Bill of Materials and Assemblies

Overview

Inventory → Inventory → BOM Lines | Inventory → Inventory → Assemble

The Bill of Materials (BOM) system manages assembly structures and component relationships for manufacturing operations. It defines what components are needed to build assemblies and integrates with work orders for production management.

Creating Bill of Materials

BOM Setup Process

1. Navigate to Inventory → Inventory → BOM Lines
2. Select assembly item (must have Make flag enabled)
3. Add component lines:
   • Component: Select part number
   • Quantity: Units needed per assembly
   • Yield %: Material loss factor
4. Click “Save” to store BOM structure

BOM Operations

• Copy BOM: Duplicate existing BOM for new assembly
• Component Reports: Generate detailed component listings
• Cost Reports: Calculate assembly costs from component costs

Assembly Methods

Inventory Pro provides two methods for assembling items. Choose the method that best fits your operational needs:

Direct Assembly (Assemble Stock)

Access: Inventory → Inventory → Assemble

Security: Security ID 40 (Assemble Stock)

Direct assembly allows you to build assemblies immediately without creating a work order. This is ideal for quick, one-off assemblies or when work order overhead isn’t needed.

Assembly Modes

Assemble Mode - Build new assemblies from components:

1. Navigate to Inventory → Inventory → Assemble
2. Select Assemble mode
3. Choose assembly from dropdown
4. Enter quantity to build
5. Click Load All to populate BOM components
6. Review and adjust components if needed
7. Click Assemble to complete

Replacement Mode - Replace components in existing assemblies:

1. Select Replacement mode
2. Choose existing assembly
3. Enter new components
4. System archives old components and adds new ones

Exchange Mode - Swap components returning old to stock:

1. Select Exchange mode
2. Choose existing assembly
3. Enter new components
4. System returns old components to stock and consumes new ones

Admin Option 219: Controls whether job association is available during direct assembly.

Work Order Assembly

Access: Work Orders → [Select Work Order] → Line Items → Assemble

Security: Security ID 159 (Work Orders / BOM)

Work order assembly provides full production planning with cost tracking, job costing, labor time tracking, and approval workflows.

Workflow:

1. Create a work order (Orders → Work Orders → Create Work Order)
2. Select assembly and quantity on the work order header
3. Navigate to Line Items tab
4. Click Load Top or Load Assembly to load BOM components
5. Components are scaled to the work order quantity
6. Review committed stock and availability
7. Click Assemble to consume components and produce assemblies

Work Order Advantages:

• Cost tracking and variance analysis
• Job/customer assignment for billing
• Labor time recording
• Approval workflows
• Production sequence planning
• Complete audit trail

Choosing Between Methods

Work Order Integration

The BOM system connects to work orders for production planning:

• Component Loading: Work orders auto-load BOM components
• Quantity Scaling: Components scaled by work order target units
• Cost Integration: BOM costs feed into work order estimates
• Progress Tracking: Assembly operations update work order status

Key Features

• Multi-Level BOMs: Assemblies within assemblies
• Serial Tracking: Component and assembly serial numbers
• Job Integration: Link assemblies to customer jobs
• FIFO Selection: Auto-select oldest components first
• Yield Calculations: Account for material waste and efficiency

The BOM system provides essential assembly structure management with seamless integration to work orders for complete production control.