SYSPRO Ribbon bar > Setup > Manufacturing > Bill of Materials Setup

Bill of Materials Setup

You use this program to define the setup options for your Bill of Materials module.

For this module to run efficiently, we recommend that you indicate the options you require before processing any transactions. However, most of the options can be changed later, if necessary.

General

Field Description
Options

Structure on/off dates required

Select this to be able to assign dates to a structure indicating when the structure is active.

Components that are Off (compared to the system date) are ignored from the Cost Implosion program which is designed to re-cost stock items from raw material level through to the finished part.

Structure amendment journals required

Select this to be able to monitor information that has changed for structures held on file.

A journal is output whenever changes are made to structures within the Structures and Routings program. This information is listed using the Structure Amendment Journal program.

Structure narrations required

Select this to be able to enter text notes against a structure, allowing you to describe the link between a parent and its component parts.

These narrations can be printed on a number of reports.

Standard narrations for operations required

Select this to be able to assign coded text notes to a number of different operations.

This text is linked to a narration code which is in turn assigned to your operations.

If you do not select this option, then your text narrations must be unique for each operation.

Alternate routings required

Select this to be able to assign alternate routings for each set of operations for a parent part.

The primary routing defaults to 0, while any selection in the ranges: 1-9; A-Z or a-z indicates an alternate routing.

Component inclusion by job number

This option applies to jobs created through Work in Progress and Requirements Planning.

Select this to allocate components (from a Bill of Materials) to jobs based on a range of job numbers. This is similar to the concept of structure on/off dates except that it is based on job numbers instead of date ranges.

[Note]

You cannot run the Requirements Calculation program when you enable this option and your job numbering method is set to Manual or Scripted.

Split subcontract operation costs from material costs

Select this to record subcontract costs and material costs separately.

If you do not select this option, then subcontract and material costs are recorded as a single amount.

[Note]

When you change this option and save your selections, you are prompted to run the Cost Implosion program. This will either split or merge the subcontract and material costs, depending on your selection.

If you do not run the Cost Implosion program, the BOM costs recorded against your stock items will be incorrect.

When you select this option, individual values for subcontract and material costs are printed on the Costing Report, BOM-Inventory Cost Comparison, Costing Profile and Route Cards - Subcontract reports. In addition, the individual values can be viewed in the Costing Query, Stock Code Maintenance and Requirements Calculation programs.

Progressive scrap required

Select this to take account of scrap at operation level.

Because Work in Progress is often scrapped during an operation and the amount of scrap is usually known for each parent part of a process, it may be easier to record and track scrap at parent part level than to account for it at material level.

Enabling progressive scrap allows you to capture a scrap percentage and a scrap quantity against each operation configured within the Structures and Routings or Labor Allocations programs.

At the time of creating a job, the material allocations are inflated according to the scrap percentages and/or scrap quantities defined against the associated operations.

The Requirements Calculation program caters for progressive scrap at the time of calculating the demand of material allocations for jobs.

[Note]
  • The facility to track scrap at operation level does not prevent you from also tracking scrap at material level against the component (i.e. you can use both methods to track scrap, if required).

  • You cannot maintain scrap details once the job is confirmed, or allocations have been issued.

Use factory calendar for move times

Select this use the company calendar (see Company Calendar), to calculate the start date (or job delivery date) for operations.

[Note]

This only applies to calculating operation movement time. It does not apply to calculating the actual elapsed time for operations.

When this option is enabled, the factory calendar is used in the following programs:

You typically select this option if the work center against the current operation does not have the same working days as the following work center.

If you do not select this option, then the work center calendar (see Capacity Calendar Maintenance), is used to calculate the start date for operations. Note that if the work center calendar is not set up, then the system assumes that every day is a working day.

Warn about cost implosion not being completed Select this to display a warning message when the Cost Implosion is not run for all stock codes and warehouses. The operator can select to ignore the warning or to continue.

The message: A range of stock codes or warehouses may corrupt some costs is displayed in the Cost Implosion program. This indicates that you have not selected to run a full cost implosion and therefore the costs of the excluded items may not be up to date.

The message: BOM costs may be incorrect due to last implosion run. Ok to continue? is displayed in the following programs:

You are prompted to continue or exit.

Maximum number of decimals in quantity per

Indicate the maximum number of decimal places (up to 6) that is allowed when making an entry at the structure's quantity per field.

Default operation movement time

Indicate the default time required for an operation to move between work centers.

This entry is used only when a movement matrix for the work center is not defined.

Default description of time units

Indicate a description of the time units applicable to your company.

This description is displayed throughout the manufacturing modules whenever a field relates to a time unit.

Save

Select this to save the selections you made on all the tab pages and to exit the program.

Print

Select this to print a report of your Bill of Materials setup options.

It is advisable to keep this report for disaster recovery purposes.

Cancel

Select this to exit the program without saving any changes you made.

Help

Select this to view the latest online Help documentation for this program.

Sequencing

Field Description
Structure sequencing

Structure sequencing required

This assigns a sequence number to each structure added using the Structures and Routings program.

This applies when you have multiple occurrences of the same parent/component combination.

Within the Bill of Materials module, it can also be used as a method of printing components in a sequence other than by stock code.

Milestone operations are used when sequence checking is selected. If sequence checking is required, then SYSPRO always assumes that there should be at least one milestone operation and that you would typically post labor to that operation.

Sequencing key

Numeric

Select this to set the sequencing key to numeric.

If you select this option, then you can change the sequence of components assigned to the parent stock code (see Resequence Materials).

Alphanumeric

Select this to set the sequencing key to alphanumeric.

Both numeric and alphabetic characters can be assigned as the component sequence.

[Note]

Re-sequencing of components only applies to numeric sequence keys.

Default sequence number

Indicate the default sequence number (numeric or alphanumeric) that must be used when adding structures using the Structures and Routings program.

If structure sequencing is not required, then the entry defined here is still assigned to each structure added, in case you enable this feature at a later stage.

AB Costing

Field Description
Activity based costing required
[Note]
  • You can only activate Activity based costing if you installed the Inventory and Bill of Materials modules.

  • You cannot access any AB Costing options when Inventory cost to be held in a unit of measure other than stocked (Inventory Setup) is enabled.

Yes

Select this to apportion elements of cost for a product at the point of transition in the purchasing, manufacturing and sales cycle.

This enables you to more accurately attribute overhead costs to specific products.

No

Select this if you do not want to implement activity based costing.

Yes, but costs not updated

Select this to use the Activity Based Costing system for reporting purposes only (i.e. no costs are updated).

If you select this option, then the ABC fields are accumulated in parallel with conventional costs when the Cost Implosion program is run, but only the conventional costs are used in the accounting system.

Descriptions for user defined fields

Description for field 1 - 3

Indicate your own wording for the three user-defined fields displayed in the Browse on Element Descriptors program.

Element descriptors are assigned to stock items to establish their recovery costs at points of transition in the purchase, manufacturing, and sales cycle.

Engineering Change Control

Field Description
Structure and routing archiving

Batch

Select this to archive bill of material changes manually using the Structure and Routing Archive program.

You can archive prior revisions/releases of products according to selection criteria.

[Note]

An ECC Bill of Materials can be selected for archiving only when an engineering change order is moved to a status that accepts the changes made to the bill of material.

Immediate

Select this to archive a Bill of Materials automatically at the time of moving an engineering change order to a status that accepts the changes made to the bill of material.

Immediate (prompted)

Select this to be prompted to archive a Bill of Materials at the time of moving an engineering change order to a status that accepts the changes made to the bill of material.

[Note]

If you choose not to archive the bill of material when prompted, then you can still archive the bill of material manually using the Structure and Routing Archive program.

Set (---/---) to current rev/rel

Select this to set the revision/release for an ECC controlled component to the current revision/release when using the Structure and Routing Archive program to archive bills of materials.

When you retrieve the Bill of Materials from archive, the revision/release saved at the time of archiving is retained.

If you select this option then instead of the structure record being archived with --- in the component's revision and release it is archived with the actual current revision/release. This means that any future use of the archived BOM Structure record will use what was the current revision/release of the component at the time of archiving.

This option applies only when you enable the Use current option when adding an ECC component to an ECC controlled bill of materials in the Structures and Routings program.

If you do not select this option, then any bill of materials which has the revision/release marked as current (i.e. ---/---) is archived exactly as that. When you retrieve the bill of materials from the archive, the revision/release for the component is replaced by the revision/release which is current at the time of retrieval.

Stock control level

Stock code

Select this to control your engineering changes at stock code level.

Choosing this method leads to different iterations of a bill of material for the same stock code.

You typically choose this option if you want to formalize the procedures for changing your bill of materials, but do not need to retain previous iterations of the bill.

Revision

Enable this to control your engineering changes at revision level.

When processing purchase orders, sales orders and jobs you will be required to indicate the revision level to use.

See also: Glossary.

Release

Enable this to control your engineering changes at release level.

When processing purchase orders, sales orders and jobs you will be required to indicate the revision and release level to use.

[Note]

If you change from release to revision, then you won't be able to view or maintain bills for ECC-controlled items. Before changing the stock control level, you must unset ECC for all items.

See also: Glossary.

ECC

Initial ECO status

This indicates the first status in your workflow. All engineering change orders are assigned this status when they are created.

[Note]

You can prevent users from creating engineering change orders by denying them the authority to access the initial engineering change order status (see ECC Status Authorities).

Default ECC user

This indicates the engineering user to use when no responsible user has been assigned to an ECC-controlled stock item.

User defined fields

For all these fields, when spaces are held against a field then the original wording is displayed for that field.

Revision

Enter the default wording to display for the Revision field throughout the system.

Release

Enter the default wording to display for the Release field throughout the system.

Rev

Enter the default wording that you want to display for the Rev field throughout the system.

Rel

Enter the default wording that you want to display for the Rel field throughout the system.

Deplete oldest Rev/Rel first  
Allow issues from multiple rev/rels

Enable this to allow the creation of more than one allocation against the same job at the time of issuing ECC material allocations to the job and depleting the oldest revision/release.

This is only available when Deplete oldest rev/rel first (Component) under Job creation is enabled.

When you enable this option, all ECC components against BOMs and jobs with an ECC consumption method of Use oldest are set to Use current (Structures and Routings).

An allocation is created per revision/release, from the available quantity to issue of the rev/rel, for the quantity required for the job.

When not enabled, it prevents mixing different revisons/releases in one transaction when issuing ECC components to a job or when backflushing using the Inventory Movements program if Deplete oldest rev/rel first during Backflushing is enabled. In this case, the oldest rev/rel is not depleted when there is insufficient quantity to issue and the next single revision/release with sufficient quantity on hand is used instead.

Component reservation and depletion are mutually exclusive, so this option is not available when Reserve stock for allocations is enabled (WIP Setup).

Engineering change orders

Allow cosmetic changes

Indicate how the Revison/Release of an item is affected by cosmetic changes made to an Engineering Change Order.

Field Description
No Enable this to indicate that no changes are cosmetic. The Revision/Release is changed for each ECO change made.
Automatic control

Enable this to allow the system to decide if the changes are cosmetic or major.

Components added and deleted are considered significant changes, as are changes to the following fields:

  • Revision (Component)

  • Release (Component)

  • Unit of Measure

  • Quantity per

  • Fixed quantity flag

  • Parent per fixed quantity

  • Structure on date

  • Structure off date

  • Include from job number

  • Include to job number

  • Scrap percentage

  • Scrap quantity

  • Warehouse to use

When checking for cosmetic changes, if a structure or routing is not found, then the item is assumed to be a component and its revision/release is changed.

When saving cosmetic changes for an affected parent item, if a component against the BOM of the parent is also an affected item, then this component revision/release is not applied to the parent, as this constitutes a major change. This applies even if the component revision/release is changed at the time of applying BOM changes (Change Orders).

Manual control

Enable this to allow the operator to decide whether the changes are cosmetic or major.

The following prompt is displayed when changes are made to an ECO:

Are the changes for the affected items cosmetic? If yes, then the revision of the " " affected items will not be changed. If no, then the revision of the affected " " items will be changed.

Roll-up ECO changes to update parent

With this option selected, if you are applying BOM changes to an ECO, and if a component revision/release has changed then the component revision/release will be updated against BOMs of affected parent items in which the component exists.

If structure amendment journals are required, then an amendment journal is created reflecting the change in the component revision/release.

[Note]

If a component revision/release against the BOMs of affected parents is current (i.e. the component revision/release is the same as the current revision/release of the component before it was updated) then the component revision/release against the BOM is updated automatically with the new revision/release of the component irrespective of this option.

If the component revision/release against the BOMs of affected parent items is '--' then this option would also not be applied.

Track release

Enable this to apply a check (at the time of applying BOM changes) to establish whether major or minor changes were made against the BOM.

The purpose of this option is to prevent SYSPRO incrementing the release number of an item when only minor changes were made to the BOM. Minor changes are changes that do not materially impact the composition or functionality of the part. For example correction of a misspelling on a circuit board, change in the title or font size for printing, change in printed schematic not affecting connectivity or components, change in the allocated labour time against the BOM, etc.

When changes are made to a component in a BOM, the sub part is allocated a new Release level. This leads to SYSPRO identifying a shortage of the sub part at the current Release level while ignoring perfectly usable stock on hand of an earlier Release even though they are perfectly interchangeable. Enabling this option means you can ignore insignificant changes in a BOM and keep the Release level the same.

Components added and deleted are considered major changes, as are changes to the following fields:

  • Revision (Component)

  • Release (Component)

  • Unit of Measure

  • Quantity per

  • Fixed quantity flag

  • Parent per fixed quantity

  • Structure on date

  • Structure off date

  • Include from job number

  • Include to job number

  • Scrap percentage

  • Scrap quantity

  • Warehouse to use

When any major change is made against the BOM, the Revision must be changed, otherwise the operator can select a revision or release and save the changes. When the operator selects to change the Release, the BOM is updated without changing the revision.

[Note]

When checking for minor changes, if a structure or routing is not found, then the item is assumed to be a component and the only change that can be applied is a change to the revision of the item.

When changing the release for an affected parent item and a component against the BOM of the parent is also an affected item, then the component's revision is not applied to the parent, even if the component's revision is changed at the time of applying BOM changes. The reason is that this constitutes a major change.

When this option is enabled, the revision and release of an item are stored on both the ECC Detail and the ECC Revision History tables. The release can only be seen in the ECC module.

The InvMaster (INVMST) table only ever holds the revision. The BomStructure (BOMMST) and tables BomOperations (BOMOPS) tables only ever hold the revision.

The Allow non-sequential entries option only applies to the revision and not the tracked release when the Track release option is enabled.

This option is only available when the Stock control level is set to Revision.
Job creation

Indicate the revision/release to use (i.e. the consumption method) for jobs created from the Bill of Materials.

No default for rev/rel

Enable this to force the manual entry of a revision/release at the time of adding components to a job.

Blanks are displayed at these fields as the system does not assume a default revision or release.

Default to current rev/rel

Enable this to assume the current (latest) revision/release by default at the time of adding components to a job.

Although the current revision/release is displayed by default, it can be overridden.

Assume current rev/rel at time of adding job

Enable this to assume the current (latest) revision/release levels at the time of adding components to a job.

Your selection at the Stock code level field determines whether the revision and/or release can be entered.

Apply current at job creation (Component)

Enable this to change the BOM components with an ECC consumption method of Use current to a consumption method of Specific and to set the current revision and release against these allocations when creating a job (Structures and Routings).

This means that when you create a job and a BOM component uses the ECC consumption method - Use current, (Structures and Routings) then the ECC consumption method of Specific can be used when creating the allocations.

Deplete oldest rev/rel first (Component)

Enable this to issue the oldest revision/release when issuing components to a job. This enables you to ''use up'' the oldest ECC components first.

In addition, you can specify whether multiple revisons/releases of components can be issued to the job by setting the Allow issues from multiple rev/rels option.

When you deselect this option:

  • All components in all bills of materials that were set to Deplete oldest (Structures and Routings) are changed to Use current and the revisions/releases are set to '---/---' for the components.

  • All material allocations against existing jobs are set to Use current and the revision/release fields are set to spaces.

You cannot deselect this option if a MRP snapshot exists and any material allocations in the snapshot tables (MRPMAL and MRPSML) are set to Deplete oldest. The snapshot must be deleted before you can deselect this option.

Depletion and component reservation are mutually exclusive so this option is not available when the Reserve stock for allocations option is enabled (WIP Setup).

You will be unable to create subjobs for ECC items set to deplete oldest. Subjobs are created for specific revision/releases of an item; in this case you are not wanting to deplete from the oldest.

Purchase order creation

These options apply to the creation of purchase orders for ECC items.

No default for rev/rel

Enable this to force the manual entry of a revision/release at the time of adding a purchase order.

Blanks are displayed at these fields as the system does not assume a default revision or release.

Default to current rev/rel

Enable this to assume the current revision/release by default at the time of adding a purchase order.

Although the current revision/release is displayed by default, it can be overridden.

Assume current rev/rel at time of adding order

Enable this to assume the current revision/release levels at the time of adding a purchase order to the system.

[Note]

Your selection at the Stock control level field determines which fields (i.e. revision and/or release) are affected.

Inventory movements

These options apply to the creation of Inventory movements for ECC items.

No default for rev/rel

Enable this to force the manual entry of a revision/release at the time of adding an Inventory movement transaction to the system.

Blanks are displayed at these fields as the system does not assume a default revision or release.

Default to current rev/rel

Enable this to assume the current revision/release by default at the time of adding an Inventory movement transaction to the system.

Although the current revision/release is displayed by default, it can be overridden.

Assume current rev/rel at time of transaction

Enable this to assume the current revision/release levels at the time of adding an inventory transaction to the system.

[Note]

Your selection at the Stock control level field determines which fields (i.e. revision and/or release) are affected.

Deplete oldest rev/rel first during Backflushing

Enable this to issue the oldest revision/release when issuing components during backflushing.

This is only available when Deplete oldest rev/rel first (Component) under Job creation is enabled.

You should also select the Allow issues from multiple rev/rels option to ensure that when the oldest rev/rel does not have enough quantity on hand for the issue, the remaining amount from the next rev/rel is depleted.

If Allow issues from multiple rev/rels is not enabled, then the oldest rev/rel is not depleted even though it is flagged to deplete oldest. This only happens if the oldest rev/rel has an insufficient quantity to issue. In this case the system skips the rev/rels with insufficient quantities and issues from the next rev/rel that has enough on hand.

Sales order creation

These options apply to the creation of sales orders for ECC items.

No default for rev/rel

Enable this to force the manual entry of a revision/release at the time of adding a sales order.

Blanks are displayed at these fields as the system does not assume a default revision or release.

Default to current rev/rel

Enable this to assume the current revision/release by default at the time of adding a sales order.

Although the current revision/release is displayed by default, it can be overridden.

Assume current rev/rel at time of adding order

Enable this to assume the current revision/release levels at the time of adding a sales order to the system.

Assume current rev/rel at time of shipping order

Enable this to assume the current revision/release levels at the time of shipping the order.

[Note]

Your selection at the Stock control level field determines which fields (i.e. revision and/or release) are affected.

Numbering

[Note]

You should not change your method of numbering once it has been defined and used, as this could compromise your access to that data.

Field Description
Engineering change order numbering

This indicates the method according to which you want to generate engineering change order numbers.

Alpha

Select this to set engineering change order numbering to be alphanumeric.

Numeric

Select this to set your engineering change order numbering to be numeric.

Manual

Select this to enter engineering change order numbers manually.

Automatic

Select this to let the system to generate engineering change order numbers automatically.

Next ECO number

Indicate the next engineering change order number that must be used.

Revision numbering

This indicates the method according to which you want to generate revision numbers.

Alpha

Select this to set your revision numbering to be alphanumeric.

Numeric

Select this to set your revision numbering to be numeric.

Manual

Select this to enter revision numbers manually.

Automatic

Select this to let the system to generate revision numbers automatically.

Release numbering

This indicates the method according to which you want to generate release numbers.

Alpha

Select this to set your release numbering to be alphanumeric.

Numeric

Select this to set your release numbering to be numeric.

Manual

Select this to enter release numbers manually.

Automatic

Select this to let the system to generate release numbers automatically.

Revision and release numbering  
Allow non-sequential entries

Select this to be able to apply a revision/release which is smaller than the current revision/release when you apply a new revision/release through an ECO (see ECC Change ECO status).

A warning message is displayed, but you can proceed.

This option applies when your stock control level is set at revision or at release level.

[Note]
  • This option does not apply when both Revision numbering and Release numbering are set to Automatic. In that case your selection here is ignored.

  • The Allow non-sequential entries option only applies to the revision and not the tracked release when the Track release option is also enabled (Engineering Change Control tab).

If you do not select this option, then when you apply a new revision/release through an ECO, you cannot apply a revision/release which is smaller than the current revision/release.

For example:

You want your Revision to indicate where the item is in the plant and the Release to be the iteration within that.

Assume you have:

  • DES - Design and engineering
  • PRD - Production beta
  • STD - Standard production

When you initially design the item, the revision/release = DES/001. You then beta produce it and the revision/release = PRD/001. Finally you put it into standard production and the revision/release = STD/001.

Assume you now want to put it back into design to make some changes, so you want to allocate it a revision/release of DES/002. If you select this option, then you can set the revision/release to DES/002. If this option is not selected, then the system will prevent you from doing this.

Increment release within revision

When you select his option and you update the revision/release of items within an ECO and you go back a revision, the release is incremented from the last release within the revision. This applies when release numbering is automatic.

If you don't select this option, then the release numbering starts at zero again.

This only applies when you enable the Allow non-sequential entries option.