2016 International Conference on Applied Mathematics and Mechanics (ICAMM 2016)

ISBN: 978-1-60595-399-1

A Bill of Material Transformation Method

for Design-Manufacturing Integration

Wei MU1, Chun-liu ZHOU2,*, Hong-guang BO2 and Jun-yi LIANG1

1
Department of Production Management, CRRC Qingdao Sifang CO., Ltd., Qingdao, 266109, China
2
Department of Management, Dalian University of Technology, Dalian, 116023, China
*Corresponding author

Keywords: BOM, DMI, Feature reorganization, ERP, PDM.

Abstract. In order to support design–manufacturing integration (DMI), a transformation method is

proposed by recognizing the features of EBOM and MBOM, to effectively ensure data integrity,
correctness and consistency in systems. By defining different components, the transformation
processes are identified and a formal transformation model of BOM view is proposed. Then, rules for
BOM transforming and conversion algorithms are described. Engineering change problems also are
solved by processing rules. This research has achieved an automatic conversion of BOM. Finally, the
practical application in the enterprise indicated that this method is effective for DMI.

Introduction
Design–manufacturing integration (DMI) activities can raise an organization’s ability of
identifying and effectively addressing product process design interdependencies [1], in which
computer systems and data integration plays a vital role. Bill of material (BOM) is initially defined in
the product drawings and then converted into different BOM definitions and configurations, which
are extended throughout the product life cycle. BOM is core data in production industry, which is the
bridge of product design and manufacturing [2]. BOM is the technical description document of a
product structure. During the implementation of computer integrated manufacturing systems, most
manufacturing companies have applied Enterprise Resource Planning (ERP) system and Production
Data Management (PDM) system. Each system is controlled independently in different department,
which leads to inefficient information communication and interaction between two systems and exist
reduplicative BOM data, and lack of data integrity and consistency [3].
Thus, manual intervention has to be used to coordinate consistency of BOM information. This
phenomenon has seriously influenced integration of product design, manufacturing and management,
even extended time for product development. In order to propel DMI, this paper proposes a
transformation method based on feature recognition, which focuses on the transformation from
Engineering BOM (EBOM) to Manufacturing BOM (MBOM).

BOM Views in PDM and ERP

Introduction of EBOM and MBOM

BOM information of a product in PDM system and ERP system respectively has two different BOM
views, EBOM in PDM and MBOM in ERP.
EBOM is used to describe product design structure for organizing and managing list of parts in
product design department. Designers design products according to customers’ requirements and
design needs. After finishing design, information which derives from design drawings, including
product name, product structure, and assembly relationship among parts, makes up EBOM.
MBOM is used to organize and manage lists of materials in actual production process of
manufacturing department. MBOM generates from EBOM. Because manufacturing information is

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more complicated than design information, MBOM is more complicated than EBOM naturally,
which reflects assembly structure and manufacturing information of self-made parts. MBOM is
significant for operations management, especially in computing MRP. Amounts and arriving time of
all required materials can only be known from BOM, which is also used to make a plan for
manufacturing and purchasing.
Thus, there exist essential differences between EBOM and MBOM. EBOM is a technical file while
MBOM is a managerial file. More exactly, MBOM is a core business information model which
synthesizes information of sales, manufacturing and supply.
Figure 1 shows the differences in structure between EBOM and MBOM. In the figure, letters
represent parts and numbers shows assembly relationship in quantities between father-node and
sub-node [4].
Purchased
Virtual Outsourcing component
component M component

a|2 b|3 c|3 d|2 e|2 f|2

c1|2 c2|1 d1|3 d2|2

g|1 c1|6 c2|3 d|2 e|2 f|2

Intermediate Inherited
a|2 b|3 component component

Figure 1. Structure of EBOM and MBOM.

Math Model for EBOM and MBOM

In order to accurately define the mapping functions of EBOM and MBOM according to their
characteristics, mathematical descriptions are shown respectively as follows.
EBOM contains properties like father-node codes, sub-node codes, versions, required amounts,
total amounts, process backup amounts, start time, end time and so on [5].
Definition 1. A triple (A, C, Q) is used to denote EBOM, noting for EBOM = (A, C, Q). Wherein, A
is a set of components ai (i  1, 2, , m) ; C is a set of components assembly relation cij , which
represents the assembly relation between ai and a j ; Q is a set of the number of components in the
assembly, qij  q(cij ) , which represents that a parent component is made up of qij sub-parts in an cij
assembly relationship. Thus, it is listed for figure 1 case as below:
A  {M , a,b,c,c1 ,c2 ,d ,d1 ,d 2 ,e,f } ;
C  {( M , a),( M ,b),( M ,c),( M ,d ),( M ,e),( M ,f ),( c,c1 ),( c, c2 ),( d ,d1 ),( d , d 2 )}；
Correspondingly, Q  2,3,3, 2, 2, 2, 2,1,3, 2
Definition 2. A seven-tuple (AM,CM,QM,Z,X,R,T) is used to denote MBOM, noting for
MBOM=(AM,CM,QM,Z,X,R,T). Wherein, AM is a set of components aiM in MBOM; CM is a set of
components assembly relations cij in MBOM; QM is a set of assembly number qij ; Z is a set of the
M M

process state zij of parts, which is the j th process state description of components aiM ; X is a set of
processes xij ,which represents the j th process; R is a set of resources rij , which means resource

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occupied by process j; T is a set of work hours tijk which represents the time consumed by part aiM in
process j with resource k. Thus, it is listed for figure 1 case as below:
AM  {M , g , a,b,c1 ,c2 ,d ,e,f } ; C M  {(M , g ),(M ,c1 ),(M ,c2 ),(M ,d ), ( M ,e),( M ,f ),( g ,a),( g , b)}；
Correspondingly, QM  {1,6,3, 2, 2, 2, 2,3}
As it can be seen from the above definition, the elements contained in MBOM differ from ones in
EBOM, which makes it more difficult to achieve conversion from EBOM to MBOM [6]. To ensure the
consistency of BOM data conversion, this paper introduces PPBOM (Process Planning BOM)
concept [7]. PPBOM information mainly comes from process sector, which includes: the product
process design documents and assembly process design document.
Definition 3. A six-tuple (A,S,Z,X,R,T) is used to denote MBOM, noting for
PPBOM=(A,S,Z,X,R,T).
Wherein, A is still a set of part ai(i=1,2,…m); S is a set of parts production type properties, which
describes not only the type of production of its components (homemade member, the association
member, purchased parts), but also the state whether the component is virtual, intermediate or
inherited parts, Si(i=1,2,…m) defines the production type attribute. As shown in figure 1,
A  {M , a,b,c,c1 ,c2 ,d ,d1 ,d 2 ,e,f }
Correspondingly, S  I s , M s , M s , Vs , Vs , Vs , Cs , Cs , Cs , Ps , I s 
Wherein, I s denotes inherited component; M s denotes intermediate component; Vs denotes virtual
component; Cs denotes outsourcing component; Ps denotes purchased components. Other letters have
the same meaning as described in EBOM and MBOM. In EBOM to MBOM conversion process, the Z,
X, R, T information of MBOM can be obtained directly from PPBOM [8]. AM can be re-set from the the
production of the type attribute and the set A of parts in EBOM. CM and QM both can be got from the
C and Q of EBOM. Figure 2 shows the systematic transformation process.

Design EBOM
PDM

1 Manufacturing Resource
PPBOM 2 Factory Planning
Process
3 Virtual Validation
4 Assembly Animation

Manufacturing MBOM
ERP

Figure 2. BOM transformation process.

Transformation Rules from EBOM to MBOM

In order to be convenient, CI is defined as a set of all the inherited components, CV is a set of all the
virtual components, C M is a set of all the intermediate components, CC is a set of all the outsourcing
components, and C P is a set of all the purchased components. Various types of processing rules in the
transformation are given below.
Transformation Rules of Inherited Components
For product P, if component ai in EBOM is an inherited component, then the assembly relation is the
same in MBOM with the relation in EBOM. The mathematical description is as follows:

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  aiM  ai

ai  C I ,exists  cijM  cij (1)
q M  q
 ij ij

In formula (1), cijM and qijM respectively represent assembly relationships and the number of
assembly in MBOM. Here, cij and qij respectively represent assembly relationships and number of ai
and a j assembly of in EBOM.
Transformation Rules of Virtual Components
If there is virtual component in EBOM / PBOM, then its sub-parts and the relations can be moved to
its parent component in MBOM. The mathematical description is as follows: ai  CV , ak is the
parent part of a i , a j is the child part of a i , there exists

 ai  AM

cij  C ; ckj  C
M M M
(2)
 q  q q
M
 kj ki ij

In formula (2), ckj  C represents the assembly relationship between ak and a j in MBOM, qki
M M

represents assembly number of a i for ak , qij assembly number of a j for a i .

The algorithmic process of virtual component mapping rule is as follows:
Step1: Put all the virtual components into a “P-Stack (P means a part)”.
Step2: When P-Stack is not null, assign an element in the stack to P, or go to Step 9.
Step3: Search the father ID of P and its assembly number towards its father component in EBOM.
Step4: Search all the child parts of P, including information like child ID and assembly number, and
then keep them in “C-Stack (C means child part)”.
Step 5: When C-Stack is not null, assign an element in the stack to C; or go to Step 6.
Step 6: Change the ID of C’s father to the “father ID”, assembly number is the result of multiply.
Step 7: Go to Step 5.
Step 8: Go to Step 3.
Step 9: Over.
Transformation Rules of Intermediate Components
If there is an intermediate component, then add the parent-child relations and the relevant process
requirements to MBOM. The mathematical description is as follows:
M
a  C , a is the child parts of ai , ak is the parent parts of a j , there exists:
M M
i M j

 a Mj  a j
 M
cij  C ; cki  C
M M M
(3)
 qM  q ; qM  1
 ij kj ki

In formula (3), cij  C and ckiM  C M represent respectively the assembly relationship between aiM
M M

M
and a j , and the relationship between akM and aiM .
The mapping process of intermediate components is similar to the mapping process of virtual
components, which will not be mentioned here.
Transformation Rules of Outsourcing/ Purchased Components
Outsourcing components generally exists when enterprise outsources a process or a whole component
to other manufactures due to its capacity and cost restrictions. For the process outsourcing
components, the transformation rule is the same with inherited component, but the description is
marked as outsourcing on the process. For the whole outsourcing component, only the component is
described in MBOM, no information about its child parts are listed. Thus, this kind of outsourcing
components can be dealt as a part in MBOM.

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 Since purchased component come from outside company, it can be dealt with in the same way with
the whole outsourcing component.
The mathematical description is as follows: ai  CC , a j is the child part of ai , there exists

ai  AM ; a j  AM

 cij  C M (4)
 qij  Q M

In formula (4), cij  C M represents that the assembly relation between ai and a j is canceled in
MBOM. In the same way, qij  Q M represents that the assembly number relationship between ai and
a j is canceled in MBOM.
In summary, in accordance with the four rules above, transformation function from EBOM to
MBOM is: MBOM  fC ( f M ( fV ( f I ( EBOM , PPBOM )))) , where
fI — Transformation function of inherited components
fV —Transformation function of virtual components
fM —Transformation function of intermediate components
fC —Transformation function of outsourcing/purchased components
Transformation Rules for Engineering Change in BOM
In the enterprise actual production process, engineering change is an act frequently encountered, such
as the introduction of new parts, upgrade older parts, modifications of the reference document. These
changes may result in changes of BOM, leading to changes of EBOM and MBOM. Therefore, in the
conversion process from EBOM to MBOM, we must consider the impact of engineering changes to
the BOM conversion. Since most of the engineering changes are based on the BOM change, BOM
change is divided into two categories, namely: non-structural BOM changes and structural BOM
changes.
DEFINITION 4: Non-structural changes mean although the change exists in product, the
description of production type in PPBOM to EBOM does not change. For this situation, MBOM can
be getting via inherited mapping from EBOM.
DEFINITION 5: Structural changes generate when the description of production type in PPBOM to
EBOM changes, leading to the assembly structure of virtual, intermediate, outsourcing or purchased
components different in EBOM and MBOM. In this situation, the transformation from EBOM to
MBOM by judging production type of parts and dealing in each rule respectively.
By defining transformation rules and BOM engineering changes, automatic conversion process is
shown in figure 3.
If it is non-structural
change of BOM?
Start

Extract
Inherited
EBOM
Component?
Y fI
/PPBOM

Virtual
Component
Y fV

Intermediate
Component
Y fM
Product
redesign N

Outsourcing/Purc
hased Component
Y fC

Data check
and
If it is structural feedback
change of BOM?
Get
MBOM
N

End

Figure 3. The process of transformation from EBOM to MBOM.

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Case Study
Figure 4 shows an example of transformation from EBOM to MBOM of a locomotive production. In
EBOM, according to actual assembly, the cab will be put on the locomotive body after it is assembled,
thus Cab general view is a virtual component, which will not show in MBOM. In the assembly of
Diesel generator installation, due to the requirement of process, flange (1) and flange (2) must be
assembly first to be an assembly part- elastic flange assembly, and then it will be drilled and stored. So,
the elastic flange assembly is an intermediate component. Besides, although windshield assembly is a
sub-part of cab general view in EBOM, it is the last one to be assembled in actual operations, then its
position changes in MBOM relative to EBOM.

Conclusion
This study built a transformation model by recognizing the features of EBOM and MBOM to solving
the problem of overlaps and inconsistencies of BOM data in PDM and ERP systems for
design-manufacturing integration. By introducing inherited, virtual, intermediate, outsourcing,
purchased components and engineering change, as well as defining processing rules respectively,
automatic conversion has achieved. Focusing on testing and feedback of product data in the
conversion process ensures accuracy, completeness and consistency of BOM data. Practical
application verified that BOM conversion technology based on feature recognition is reasonable and
feasible. This method is hoped to be used in digital manufacturing environment and extend to
maintenance data management area to realize production life time management.
Transformation
EBOM MBOM
Diesel
Diesel locomotive assembly
locomotive assembly drawing109J000000
drawing109J000000 11 Diesel
Diesel locomotive assembly
locomotive assembly drawing109J000000
drawing109J000000 11
Bogie
Bogie assembly
assembly drawing
drawing 109Z000000
109Z000000 22 Bogie
Bogie assembly
assembly drawing
drawing 109Z000000
109Z000000 22
Systematic
Systematic drawing
drawing 109X000000
109X000000 11 Systematic
Systematic drawing
drawing 109X000000
109X000000 11
Body
Body assembly
assembly drawing
drawing 109T000000
109T000000 11 Body
Body assembly
assembly drawing
drawing 109T000000
109T000000 11
Brace
Brace assembly109T200000
assembly109T200000 11 Brace
Brace assembly109T200000
assembly109T200000 11
Cab
Cab general
general view
view 109T10000B
109T10000B 11 Cab
Cab steel
steel assembly
assembly 109T11000A
109T11000A 22
Cab
Cab roof
roof assembly
assembly 109T11100B
109T11100B 22 Cab
Cab roof
roof assembly
assembly 109T11100B
109T11100B 22
Cab
Cab steel
steel assembly
assembly 109T11000A
109T11000A 22 Cab
Cab headlamp
headlamp bezels
bezels 106T111101
106T111101 22
Cab
Cab headlamp
headlamp bezels
bezels 106T111101
106T111101 22 Cab
Cab door
door assembly
assembly 106T11100A
106T11100A 22
Windshield
Windshield assembly
assembly 109T11100C
109T11100C 22 Flange
Flange lubrication
lubrication system
system assembly
assembly drawing
drawing 109Q100000
109Q100000 11
Cab
Cab door
door assembly
assembly 106T11100A
106T11100A 22 Paint
Paint and
and decoration
decoration 109J020000
109J020000 11
Flange
Flange lubrication
lubrication system
system assembly
assembly drawing
drawing 109Q100000
109Q100000 11 Diesel
Diesel generator
generator installation
installation 109J010000
109J010000 11
Paint
Paint and
and decoration
decoration 109J020000
109J020000 11 Elastic
Elastic flange
flange assembly
assembly TJ003000-88
TJ003000-88 11
Diesel
Diesel generator
generator installation
installation 109J010000
109J010000 11
Flange Flange
Flange (2)
(2) TJ003003-88
TJ003003-88 11
Flange (2)
(2) TJ003003-88
TJ003003-88 11 Flange
Flange
Flange (1)
(1) TJ003002-88
TJ003002-88 11 Flange (1)
(1) TJ003002-88
TJ003002-88 11
Ball Ball
Ball head
head 106J011003
106J011003 22
Ball head
head 106J011003
106J011003 22 Theravada
Theravada Theravada 106J011002
106J011002 22
Theravada 106J011002
106J011002 22 Shimokura
Shimokura Shimokura 106J011001
106J011001 22
Shimokura 106J011001
106J011001 22 Transmission
Transmission assembly
assembly drawing
drawing 109F000000
109F000000 11
Transmission
Transmission assembly
assembly drawing
drawing 109F000000
109F000000 11 Cardan
Cardan shaft
shaft TF022000-87
TF022000-87 11
Cardan
Cardan shaft
shaft TF022000-87
TF022000-87 11 Transmission
Transmission shaftshaft TF021000-87
TF021000-87 11
Transmission
Transmission shaftshaft TF021000-87
TF021000-87 11 Hydrostatic
Hydrostatic transmission
transmission 106F200000
106F200000 11
Hydrostatic
Hydrostatic transmission
transmission 106F200000
106F200000 11 Start
Start transmission
transmission 106F110000
106F110000 11
Start
Start transmission
transmission 106F110000
106F110000 11 Electric
Electric equipment
equipment assembly
assembly drawing
drawing 109D000000
109D000000 11
Electric
Electric equipment
equipment assembly
assembly drawing
drawing 109D000000
109D000000 11 Preheating
Preheating system
system 106R000000
106R000000 11
Preheating
Preheating system
system 106R000000
106R000000 11 Air
Air system
system 106K000000
106K000000 11
Air
Air system
system 106K000000
106K000000 11 Windshield
Windshield assembly
assembly 109T11100C
109T11100C 22

Figure 4. Transformation process from EBOM to MBOM.

Acknowledgement
This research was financially supported by a project supported by National Science and Technology
Support Program, China (2015BAF08B02) and the State Key Program of NSFC (61533005).

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