Making Mass Engineering Bill of Material Changes

This chapter provides an overview of mass bill of material (BOM) changes and discusses how to:

• Define BOM mass maintenance codes (MMCs).

• Make BOM mass changes and create automatic revisions.

• View and correct BOM messages using the staged BOMs process.

• Process staged BOMs.

Understanding Mass BOM Changes

This section discusses:

• Mass BOM changes.

• Example scenarios for mass BOM changes.

Mass BOM Changes

Engineering and production departments must apply multiple additions and changes directly to BOMs. Engineering can use this functionality to more easily implement approved changes on an engineering change order (ECO). Production also needs this functionality because not all changes go through engineering. You can also apply mass maintenance directly to manufacturing BOMs.

PeopleSoft Engineering mass maintenance enables you to apply, in a single process, the same set of changes, by ECO or MMC, to many manufacturing or engineering BOMs. For example, you can change all occurrences of one component for another or add components to an assembly.

The BOM mass maintenance code setup page enables you to define an MMC that can then be applied to an assembly range, assembly list, or an ECO-affected item. An MMC enables you to define a specific set of component changes such as reference designator and component dimension changes. A component can be added, and associated BOM information can be changed. The MMC also enables you to change or add specific multiple output values. You can even generate automatic revisions for revision-controlled items. You can then place the MMCs on ECOs and later run the MMC changes for that particular ECO. You can also view all BOM mass maintenance exceptions.

See Creating and Maintaining ECOs.

Note. In addition to generating mass maintenance changes to BOMs, the mass maintenance process also enables you to automatically create new revision numbers based on a revision scheme that you define for the business unit.

See Also

Maintaining BOMs by Revisions or Effectivity Dates

Example Scenarios for Mass BOM Changes

You can complete a mass update of BOMs in several ways. You can mass update engineering BOMs and manufacturing BOMs; in either case, you can choose whether to use ECOs. For manufacturing BOM changes, you can change the BOMs directly. For engineering BOM changes, use the transfer functionality. In addition, you can update BOMs directly, or you can stage and validate mass maintenance BOM changes so that you can then review and modify the mass-maintained version prior to completing the updates to your production BOM.

The following sections present some BOM update scenarios:

Scenario 1: Updating Engineering BOMs With or Without Using ECOs

To update engineering BOMs (EBOMs) using ECOs:

1. Create an ECO listing the affected assemblies.

   For example, if you are obsoleting a component, you can identify and create the list of affected assemblies by using the where-used search within ECO maintenance.

2. If the BOMs are in manufacturing, use this ECO to transfer the BOMs to engineering.

3. If not already done, create the MMC and associate it with affected assemblies within ECO maintenance.

   This step is required because the process to run all MMCs for the ECO is done by ECO number.

4. Process BOM mass maintenance by ECO and specify EBOMs.

To update engineering BOMs using MMCs:

1. If the BOMs are in manufacturing, transfer to engineering the assemblies that you want to change by item range or list.

2. If not already done, create the MMC.

3. Process BOM mass maintenance by MMC, and specify the MMC, engineering BOMs, and the assemblies by item range or list.

Scenario 2: Updating Engineering BOMs for Use-Up Items Using ECOs

With use-up functionality (using substitute items on the BOM), you can use an ECO to make permanent BOM changes once you know the phase-out date of the component. For example, say that item A is discontinued, item B replaces item A on five of six existing BOMs, and item C replaces item A on one of six existing BOMs. In this case, you most likely will have already defined item B as a valid substitute for component A on these six BOMs. Once the use-up date is determined (based on information from planning), you can use this information to make changes on the BOM.

For example, you could:

• Create an ECO (ECO-A, for example) and place all six items on the ECO.

  Run Process Engineering Transfer to copy the MBOMs (manufacturing) to EBOMs that specify ECO-A.

• Create a MMC (MMC-100, for example).

  For sequence 10, for example, specify search criteria to uniquely identify the five assembles for which you will replace component item A with item B. For sequence 20, specify search criteria that uniquely identify the one assembly for which you will replace component item A with item C. When defining the effective date of new components B and C, you can specify the scheduled date within the MMC. This indicates the scheduled date for the ECO. Or, if you already know the exact date of the changeover, you can specify that date as the effective date.

• Place MMC-100 on the ECO lines associated with the six assemblies to be updated.

• When the quantity on hand goes to zero, using the use-up information from planning, you can use this date as the ECO schedule date.

• Run Process Mass Maintenance by ECO to make the component changes for you.

• Approve ECO-A.

• Run Process Engineering Transfer to copy the EBOMs to MBOMs that specify ECO-A.

Note. In the second item of this scenario, be careful to uniquely identify the five assemblies versus the one assembly. Because you are associating the same MMC with all six assemblies, make sure that all six won't have item A replaced with item B and item A replaced with item C, or both. An alternative solution is to create two separate MMCs.

For example, create MMC-100, which defines the replacement of component item A with item B, and create MMC-200, which defines the replacement of component A with item C. Then place MMC-100 on the ECO lines of the five assemblies for which item A should be replaced with item B. On the other assembly, place MMC-200 to replace item A with item C.

Scenario 3: Updating Manufacturing BOMs Using ECOs

You can update MBOMs using ECOs in two ways. You can transfer the MBOMs to EBOMs, make the changes, and transfer them back to manufacturing. Alternatively, you can make the changes directly to the MBOMs within PeopleSoft Manufacturing.

The transfer scenario is:

1. Create an ECO with the assemblies on it that you want to change.

2. Use the ECO that you just created to transfer the BOMs to engineering.

3. If not already done, create the MMC and document it on the ECO.

   This step is required because the process to run all MMCs for the ECO is done by ECO number.

4. Process BOM mass maintenance by ECO and specify engineering BOMs.

5. Approve the ECO.

6. Use this ECO to transfer the BOMs back to manufacturing.

To directly update MBOMs in manufacturing using ECOs:

1. Create an ECO with the assemblies that you want to change on it.

2. If not already done, create the MMC and document it on the ECO.

   This step is required because the process to run all MMCs for the ECO is done by ECO number.

3. Approve the ECO.

4. Process BOM mass maintenance by ECO and specify manufacturing BOMs.

Scenario 4: Updating Manufacturing BOMs Using MMCs Without ECOs

You can also update MBOMs using MMCs in two ways. You can transfer the MBOMs to EBOMs, make the changes, and transfer the manufacturing BOMs back. Alternatively, you can make the changes directly to the manufacturing BOMs within production.

The transfer scenario is:

1. Transfer the BOMs, by item range or list, to engineering.

2. If not already done, create the MMC.

3. Process BOM mass maintenance by MMC, and specify engineering BOMs.

4. Transfer the assemblies, by item range or list, back to manufacturing.

To directly update manufacturing BOMs in production, using MMCs:

1. If not already done, create the MMC.

2. Process BOM mass maintenance by MMC, and specify the MMC, manufacturing BOMs, and the assemblies by item range or list.

Defining Engineering BOM MMCs

To define engineering BOM MMCs, use the BOM Mass Maintenance component.

This section provides an overview of BOM MMCs, lists prerequisites, and discusses how to:

• Identify BOMs for change.

• Enter reference designator search criteria.

• Enter substitute item search criteria.

• View assembly/component matches.

• Change components.

• Enter component dimension change criteria.

• Enter component reference designator change criteria.

• Enter component substitute change criteria.

• Add components.

• Enter component substitute add criteria.

See Also

Quantity Rounding Exceptions in PeopleSoft Manufacturing

Understanding Engineering BOM MMCs

With the BOM Mass Maintenance component, you can create and maintain BOM MMCs. You can specify multiple BOM component or output changes and additions, including substitute items. An MMC consists of search pages that enable you to identify existing components that will be affected, change pages that enable you to change instances of those components on specific BOMs, and Add pages that allow for the introduction of new components and detail information. After you have used these pages to define MMCs, you can then implement these changes directly using the Process BOM Mass Maintenance pages. Alternatively, you can associate MMCs to engineering change orders (ECOs) and implement the changes by ECO processing.

Note. To maintain components for revision-controlled BOMs en masse by using mass changes, you must enter effective and obsolete dates for the revision within these pages, regardless of whether the revision is controlled by revision name or by effectivity date.

Prior to accessing any mass maintenance code pages, you must select a business unit and MMC. The MMC value can be automatically generated.

Note. Any MMCs created in PeopleSoft Engineering are available only in engineering; any MMCs created in PeopleSoft Manufacturing are available only in manufacturing.

Note. To provide greater flexibility when defining EBOMs, the Quantity field does not need to follow the quantity precision rules defined for the item. A warning is issued if you define a decimal quantity value for an item whose quantity precision value is a whole number. This is an example of when you may need the quantity precision flexibility. If one B0004 component is required to make two assembly A0001s, then when defining the BOM, the QPA for B0004 would be 0.5. If you applied the rounding rules to the QPA, then it would round the QPA for B0004 to 1, and thereby inflate the production costs.

Mass BOM Changes Example

To better understand how you can use these pages to effect mass change, let's look at an example.

To obsolete a component on several BOMs and introduce another component in its place:

1. Create an MMC code by entering the search criteria (on the BOM Mass Maintenance Code - Search page) that identifies the component that you want to obsolete.

2. On the BOM Mass Maintenance Code - Change page, specify the date that the component is to become obsolete (or choose one of the available options).

3. Add the new component information on the BOM Mass Maintenance Code - Add page, including required information, such as operation sequence and effective date for the new component.

4. Add additional component information with the dimensions, reference designator, or substitutes links, as required.

5. Process the BOM mass maintenance and isolate the BOMs to be changed by specifying the appropriate ECO.

   If you're using MMCs without ECOs, isolate the BOMs to be changed by specifying the assembly item list or range.

Prerequisites

Prior to making BOM mass maintenance changes, define these in PeopleSoft Engineering:

• Appropriate assemblies.

• BOMs.

• If you're using ECRs, ECOs and MMCs associated with ECOs.

You also must define as revision-controlled with automatic revisions any items for which you plan to create automatic revisions.

Pages Used to Define BOM MMCs

Identifying Specific BOMs for Change

Access the BOM Mass Maintenance Code - Search page.

Before you associate changes or additions to an MMC, identify the outputs, components, or component revisions (and, therefore, BOMs) to change. When adding components, use this page to further identify the BOMs to which the new component should be added. For example, you may want to add component ID LT5001 only to BOMs that already have a component ID called LT5000 and a 12/31/97 obsolete date, or perhaps where you already have component ID LT5000 and LT5001 defined. Similarly, you can use this page to further identify the BOMs to which the new output should be added.

Note. In this component, the fields that you see vary depending on your selection in the Sequence Type field. The page examples in this section are based on selecting Component in the Sequence Type field. If you select Output, the system doesn't display the Component ID, Component Rev (component revision), Quantity, Yield, Pos (position), Sub Supply (supplied by subcontractor), Non-Owned, and Teardown fields. It also doesn't display the Dimensions, Ref Desigs (reference designators), and Substitutes links. Instead, it displays the Output Item, Output Type, Output Qty (output quantity), Res % (resource allocation percentage), and Cost % (cost allocation percentage) fields.

You may want to universally change the status of or add a new substitute item. You can search for substitutes by item or substitute. You can also search by item and substitute. To search for an item or substitute only, enter the original or substitute item in the Component ID field.

To search by both original and substitute, enter the original item in the Component ID field and click the Substitutes link.

See Also

Defining EBOM Outputs

Viewing Assembly/Component Matches

Access the Assembly/Component Matches page.

Entering Reference Designator Search Criteria

Access the Reference Designators - Search page.

For any sequence, you can search using multiple reference designators. If you enter more than one reference designator, the system searches for BOM components using a logical andoperator between reference designators. To search references designators using an or operator, you must use multiple sequences.

Entering Substitute Items Search Criteria

Access the Component Substitutes - Search page.

You can narrow the search by using all or any combination of the substitute item search criteria.

Changing Components

Access the BOM Mass Maintenance Code - Change page.

Component ID	Enter a new value if you intend to change the component ID field. Note. This is typically done for correcting BOMs. To keep history of a component change, do not enter a value here.
Output Item and Output Type	If you selected Output, enter the required output change-to data on this page. The effectivity dates operate the same as they do for a component sequence type.

Using Automatic Revisions and Effectivity Dates

Note. You can enter only one effective date or obsolete date. Therefore, if you specify a calendar date and then select Schd Date, the system clears the calendar date. Similarly, if you select a scheduled date and then enter a calendar date, the system clears the scheduled date.

This table outlines the automatic revision impact that the second set of effective date and obsolete date values have, both on revisions and the dates reflected on the BOMs. This example applies only to items that have been defined as revisions controlled on the Define Business Unit Item - Manufacturing: General page.

Also provided is an example of how the dates change on the BOM if the scheduled date is 06/15/02 on the ECO and the newly created revision is the latest revision for the item.

As you can see from the previous table, with the exception of the Schd Date and Prior Date combination, all scenarios are valid and lead to the automatic generation of revisions for revision control/automatic revision items.

This table shows items that have not been defined as using automatic revisions:

Note. Automatic revision is operative only for items that are defined as using automatic revisions on the Define Business Unit Item - Manufacturing: General page. The system uses the ECO schedule date to create revisions when mass maintenance is used in conjunction with an ECO. It uses the run date of the mass maintenance process to create revisions when mass maintenance is run by MMC as a standalone.

See Also

Maintaining BOMs by Revisions or Effectivity Dates

Entering Component Dimensions Change Criteria

Access the Component Dimensions - Change page.

Enter the existing dimension on the Component Dimensions - Search page (optional), and then enter a new value on the Component Dimensions - Change page. Entering the existing dimension on the Component Dimensions - Search page is necessary only when it must be part of the search criteria. For example, to change the weight for all occurrences of component LT5000 to 10, then enter 10 on the Component Dimensions - Change page. If this value should be changed only where its current weight is 9, then enter 9 on the Component Dimensions - Search page and 10 on the Component Dimensions - Change page.

Entering Component Reference Designator Change Criteria

Access the Reference Designators - Change page.

To add, change, or delete reference designators, specify the reference designators on the Reference Designators - Search page. Only the designators must be part of the search criteria.

Otherwise, use the Reference Designators - Change page to specify an action of Add, Change, or Delete. When adding, specify only the new reference designator. When deleting, specify only the reference designator to be deleted. When changing, specify the current and new reference designators.

Entering Component Substitute Change Criteria

Access the Component Substitutes - Change page.

Action

Select a value: Add Change Delete You can add, change, and delete component substitutes in much the same manner as you add, change, and delete reference designators. However, you have more information to maintain. If adding a new substitute, specify all the required new values. If deleting a substitute, specify as many of the current values as necessary to process the deletion. If changing substitute information, enter the current and new values. For example, to delete all occurrences of LT5001 as a substitute, enter only LT5001 as the substitute item. To delete only the substitute LT5001 if it has priority 1, then enter LT5001 as the substitute item and 1 as the priority.

Current Values

New Values

Adding Components

Access the BOM Mass Maintenance Code - Add page.

Note. Automatic revision is operative only for items that are defined as using automatic revisions on the Define Business Unit Item - Manufacturing: General page. The system uses the ECO schedule date to create revisions when mass maintenance is used in conjunction with an ECO. It uses the run date of the mass maintenance process to create revisions when mass maintenance is run as a standalone.

Note. The values that you select on these pages are subject to the same validation checks that apply to any engineering BOM or manufacturing BOM component or output values. Some of these checks occur when you create the MMC, and the remaining validation checks occur at the time that the MMC is applied.

Entering Component Substitute Add Criteria

Access the Component Substitutes - Add page.

	Click the Copy Substitute button to display all valid substitute items for the business unit.
OK	Click this button to add all valid substitute items for the business unit.

If you don't want to add all valid substitute items for the business unit, enter each individual substitute item that you want to add, as well as the priority, from date, to date, and conversion rate for each substitute.

Note. Substitute items must be unique for the item. You cannot enter the same item twice as a substitute with different dates. For example, substitute A with effective dates from 01/01/99 to 02/01/99 and substitute A with effective dates from 02/01/00 to 08/30/00 couldn't be substitutes for the same item. In this case, define a different substitute for the second set of effective dates.

Making BOM Mass Changes and Creating Automatic Revisions

This section provides an overview of BOM mass changes and automatic revisions, lists common elements, and discusses how to:

• Make mass changes by ECO.

• Make mass changes by MMC.

• Use assembly item options.

• Select assemblies by items where used.

• View mass maintenance exceptions.

Understanding BOM Mass Changes and Automatic Revisions

You can make BOM mass changes, as well as create automatic revisions, in two ways: by ECO or by MMC. While the processing in each case is similar, the way in which you determine the assemblies to change differs.

Both mass maintenance processes can generate automatic revisions.

To create automatic revisions (no BOM changes) using mass maintenance by ECO:

1. Create the ECO.

   Include items (make or buy) that you want to automatically revise and select the Auto Rev check box.

2. Run the mass maintenance by ECO process (an MMC isn't required).

   The system creates a new revision effective on the ECO schedule date.

To update BOMs and create automatic revisions using the mass maintenance by MMC process:

1. Define the MMC using the BOM Mass Maintenance component.

2. Create the ECO.

   Attach the MMC to one or more items on the ECO. (If the MMC is defined with the Auto Rev check box selected, and the ECO item is revision-controlled and defined to allow automatic revisions, the Auto Rev check box on the ECO is selected and cannot be cleared.)

3. Run the mass maintenance by MMC process.

   The system creates a new revision, effective on the ECO schedule date.

Note. You can also include additional items on the ECO that aren't affected by the MMC but that are to be automatically revisioned. List them and select the Auto Rev check box on the ECO. When the mass maintenance process by ECO runs, it creates new revisions for these items as well.

To create automatic revisions using the mass maintenance by MMC process:

1. Define the MMC using the BOM Mass Maintenance component.

2. Run the mass maintenance by MMC process.

   The system creates a new revision effective on the mass maintenance by MMC process run date.

Common Elements Used in This Section

Pages Used to Make BOM Mass Changes and Create Automatic Revisions

Making Mass Changes by ECO

Access the Mass Maint ECO Options page.

You have two ECO options: you can enter only an ECO number range or both a number range and an ECO schedule date range.

The system uses the BOM MMCs that you specify on an ECO to make the mass changes and to create automatic revisions.

If the MMC on the ECO has been set to include automatic revisions, then the system also automatically creates revisions. Revisions are effective as of the ECO schedule date.

Note. Only items that have been defined as revision-controlled with automatic revisions (on the Define Business Unit Item - Manufacturing: General page) and that are also set up to use automatic revisions (on the BOM Mass Maintenance - Search page) are automatically incremented.

The system also uses the BOM code and BOM type that you specified on the ECO Maintenance - Items Affected page to determine the BOMs to change. If you left the BOM Code field blank, the MMC applies to all BOM codes. There can be one MMC for all BOM changes on an ECO, or there can be a different MMC for each BOM change on the ECO.

Note. When running the BOM Mass Maintenance process to create new revisions only, you must run the process with the update option of Validate and Update to create new revision numbers. Validate, in this context, means that all BOMs are valid for update (including no duplicate components and overlapping effectivity dates); it doesn't mean that the system checks for loops. To check for looping BOMs, you must run the BOM verification process after you have run the BOM Mass Maintenance process.

For any manufacturing BOM or engineering BOM that is updated by the BOM Mass Maintenance process, the ECO Number field on the BOM and engineering BOM maintenance component details pages is updated with the ECO number used in this process. The ECO number shown on the component details is the last ECO number that updated the component on the assembly. The ECO button on the same page reflects any pending ECOs.

This process also updates the MMC status on the ECO Mass Maintenance page. For BOMs with errors, the system sets the status to Error. For BOMs that were updated, the status is set to Success. Finally, for BOMs that weren't affected by the MMC (that is, they didn't meet the search criteria), the system sets the status to No Affect.

If you resubmit this process against the same ECOs, the system processes only the BOMs whose mass maintenance status is either Pending, Error, or No Affect.

Any ECO items that were both successfully changed and were flagged with only a BOM change (no routing change) on the ECO Header or Items Affected page are released. If all items on the ECO are released, then the ECO itself is also released.

See Also

Maintaining BOMs by Revisions or Effectivity Dates

Making Mass Changes by MMC

Access the Mass Maint Code Options page.

See Also

Making Mass Changes by ECO

Using Assembly Item Options

Access the Assembly Item Options page.

Selecting Assemblies by Items Where Used

Access the Select Assemblies by Items Where Used page.

Search	If you select Components Only, the system displays basic component information. If you select Outputs Only, the system displays basic output information, including output type, BOM code, output quantity, and effectivity dates.
Sel (select)	Select the check box for all the outputs to transfer to the main page.
Search	Click this button to populate the page.
View	Select either Indented or No-Indent.
Comp Rev (component revision)	This field appears if the component is revision-controlled. If you enter a component revision, the Select Assemblies by Items Where Used page returns all assemblies where that component is an exact match or where the current revision is used. If you leave the field blank, the system returns assemblies that use any revision of the component.

ECO or ECR Maintenance Pages

If you have accessed this page from either the ECO or ECR maintenance pages, you can:

• Change the BOM state to either Engineering or Manufacturing.

• Select default ECO values.

  These values include the ECO item type and whether the item requires a BOM change (BOM check box) or routing change (Rtg check box). When accessed from ECO maintenance pages, there is an additional default value called Rev Up. This check box is available only if you have selected a type of IMP and if you have selected the BOM check box.

Note. These are only default value; therefore, when the selected items are returned to the ECO, the Rev Up check box is selected only for the items that are auto-revision controlled.

Engineering Transfer or Process BOM Mass Maintenance by MMC Pages

If you have accessed this page from either the Engineering Transfer or Process BOM Mass Maintenance by MMC pages, then BOM state is unavailable for selection. BOM state reflects the selection that you made in the From/To field on the Transfer Selection page or the on the BOM Mass Maintenance Codes pages.

See Also

Entering ECO Header Information

Viewing Mass Maintenance Exceptions

Access the Mass Maint Except page.

Click the Count button to view the number of errors.

After you have reviewed the exceptions and made any needed changes to the BOMs or mass maintenance data, you can rerun the mass maintenance process.

If you ran mass maintenance in update mode by ECO, any ECO items that had errors are noted on the Maintain ECO Mass Maintenance page for each ECO BOM that had an error. If you rerun the mass maintenance process by ECO, the mass maintenance process attempts to apply changes to only those BOMs in error, as well as to any BOMs with a status of No Affect or any new BOMs added to the ECO with a mass maintenance status of Pending.

You can view the reasons why BOMs (displayed by item ID, BOM type, and BOM code) weren't changed by the BOM Mass Maintenance process.

Validation Checks

All requested changes made with either of the Process EBOM Mass Maintenance pages are validated before any engineering or manufacturing BOM changes are made. The system checks the interaction of all components and outputs on the product structure: these same checks are made within the BOM maintenance pages.

See the troubleshooting documentation on the PeopleSoft Customer Connection website.

Viewing and Correcting BOM Messages Using Staged BOMs

As part of the mass maintenance process, you can correct BOM messages with data errors using the Staged BOMs pages. You can view each BOM message and correct the errors using these pages. You can then change the status to Reprocess and submit the BOM for reprocessing immediately, or use the MMC Staged BOM process to reprocess a range of BOMs.

This section discusses how to:

• View staged BOM status.

• Correct staged BOM summary errors.

• Correct staged BOM multiple output summary errors.

Pages Used to View and Correct BOM Messages Using Staged BOMs

Viewing Staged BOM Status

Access the Update Staged EBOM Details - BOM Status page.

BOMs tab

If you are correcting multiple messages, you can manually change the status of each message to Reprocess after you've corrected the data. Then run the BOM Loader process to reprocess the data for multiple messages. The system changes Reprocess and New messages to the Complete status after confirming that there are no errors in the message.

To correct a single message, select the Reprocess check box to set the message status to Reprocess, and click OK or Apply to initiate the validation background process.

Messages

In the Messages scroll area, the system displays the error message, the result of the message, and the BOM details for the message.

This page lists of all the errors and warnings for the BOM, whether for the overall BOM, a specific component, or output. The Result column indicates the severity of the message. W indicates a warning and doesn't stop the BOM from being valid. E indicates an error and must be fixed for the BOM to be valid.

Correcting Staged BOM Summary Errors

Access the Update Staged EBOM Details - Summary page.

See Also

Maintaining BOM Summaries

Correcting Staged BOM Multiple Output Summary Errors

Access the Header - Outputs page.

For each output, you can change the output type, output item, source code, resource allocation percentage, and cost allocation percentage.

See Also

Defining BOM Outputs

Processing Staged EBOMs

After you've viewed and corrected staged BOMs, run the MMC Stage Application Engine process (EN_BOM_MSG) to reprocess the BOMs.

Page Used to Process Staged EBOMs

Running the MMC Stage Application Engine Process (EN_BOM_MSG)

Access the MMC Stage page.