Common data >  BOMs >  Replacement >  Components  

Display all Hide all

This function is used to replace a component with another, for one or several BOM codes to select, and for one or several parent products using this component.

The replacement does not mean that a "physical" deletion of the replaced component takes place. It is rather a logical deletion that occurs. The processing modifies the validity end date of the replaced component, on the relacement application date minus 1 day (the application date can be set in the future, thus allowing a provisional replacement).

The new links with the replacement component are created with a validity start date that is equal to the application date, and to the same sequence number as the replaced link. If the replacement creates an already existing reference to the same sequence, the corresponding link is created upon sequence n+1 (n+2 if the component already exists as n+1, etc.).

Moreover the quantity of the replaced component can be modified for the replacing component (in the absence of strict equivalence between both references), via the manual entry of a multiplying factor of the link quantities.

The calculation of the lower-level code is carried our for the replaced and replacement components, and for the update of the "Where-used" flag.

Prerequisite

SEEREFERTTO Refer to documentation Implementation

Screen management

The component replacement screen is subdivided into two parts:

  • selection entry,
  • validation screen.

Selection entry

This is used to supply selection criteria:

  • component to replace,
  • replaced component,
  • quantity factor,
  • application date,
  • selection of the BOM codes to be processed.
    The BOM codes which the user is not authorized to modify (according to the access codes defined in the profile and BOM code table) are not taken into account by the processing,
  • Selection of components, useful to avoid validating the replacement of all the parent products using this component: the system submits by default the replacement of the component at all the BOM levels where the component is used.

Validation screen

Presentation

The other screen displays the list of the selected components, using the component to be replaced, with the modifications already carried out (new component, validity start date and link quantity).
If both production and sales codes have been selected, the links appear in two different grids corresponding to each code type. These grids are present in the "Component product (Production)" and "Component product (Sales)" tabs.

The validation screen includes a first column "Yes/No" to validate (Yes) or exclude (No) the replacement for the link. By default the validation column displays the value "Yes", except for links with anomalies:

  • All the links with the product to replace are selected, even those having an expired validity date: the application start date of the replacement is then later than the end date. If the replacement should nevertheless take place for the invalid links, the validity end date must be modified manually in the grid, and the indicator of the first column switched to the value "Yes".
  • The replacing component generates a loop and cannot be validated. If the value of the first column is forced to "yes", the program detects the loop at the time of the replacement and writes a log of the error in the process execution report.

The Validation button is used to start the replacement processing for all the links ticked in the grid, and the manual modifications made are taken into account.

Close

 

Fields

The following fields are present on this tab :

Grid Production links

  • Valid (field VALID)

This field is used to validate (value "YES") or exclude from the process (value "NO") the selected lines.

Multiple bills of materials (BOMs) can be defined for a single product. Each BOM code can be assigned specific management features. For manufactured or subcontracted products this includes restriction of the BOM to a specific site and to specific areas of functionality (for costing or for capacity planning).

This product code describes what is referred to as a "Bill of Materials" or a "BOM". A BOM contains structured information for making and costing a product. It defines the components that make up a product, and given this, the cost of the product.

The BOM code matches the product code.

  • Sequence (field BOMSEQ)

This field identifies the sequence number of this component in the BOM (bill of materials).

This field displays the unit of measure (volume or mass).

  • UOM-STK factor (field BOMSTUCOE)

This is the conversion coefficient between the operation unit of the component and the storage unit.
It is initialized from the value specified at BOM level.

  • UOM link quantity (field BOMQTY)
  • STK link quantity (field LIKQTY)
  • Component type (field CPNTYP)
  • Link quantity code (field LIKQTYCOD)
  • Qty rounding (field QTYRND)

Use this field to define the rounding rule to be applied to adjust the calculated quantity of this component to the number of decimal places defined for the stock unit of the parent product. You can set this field to one of the following values:

  • Round to the nearest.
  • Greater than. Round up.
  • Less than. Round down.

  • Base quantity (field BASQTY)

The base quantity entry depends on the management unit chosen:

  • the management unit is equal to 1, 100, 1000 or is expressed as a percentage. the base quantity is forced respectively to values 1, 100, 1000 or 100,
  • The management of the unit is set by lot: the base quantity can be entered.
    If the BOM code is dedicated to a site, it is initialized by lot size of the product for the site.
  • Management unit (field QTYCOD)

The management unit is used to define the quantity of the BOM links on another basis than the product unit.
It is thus possible to enter a BOM for 1 product unit, 100 product units, 1,000 product units, in percentage or for a specific product lot size.
In the percentage definition, the total link quantities must be equal to 100.
The basic quantity section is initialized or entered depending on the chosen management unit.

  • % scrap (field SCA)
  • Valid from (field BOMSTRDAT)
  • Valid to (field BOMENDDAT)
  • Link description (field BOMSHO)
  • From lot (field BOMSTRLOT)

For components that are managed b y lot, this is the first lot for which this link is valid.

  • To lot (field BOMENDLOT)

For components that are managed b y lot, this is the last lot for which this link is valid.

  • Routing oper (field CPNOPE)
  • Ope LT (field BOMOFS)

The operation lead-time is used during launch and in the MRP calculations. It is used to calculate the date of the component (material) requirement with respect to the production start date of the parent product.

It is expressed in calendar days. You can enter a negative value.

Example: A work order has a start date of the 26/06:

  • If the operation lead-time is 7 days, the material requirement date will be calculated on the 03/07 (26/06 + 7);
  • If the operation lead-time is -7 days, the material requirement date will be calculated on the 19/06 (26/06 - 7).

  • Valuation (field CSTFLG)

Leave as 'Yes' if the value of this component must be taken into account when calculating the standard cost of the parent product; if the value of this component must not be included in the standard cost, set to 'No'.

  • Materials requisition printing (field PICPRN)

Use this field to specify if this component must be printed on work order material issue slips.

  • Pick list code (field PKC)

Use this field to inform warehouse staff of any actions that apply when this component is picked for issue. You can select one of the following actions:

  • Component not weighed at station — Setup level and weighing tolerance fields are disabled.
  • Component weighed at station
  • Component weighed in production
  • Excipient phase at station
  • Excipient phase in manufacturing
  • Final work order excipient phase at station
  • Final work order excipient phase in manufacturing
  • Material correction at station — Blank option available for Setup level.
  • Material correction in manufacturing — Blank option available for Setup level.
  • QFS at end of manufacture

 This field is only available if the MWM-Weighing station activity code is active.

 You must be authorized to change this statement if this is a component of a versioned product (BOM).

  • Setup level (field LEVSET)

Used this field to define the tolerance value to apply when weighing a material. The value you select affects the weighing tolerance fields.

You can select one of the following levels:

- Blank — for material not weighed; only available if the Pick list code is Material correction at station or Material correction in manufacturing.

- SHI record — default value for weighed material; the weighing tolerance fields are disabled and populated with values based on the Product-sites setup (GESITF).

- Product-site — the weighing tolerance fields are disabled and populated with values based on the Product-sites setup (GESITF).

- BOM — weighing tolerance fields are enabled and you can enter weighing tolerance percentages to calculate the weight variance.

Note: This field is only available when the MWM-Weighing station activity code is active.

 
  • Weighing tolerance + (%) (field ITMTOLPOS)

This field displays the percentage used to calculate the weight variance.

You can only modify this field if the Setup level is set to BOM.

If the Setup level is SHI record or Product-site, this value is based on the Product-sites setup. (GESITF)

Note: This field is only available when the MWM - Weighing station activity code is active.

  • Weighing tolerance - (%) (field ITMTOLNEG)

 

Close

 

Tab Sub-contract links

Fields

The following fields are present on this tab :

Grid Production links

  • Valid (field VALID)

This field is used to validate (value "YES") or exclude from the process (value "NO") the selected lines.

Several BOMs can be defined for the same product reference.
They can be distinguished via the code, entered on two numbers.

The various BOM codes can be used to manage different product structures according to their use context such as:

  • MRP calculation,
  • Sales order entry
  • Manufacturing/production

This field can be left empty (value = 0) to enable manual entry of the components. In this case, only the component is loaded.

This field indicates the product reference code. It is generated by a sequence number counter (set up in function Sequence number counters) in the case when the product category has a sequence number counter code.

The reference cannot be modified. It is automatically assigned and displayed when the product creation is complete.

  • Sequence (field BOMSEQ)

This field identifies the sequence number of this component in this BOM (bill of materials). It identifies a component where multiple components with the same product code are defined as variants or options.

The BOMSTE - Component sequence increment parameter (TC chapter, BOM group) defines the first sequence number and the increment applied to subsequent component sequence numbers.

Product management unit. This is the unit expressing the quantities in the product management functions. If the asset is created from the capitalization of the expenses, this field is loaded by default with the unit of the main expense.

  • UOM-STK factor (field BOMSTUCOE)

This field indicates the UOM-S conversion coefficient used to calculate the quantity in US, from a quantity entered in UOM: Qty in US = Qty in UOM * coeff.
This coefficient is initialized from the conversion factor table if the combination exists.

  • UOM link quantity (field BOMQTY)

It is the allocated quantity expressed in UOM unit.

  • STK link quantity (field LIKQTY)

The link quantity specifies the number of components required for the basic quantity of the parent product.
It is entered in a variable format (fluctuating number of decimals).
For a management unit of 'percentage', the sum of the link quantities must be equal to 100.

  • Component type (field CPNTYP)

Use this field to define what type of component this is. You can set it to one of the following values:

  • Normal. A component of this bill of materials.
  • By-product. An unplanned by-product or secondary product.
  • Text. Free-format text to be displayed on a work order.
  • Costing. When a value must be calculated for the provisional cost and the production cost price of the parent product.

  • Link quantity code (field LIKQTYCOD)

The code of the link quantity can be:

  • Proportional: the quantity is multiplied by the required quantity for the parent product used in the processing,
  • Fixed: the quantity is fixed regardless of the quantity required for the parent product.
  • Qty rounding (field QTYRND)

The quantity of BOM links is entered with a maximum accuracy, which is not always useful for the stock management.
This code is used to manage the quantity rounding mode, based on the stock unit decimal, in the processes using the BOM.
The rounding can be to the nearest, highest or lowest.

  • Base quantity (field BASQTY)

The base quantity entry depends on the management unit chosen:

  • the management unit is equal to 1, 100, 1000 or is expressed as a percentage. the base quantity is forced respectively to values 1, 100, 1000 or 100,
  • The management of the unit is set by lot: the base quantity can be entered.
    If the BOM code is dedicated to a site, it is initialized by lot size of the product for the site.
  • Management unit (field QTYCOD)

The management unit is used to define the quantity of the BOM links on another basis than the product unit.
It is thus possible to enter a BOM for 1 product unit, 100 product units, 1,000 product units, in percentage or for a specific product lot size.
In the percentage definition, the total link quantities must be equal to 100.
The basic quantity section is initialized or entered depending on the chosen management unit.

  • % scrap (field SCA)

The loss percentage is used to increase the link quantity in order to take into account the loss due to the production process.
In the various inquiries, two quantities can be displayed:

  • net quantity: calculation of the quantity necessary to produce a parent product, without taking the loss into account.
  • gross quantity: calculation of the quantity necessary to produce a parent product, when taking the loss into account.
  • Valid from (field BOMSTRDAT)

The validity start date is the date from which the link is valid.
It is initialized by default with the validity start date of the header. It remains modifiable but it must fall between the start and end dates of the validity displayed in the header.

  • Valid to (field BOMENDDAT)

The validity end date is the date beyond which the link is no longer valid.
It is initialized by default with the validity end date of the header. It remains modifiable but it must fall between the start and end dates of the validity displayed in the header.

  • Link description (field BOMSHO)

Enter the short description.

By default the short title, the long title or the column header of a data are recorded (on creation/update) in the connection language of the user.
You can add your translation in another language using the Translation function:

  • Click Translation from the Actions icon in the corresponding field.
  • In the Translation window, add a new language code with the translation in this language.

A user who logs on with this language will view the short description, long description or column header in their connection language if a translation exists. Otherwise, these descriptions will be available in the folder language.

SEEINFO The connection language must be defined as a default language for the folder.

  • From lot (field BOMSTRLOT)

For components that are managed b y lot, this is the first lot for which this link is valid.

  • To lot (field BOMENDLOT)

For components that are managed b y lot, this is the last lot for which this link is valid.

  • Type of supply (field SCOFLG)

 

  • Reorder LT (field BOMOFS)

 

  • Valuation (field CSTFLG)

This field is only available if this component is a by-product, that is the field Component type (field CPNTYP) is set to 'By-product'.

Leave as 'Yes' if the value of this by-product must be taken into account when calculating the standard cost of the parent product; if the value of this by-product must not be included in the standard cost, set to 'No'.

  • Materials requisition printing (field PICPRN)

Use this field to specify if this component must be printed on work order material issue slips.

Close

 

Error messages

In addition to the generic error messages, the following messages can appear during the entry :

Messages for the BOM management

Since the component replacement enables the modification of the links with the replacement component, the controls for the BOM management are all activated with the same messages.

Selection entry

  • "No BOM for these selections"
    This message appears in direct mode processing, if the component to replace has no where-used case in the selected BOM codes.
  • "The date must not be prior to the current date"
    The application date can only be equal to the current date or be later.
  • "Modification not authorized for this code [x]"
    The user profile does not have a modification right on the entered code or on the selected code.
  • "At least one code must be entered"
    You have not selected any code manually and the button "All" has not been validated either.
  • "The parent product is equal to the new component!"
    The replacement of components leads to the creation of a link with the same reference as the parent product.
  • "Error when accessing the BOM file: product_reference alt"
    The records connected with the selection could not be read properly because of a problem when accessing the file.

Messages of the error log file

After the direct mode processing, the log file is displayed with possible errors:

  • "BOD: product_reference alt seq This link causes a loop in the BOM"
  • "BOD: product_reference alt seq component_replaced Write error on file"
  • "BOD: product_reference alt seq component_replacement Record already exists"
  • "ITMBOM: product_reference alt Error when accessing file"

Tables used

SEEREFERTTO Refer to documentation Implementation