Use this function to change (or replace) a component in one or a range of bills of materials with a different component.

You can set the validity start date for the replacement component as required. The default is today's date.

The new component is given the same sequence number in the bill of materials (BOM) as the component being replaced. If the component already exists at the same sequence number the sequence number is incremented.

If the quantity of the replacement component is different you can apply a factor to update the BOM to ensure an accurate substitution takes place. The component 'Where used' flag is updated accordingly.

 This function does not 'delete' the original component, it simply marks it as 'not valid' by setting the validity end date to the validity start date for the replacement component minus 1 day (n-1).

 The BOM displays components that are valid on a specific date. The new component, therefore, is only displayed in the BOM once it becomes valid (fields Reference date (DATREF)/Valid from (BOMSTRDAT)).

Prerequisites

SEEREFERTTO Refer to documentation Implementation

Screen management

The Components replacement function displays two selection screens:

  • An initial screen into which you enter your component selection (or filtering) criteria;
  • A validation screen with a set of tabs in which you select and confirm the replacement details.

A log file displays the results of the run. Any excluded version-managed bills of materials (BOMs) are listed on the log file.

Entry screen

Component selection

Type in, or select the code of the component to be replaced and the code of the new (replacement) component.

If the quantity or unit of the replacement component is different from the current component, type in the factor to update the bill of materials (BOM) with.

Leave the default validity start date for the replacement component or select a different date which is later than today. This will be used as the validity start date for the replacement component. 

Then select the types of BOMs (commercial, production, subcontract) to be included in the run.

Start/end ranges

A number of ranges are displayed.

  • To replace the component in all applicable BOMs at all levels of the BOM, leave all the fields as the default values or blank.
  • To replace the component in selected BOMs, type in the required ranges. Leave the first field blank to include the lowest value or the second field blank to include the highest value.

You can optionally select the BOMs by applying a calculation formula.

A log file displays the results of the run. Where appropriate it includes information which should be noted or acted upon.

 

Block number 1

Replaced component (field RPLCPN)

Type in, or select the code of the component to be replaced.

You must choose a component that is not version-managed.
Major version (field ECCVALMAJR)
Minor version (field ECCVALMINR)
Alternate component (field UPDCPN)

Type in, or select the code of the replacement or substitute component.

The new component is given the same sequence number in the bill of materials (BOM) as the component being replaced. If the component already exists at the same sequence number the sequence number is incremented. The validity start date for the new component will be the date defined as the Application date; the end date will be that of the original component.

You must choose a component that is not version-managed.
Major version (field ECCVALMAJA)
Minor version (field ECCVALMINA)
Quantity factor (field QTYCOE)

Use this field if the quantity or unit of the replacement component is different from the current component. Type in the factor (multiplier) to update the quantity of the component on the bill of materials (BOM) by.
Stock unit (field STU)

This field displays the unit in which the product is stored. It provides the key to prices, costs, volumes etc.
Application date (field APPDAT)

This field defaults to today's date. If the replacement or substitute component is valid from a later date type in, or select the effective date.

Start - end range

Parent product (field ITMREFDEB)

Filter for results within a range of bills of materials (BOMs). For a single bill of materials (BOM), enter the same product in the from/start Parent product and to/end Parent product fields.

 
BOM type (field ALTTYPDEB)

Use this field to filter the bills of materials (parent products) according to the selected bill of materials (BOM) types (production BOMs, commercial BOMs or subcontract BOMs).

For a single type of BOM, enter the same type in the from/start BOM type and to/end BOM type fields.
Code (field ALTDEB)

Filter for results within a range of bills of materials (BOM) codes. 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).

For a single BOM code, enter the same sequence number in the from/start Code and to/end Code fields.
Formula (field FORMULE)

Enter, select or build an Enterprise Management filter calculation expression using the formula editor.

 

Tab Production links

You use this tab to confirm the details of the component substitution in the production BOMs listed.

The default validation flag for each selected BOM (parent product) is 'Yes'. To exclude a specific BOM, set the field Valid to 'No'.

You can change selected details for the replacement component. Where a BOM is selected which has expired you must change the validation date manually.

Grid Production links

Valid (field VALID)

Use this field to confirm (value 'Yes') or exclude (value 'No') the selected line from the process.
Alternative (field BOMALT)

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).
Parent product (field ITMREF)

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).
BOM (field REPBOMUOM)
UOM (field BOMUOM)

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)

This field displays the quantity of this component that is needed to make the parent product. The default quantity is defined on the bill of materials (BOM) record. You can amend it if necessary.
STK link quantity (field LIKQTY)

This field displays the quantity of this component in the stock unit that is needed to make the parent product. The default quantity is defined on the bill of materials (BOM) record. You can amend it if necessary.
Component type (field CPNTYP)

This field displays the component type. It will be set to one of the following values:

  • Normal: A component defined on the bill of materials.
  • By-product: An unplanned by-product or secondary product.
  • Text: Free-format text.
  • Costing: When a value is calculated for the provisional cost and the production cost price of the parent product.
Link quantity code (field LIKQTYCOD)

Use this field to define how the quantity of this component in the stock unit that is needed to make the parent product is determined:

  • Proportional. When the quantity of this component is multiplied by the quantity required for the parent product.
  • Fixed. When the quantity of this component is fixed regardless of the quantity required of the parent product.
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 is determined by the management unit, as follows:

  • The management unit is equal to 1, 100, 1000 or is expressed as a percentage. The base quantity is the value 1, 100, 1000 or 100 respectively.
  • Unit management is 'by lot'. You can enter the base quantity.
    If the BOM code is assigned to a specific site, it is initialized to the lot size of the product at the site.
Management unit (field QTYCOD)

The management unit defines the quantity of the BOM links using a basis other than the product unit.
A BOM can therefore be entered for 1 product unit, 100 product units, 1,000 product units, using a percentage or specifying the size of a "lot".
In the percentage definition, the total link quantities must be equal to 100.
The management unit selected determines if the Base quantity field (BASQTY) is initialized or available for entry.

 
% scrap (field SCA)

Type in the percentage of the component that you expect to be scrap (lost during the production process).

Inquiries can display the following figures:

  • Net quantities. The loss (scrap) percentage is not included in calculations of the quantity required to produce a parent product.
  • Gross quantities. The loss percentage is included in calculations of the quantity required to produce a parent product.
Valid from (field BOMSTRDAT)

Use this field to define the start date of this component's validity period.

Leave blank to use the default date.
Valid to (field BOMENDDAT)

Use this field to define the last date of this component's validity period.

Leave blank if this is a new component that does not have a validity period, that is, it is always valid. If you are deleting a component, leave blank to use the default date.
Link description (field BOMSHO)

Type in a short description of the component.

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 thefolder.
From lot (field BOMSTRLOT)

For components that are managed by lot, this is the first lot for which this link is valid.
To lot (field BOMENDLOT)

For components that are managed by lot, this is the last lot for which this link is valid.
Routing oper (field CPNOPE)

Use this field to assign this component to a specific operation in a production routing, according to the manufacturing requirements.
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'.
Mt. slip print. (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).
Container (field CTN)
Container capacity (field CTNCAP)
Container weight unit (field CTNWEU)
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 record (GESITF).
Weighing tolerance - (%) (field ITMTOLNEG)
Major version (field BOMECCVALM)
Minor version (field BOMECCVALM)

Tab Commerce links

You use this tab to confirm the details of the component substitution in the commercial BOMs listed.

As for the production BOMs the default validation flag for each selected BOM (parent product) is 'Yes'. To exclude a specific BOM, set the field Valid to 'No'.

You can change selected details for the replacement component. Where a BOM is selected which has expired you must change the validation date manually.

Grid Commerce links

Valid (field VALID)

Use this field to confirm (value 'Yes') or exclude (value 'No') the selected line from the process.
Alternative (field BOMALT)

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).
Parent product (field ITMREF)

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).
Sequence complement (field BOMSEQNUM)

Supplementary sequence number used for options and variants in Commercial BOMs. This number relates to the component type, enabling you to define a component as a variant or an option.

The list of possible options or variants for the same component must have the same sequence number. You use the supplementary sequence number to classify component options and variants into a given order for sales transaction selection.
Link quantity (field LIKQTY)

This field displays the quantity of this component in the stock unit that is needed to make the parent product. The default quantity is defined on the bill of materials (BOM) record. You can amend it if necessary.
Component type (field CPNTYP)

This field displays the component type. It will be set to one of the following values:

  • Normal: A component defined on the bill of materials.
  • By-product: An unplanned by-product or secondary product.
  • Text: Free-format text.
  • Costing: When a value is calculated for the provisional cost and the production cost price of the parent product.
Link quantity code (field LIKQTYCOD)

Use this field to define how the quantity of this component in the stock unit that is needed to make the parent product is determined:

  • Proportional. When the quantity of this component is multiplied by the quantity required for the parent product.
  • Fixed. When the quantity of this component is fixed regardless of the quantity required of the parent product.
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 is determined by the management unit, as follows:

  • The management unit is equal to 1, 100, 1000 or is expressed as a percentage. The base quantity is the value 1, 100, 1000 or 100 respectively.
  • Unit management is 'by lot'. You can enter the base quantity.
    If the BOM code is assigned to a specific site, it is initialized to the lot size of the product at the site.
Management unit (field QTYCOD)

The management unit defines the quantity of the BOM links using a basis other than the product unit.
A BOM can therefore be entered for 1 product unit, 100 product units, 1,000 product units, using a percentage or specifying the size of a "lot".
In the percentage definition, the total link quantities must be equal to 100.
The management unit selected determines if the Base quantity field (BASQTY) is initialized or available for entry.

 
Valid from (field BOMSTRDAT)

Use this field to define the start date of this component's validity period.

Leave blank to use the default date.
Valid to (field BOMENDDAT)

Use this field to define the last date of this component's validity period.

Leave blank if this is a new component that does not have a validity period, that is, it is always valid. If you are deleting a component, leave blank to use the default date.
Link description (field BOMSHO)

Type in a short description of the component.

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 thefolder.
Print acknowledgment (field OCNPRN)

Use this field to specify if this component must be printed on sales order acknowledgements.
Print slip (field NDEPRN)

Use this field to specify if this component must be printed on delivery notes.
Print inv (field INVPRN)

Use this field to specify if this component must be printed on sales invoices.

Tab Subcontract links

You use this tab to confirm the details of the component substitution in the subcontract BOMs listed.

As for the production and commercial BOMs the default validation flag for each selected BOM (parent product) is 'Yes'. To exclude a specific BOM, set the field Valid to 'No'.

You can change selected details for the replacement component. Where a BOM is selected which has expired you must change the validation date manually.

Grid Production links

Valid (field VALID)

Use this field to confirm (value 'Yes') or exclude (value 'No') the selected line from the process.
Alternative (field BOMALT)

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).
Parent product (field ITMREF)

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).
UOM (field BOMUOM)

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)

This field displays the quantity of this component that is needed to make the parent product. The default quantity is defined on the bill of materials (BOM) record. You can amend it if necessary.
STK link quantity (field LIKQTY)

This field displays the quantity of this component in the stock unit that is needed to make the parent product. The default quantity is defined on the bill of materials (BOM) record. You can amend it if necessary.
Component type (field CPNTYP)

This field displays the component type. It will be set to one of the following values:

  • Normal: A component defined on the bill of materials.
  • By-product: An unplanned by-product or secondary product.
  • Text: Free-format text.
  • Costing: When a value is calculated for the provisional cost and the production cost price of the parent product.
Link quantity code (field LIKQTYCOD)

Use this field to define how the quantity of this component in the stock unit that is needed to make the parent product is determined:

  • Proportional. When the quantity of this component is multiplied by the quantity required for the parent product.
  • Fixed. When the quantity of this component is fixed regardless of the quantity required of the parent product.
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 is determined by the management unit, as follows:

  • The management unit is equal to 1, 100, 1000 or is expressed as a percentage. The base quantity is the value 1, 100, 1000 or 100 respectively.
  • Unit management is 'by lot'. You can enter the base quantity.
    If the BOM code is assigned to a specific site, it is initialized to the lot size of the product at the site.
Management unit (field QTYCOD)

The management unit defines the quantity of the BOM links using a basis other than the product unit.
A BOM can therefore be entered for 1 product unit, 100 product units, 1,000 product units, using a percentage or specifying the size of a "lot".
In the percentage definition, the total link quantities must be equal to 100.
The management unit selected determines if the Base quantity field (BASQTY) is initialized or available for entry.

 
% scrap (field SCA)

Type in the percentage of the component that you expect to be scrap (lost during the production process).

Inquiries can display the following figures:

  • Net quantities. The loss (scrap) percentage is not included in calculations of the quantity required to produce a parent product.
  • Gross quantities. The loss percentage is included in calculations of the quantity required to produce a parent product.
Valid from (field BOMSTRDAT)

Use this field to define the start date of this component's validity period.

Leave blank to use the default date.
Valid to (field BOMENDDAT)

Use this field to define the last date of this component's validity period.

Leave blank if this is a new component that does not have a validity period, that is, it is always valid. If you are deleting a component, leave blank to use the default date.
Link description (field BOMSHO)

Type in a short description of the component.

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 thefolder.
From lot (field BOMSTRLOT)

For components that are managed by lot, this is the first lot for which this link is valid.
To lot (field BOMENDLOT)

For components that are managed by lot, this is the last lot for which this link is valid.
Type of supply (field SCOFLG)

This field enables the replenishment mode of the component to be specified:

  • made available to the subcontractor,
  • supplied by the subcontractor.
Reorder LT (field BOMOFS)

The reorder lead-time is used during launch and in the MRP calculation, in order to calculate the date of the component (material) requirement with respect to the subcontract start date of the parent.
It is expressed in calendar days. A negative value can be entered.

Examples:
Let us consider a subcontract order whose subcontract start date is on the 26/06.

  • If the reorder lead-time is 7 days, the material requirement date will be calculated on the 03/07 (26/06 + 7).
  • If the reorder 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'.
Mt. slip print. (field PICPRN)

Use this field to specify if this component must be printed on work order material issue slips.
Major version (field BOMECCVALM)
Minor version (field BOMECCVALM)

Error messages

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

This is a versioned component. Select a non-versioned component.

Amendments to versioned components or the components of a versioned product are tightly controlled to minimize the impact on work orders. This message is displayed to warn you that the component you have selected is version-managed and as there could be consequences from changing the component you have been prevented from doing so. You must choose a different component that is not version-managed.

"Modification not authorized for this code [x]"

You do not have authorization to change one or both of the component codes.

"At least one code must be entered"

You have not manually selected a component code and the All action has not been validated.

"No BOM for these selections"

The component does not exist in the types of BOM codes selected.

"The date must not be prior to the current date"

The Application date cannot be earlier than today's date.

"The parent product is equal to the new component!"

A link will be created with the same reference as a parent product.

Version managed BOMs included in the selection criteria will not be processed. Update them manually.

Amendments to the components of a versioned product are tightly controlled to minimize the impact on work orders. The selected component is a component in one or more version-managed BOMs. The list of parent products (BOMs) will not include version-managed BOMs as these are excluded from the replacement process.

"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.

Log file messages

The log file at the end of the run might display the following messages:

"BOD: product_reference alt seq This link causes a loop in the BOM"

The selected component has the parent product as a component in its bill of materials (BOM).

"BOD: product_reference alt seq component_replaced Write error on file"

The component substitution has not taken place. It is possible that a file was locked.

"BOD: product_reference alt seq component_replacement Record already exists"

The component code that you have attempted to create already exists in the BOM.

"ITMBOM: product_reference alt Error when accessing file"

The component substitution has not taken place. It is possible that a file was locked.

Tables used

SEEREFERTTO Refer to documentation Implementation