OPTION (15) Modifications to Baseline - Minimal                               GRAPHIC EXAMPLE

(BLK-00) BULK PULL BOM EXPLOSION TOOLS

This memo concerns the BLK-00 Module that is used for rapid BOM explosion, and reporting of Component and Subassembly content, for Planning, Accounting, Purchasing, and Engineering. Spares Pricing can be performed at a markup over Standard Cost.

Net-change or regenerative capability is built in. Quantities can be added or subtracted, and Assemblies added or subtracted. NOTE: This module is written for high-speed explosion, and since none of the output is required in indented order, the BOM indenture levels are not maintained. Yield is supported.

The list of assemblies can be hand-entered by Planners, or obtained from SALES-FORECAST or MPS, including quantities and dates. The supplied date is used for BOM effectivity during the BOM explosion (today's date is the default).

Any other source of Part/Quantity data could be used, such as REP-SCHED, Planning Bills, or upload from PC Forecast packages.

Included are numerous programs which net out against available Inventory, and/or Allocations, to identify shortages, and which can assist Production, Planning, Purchasing, Marketing, Engineering, Marketing and Accounting in determining structure, materials shortages, availability, Obsolete Parts Analysis, and detail at Material-Labor-Overhead.

A "BULK PULL" can be copied to another Code as History.

Some of the major functions which are provided:

Business Plan: A Year's Forecast or MPS is exploded, to provide P.O. Dollars, Labor Hours, Cost of Goods, Work Center Capacity, and more.

One Customer used the Sub-Assemblies to break out Production, Yield, Scrap, and Remelt, by Shop Floor Group, for the next year's production planning.

Mini-MRP (BLK-R-Z207) is used to identify the first bucket in which a component shortage would occur (or the first Assembly Number), identifying outstanding PO's and WO's on the report.

Engineering reports of Components by Extended Descending Cost, to aid in reducing product cost. Reports are provided by Rev, or Reference Designators, or numerous other fields, such as Descending Lead Time.

The module can compare two similar assemblies, identifying only differences in content. M-L-O reporting is provided. The module can identify components unique to specific assemblies, by performing internally programmed Where-Used Pegging. Two Cost Versions can be compared, at Material-Labor-Overhead.

Reports can detail critical components (How Many Can We Build?) and a Weekly-Bucketed "Virtual MRP", which identifies the first week in which a component is "short", pegged to the Top-Level Assembly Part Numbers.

Parts Obsolescence Module - uses this Module to explode Active Top Assemblies, and identify Part Numbers not contained in the BOM explosion, for possible obsolescence.

Cost Rollup - Accounting explodes new assemblies, and names a list of all Subassemblies, plus the Top Assemblies. This is fed to the Cost Rollup, which rolls the entire product structure by Descending Low Level Code.

This Module includes the capability of utilizing TEMPLATES for producing price lists of Spare Parts, and generating a Sales Order for the spares at the appropriate markup.

The Z_SPARES_TEMPLATE File contains PRICING TEMPLATES, which may be optionally connected to PARTS COMMODITY CODES, allowing different Markup Percentages for specific Commodity Codes, vs. Standard Cost.

One or more Assemblies can be "exploded" to the component level and the resulting list of Part Numbers is printed against a specific TEMPLATE. Sub-TEMPLATES are permitted for one or more COMMODITY CODES, which supercede pricing from the Base TEMPLATE. As an example, Commodity Code "PACK", for packaging materials, can carry a higher markup over Standard Cost.

Since specific Effectivity Dates are handled, a Spares List can be generated for a prior Build Date, based on Product Structure at the time of the sale. This requires, of course, maintaining proper ECN History in the BOM, using Begin- and End Effectivity Dates.