Case 5. Concurrent engineering between product design and manufacturing

The engineering BOM (E-BOM) created by a product designer represents the parts structure of a product. On the other hand, manufacturing BOM (M-BOM) is created by production managers after the engineering BOM has been created, by verifying the productivity and adding inventory information and ordering information of parts. Therefore, rework in product design occurs frequently even after completion of product design work. As a result, frequent occurrence of such rework in product design may cause the problems such as failure to meet the deadline.

In addition, manufacturing equipment cannot be standardized due to unavailability of information pertaining to manufacturing equipment from product designers. As a result, fixed cost gets increased at the time of changing production lines or set-up of new manufacturing site which can lead to the major impact on capital investment. BOP will play an important role in order to resolve such kind of problems.

Specifically, highly accurate M-BOM can be created, by defining a BOP between E-BOM and M-BOM and mediating it between both BOMs to facilitate communication between product design, production engineering and production control.

In addition, giving early feedback on productivity verification results to product design work prevents the occurrence of rework in product design process and accelerating collaborative design between product design and production engineering can significantly reduce product development lead time. In addition, it is expected that fixed cost can also be reduced with the standardization of manufacturing equipment, by promoting product design that is conscious of production equipment and processes from the time of product design.

Case 6. Realization of Smart factory and Digital transformation for manufacturing industry

The BOM and BOP, which are standard information for manufacturing as defined in PLM, are the core that strengthens the linkage between the engineering chain and the supply chain and links each system seamlessly to realize a manufacturing system that is resistant to change. In this system, BOM is linked with SCM and ERP and will be transferred to production planning and procurement. In addition, BOP is also transferred to the MES and gets connected to the manufacturing site as manufacturing instruction information and enables the fast and accurate transmission of design change information to the manufacturing site.

In addition, it has become now possible to collect and visualize the results of manufacturing sites, by using IoT technology. As a result, BOP such as line configuration and production equipment setting conditions can be optimized continuously, by comparing and analyzing the actual value of the production equipment and the reference value of BOP. Production efficiency can be continuously maximized across the company by collaborating PLM, MES and IoT, and executing PDCA cycle in product development

In addition, the strengthening of collaboration between Cyber and Physical and further evolution and utilization of AI technology will realize a smart factory that can supply the parts in line with multi-product production and control processes and equipment autonomously based on the detection of abnormalities in production equipment. Furthermore, it also supports quick management decisions to ensure business continuity and profitability by integrating all information into the cyber domain and realize DX (digital transformation) in the manufacturing industry.

In order to survive in the era of New Normal, we believe it is important for manufacturers to strengthen their business transformation capabilities that respond quickly and flexibly to unforeseen circumstances, and supply products continuously to the market. In addition, we believe that BOP can make a significant contribution to the realization of such system.

We hope that this column will help your organization to make the use of BOP effectively in manufacturing.