test one setting on one of them.
BOM lines
| Line type | Behavior |
|---|---|
| Item | Normal component consumed from inventory |
| Phantom | Not stocked. Exploded into its own components on the same order |
| Vendor | Subcontracted. A purchase order is created for the service |
| Pegged supply | A subproduction or purchase order is created for that demand |
Other BOM settings:
- Flushing principle: Manual (picking list), Start, or Finish. If the line is blank, the item’s default in the production setup is used.
- Calculation: for example Per series (quantity per batch of the production quantity).
- Scrap: constant or variable scrap increases consumption.
- BOM and route versions are approved and activated for a date and quantity range.
Routes and operations
A route is a sequence of operations. Each route operation has:
- Resource requirements: by specific resource, resource group, or capability.
- Times: setup, process, and queue time before or after. Transit time covers moving between sites.
- Process quantity: how many units the process time covers (for example 100 pieces in 2 hours).
- Overlap quantity: lets the next operation start before the first one finishes.
Waiting time such as paint drying is modeled with queue time, not with a resource.
Resources
A resource belongs to a resource group. Each resource has:
- A capacity and calendar (working times).
- Capabilities: skills or traits. The route operation lists the required capabilities.
- Finite capacity and finite material settings used by scheduling.
Groups and capabilities are different tools. Groups bundle resources by site and cost, capabilities filter by what a resource can do.
Scheduling
Job scheduling books every job (setup, process) on the resource calendars. Operations scheduling only schedules whole operations using the route. Choose job scheduling when detailed sequencing is needed, such as exact times for workers or maintenance technicians.
Exam traps
- Phantom does not create a production order. Pegged supply does.
- Do not create a resource per product variant or length. Use capabilities.
- Queue time is for waiting. Transit time is for moving between sites or locations.
- A flushing principle on a BOM line overrides the item default.
Practice questions
Choose an answer, then review the explanation to check your understanding.
1. A kit has 50 components, but you do not want a separate production order for the kit. Which BOM line type do you use for the kit line?
Show answer
Answer: C.A Phantom line is exploded into its components on the parent production order, with no separate order for the phantom.
2. Only some cutting machines can cut longer lengths. How do you make sure the right operations are scheduled on them?
Show answer
Answer: C.Capabilities describe what a resource can do, and the route operation requires them. Scheduling then picks only matching resources.
3. Paint needs time to dry before assembly can start. Which setting on the assembly operation supports this?
Show answer
Answer: B.Queue time before on the next operation (or queue time after on the previous one) reserves the waiting time in scheduling.
4. Components must be consumed automatically when the production order is started. What do you set on the BOM line?
Show answer
Answer: A.Start posts the consumption when the order starts, Finish posts it at report as finished, and Manual needs a picking list.