BOM SOP Review Session

BOM SOP for standard machine:

The “What?”

Per my observations, Solid Works is crucial for the Design team. After receiving Technical Specifications
from Sales, the BOM team works to create the Design Input. This document has all sorts of machine
specifications and details, including machine data. Once that’s done, an internal meeting with the team
takes place and appropriate line drawings (2D) are created via ZWCAD.

On the SOLIDWORKS platform, the team works on the 3D model of the machine, right from drawings for
the Unwind Unit, Main Section and Rewind Unit, respectively.
 How?

How does the Design team process BOM (Bill Of Materials)?

The Design Team after creating the Line Drawing and 3D Model of the concerned machine, checks the
CAPA and DMR to ensure everything is followed accurately. Then they check the ROQ
and ROL list for stock consumption and store the 3D model and Line Drawing in the gallery.

Next, the BOM is generated from the 3D model and uploaded in the ERP system.
IS the SOP being followed? (Any suggestions?)

The SOP is being followed, overall, and as observed, a bit of coordination in each step within the
team would make things more efficient. For example, ULTRASLIT OHP - 15010 is the most recent
one being worked on. All the design engineers are looking after the 3D models via SOLIDWORKS
and Mr. Prashant is looking after the 2D drawings via ZWCAD, respectively. With time-to-time
reviews, the efficiency can go drastically up. Every once a week, Mr. Prashant could review all the
work progress to ensure maximum efficiency and effectiveness within the department.

As per my observation and understanding, it takes 2 to 3 days for the BOM team to create the
Sales BOM for a Standard Machine, 3 to 5 days for a non-standard (semi-customized) machine,
and 10 to 15 days for a non-standard (customized) machine, respectively. On the other hand, if
it’s a new project to be made from scratch, it takes 21 days for the BOM creation.
The Entire Standard Machine Sales BOM Process

The creation of Bill Of Materials by the Design Team at SP

ULTRAFLEX for a Standard Machine:
10. Store the Line Drawing and 3D model with an appropriate name
1. First, the Sales team sends in the Technical Specifications
to the BOM team 11. Generate BOM from this 3D model

2. Next, a machine allocating number is created

12. Upload BOM in ERP

3. Sales Order is created

13. Check all the design activities by Senior Engineer
4. Internal meeting takes place
14. Create/upload revised/new items master in ERP and then re-upload BOM in ERP
5. The Sales Design Input (DI) is formed

15. To upload drawings in the ERP

6. Line Drawing on the DI

7. Cross-check the Line Drawing with the Checklist and 16. Cross-check the BOM with the checklist and sign the checklist

Reference Item List

17. Upload production, commissioning details and master BOM
8. Check CAPA and DMR

18. Release BOM for MRP (Material Resource Planning) run

9. Check ROQ and ROL list for consumption
Non-standard (semi-customized and customized)
Machine Sales BOM Process
11. Prepare revised/new part drawings
1. First, the Sales team sends in the Technical Specifications to
the BOM team 12. Store the Line Drawing and 3D model with an appropriate name

2. Next, a machine allocating number is created

13. Generate BOM from this 3D model
3. Sales Order is created
14. Upload BOM in ERP
4. Internal meeting takes place

5. The Sales Design Input (DI) is formed 15. Check all the design activities by Senior Engineer

6. Line Drawing on the DI 16. Create/upload revised/new items master in ERP and then re-upload
BOM in ERP
7. Prepare the necessary calculation for the new/revised design
for validation
17. To upload drawings in the ERP
8. Cross-check the Line Drawing with the Checklist and
Reference Item List 18. Cross-check the BOM with the checklist and sign the checklist

9. Check CAPA and DMR

19. Upload production, commissioning details and master BOM
10.Check ROQ and ROL list for consumption
20. Release BOM for MRP (Material Resource Planning) run
 Inputs Received by Design from
Sales

The Sales team gets a lead and sends the inquiry sheet to a customer to understand their specific machine requirements and details.

Next, after receiving the inquiry, the Sales team creates the quotation. Once the customer approves of it, the Sales creates an order.

Later, based on the customer machine requirements and enquiry sheet, the Sales creates a document called Technical Specifications
and sends it to the BOM team. This document has all the machine specification details and data.

The BOM team creates the machine allocating number and sends it to Sales. The Sales prepares the Sales Order and sends it to the
BOM team.

The Design (BOM) team starts preparing the Sales Design Input for that particular machine, sends it to Sales for cross-checking and
circulates it to other departments by email.
Types of SALES BOM

BOM stands for Bill Of Materials for

purchasing the machine items and
parts for production.

The Design Team is responsible for

creating the Machine BOM and
Toolbox BOM. The Design team
creates two other BOMs apart from
the above-mentioned BOMs,
namely the Spares BOM and
Retrofit BOM.

On the other hand, the Pneumatic

and Electrical BOMs are created by
the Commissioning team.
 The process of releasing Spares BOM

1. First, the Spares Coordinator is intimated about the spare parts

2. Next, the BOM team sends the item part number and packaging details to the Sales
Coordinator

3. The Spares Coordinator then shares item part no. with the Purchase Dept. for quotation
details

4. Later, the purchase quotation is shared with the customer and if approved, then the Spares
Coordinator informs the Design team to release the Spares BOM
Retrofitting BOM
The same steps are followed for releasing the Retrofitting BOM except in this
case, the line drawings and 3D Models are already in place to match the
customer requirements precisely. In most cases, very few upgrades are required
to create the same machine part or item needed by the customer.
 The importance of CAPA and
DMR

CAPA stands for Corrective Action and Preventive Action. CAPA is used to mainly correct
or prevent a
problem and therefore, avoid (prevent) it in the future by taking corrective measures or
actions. Hence, it is reactive in nature. It can be used by any department in the
Company.

DMR stands for Design Modification Request. DMR can be used by any department but
mainly it is seen to be used the most by the Service and Sales Department. It is
proactive in nature.
TYPES OF SOFTWARE USED FOR DRAWINGS

For Line Drawing and 2D Drawings, ZWCAD is used.

Line Drawings are inclusive of the Machine Plan View

and Layout.

For the creation of 3D models and drawings,

SOLIDWORKS is used.

The various types of 3D Drawings include different

assemblies such as those of the Cutter, Dancer, Door,
Fabrication, Trim Blower, Laser, Layon, Mainframe, Nip,
Rewind, Unwind, Rotary Cutter, and the Master
Drawing.
What does the Technical Specifications document
contain?

The Technical Specifications document contains two parts, namely

Technical Specifications in general and Machine Description
consisting of the machine data related to the 1) unwind and nip
unit, 2) slitting and trim disposal unit, 3) cantilevered duplex
rewinding unit as well as 4) control cabinet and HMI human-
machine interface unit and 5) Included features if any.

It is created in a PDF format.

Examples of included features: Electromechanical or Linear Floor

Lift. Pneumatic Splice Table at Unwind. Motorized Ejector.

In general technical specifications of any machine would include

details about the machine type (Edition, Series, Version), core and
web width details, reel weight and diameter, tension range, razor
blades or rotary cutter quantity, operating speed, material
thickness range and dimensions.
What machine models does SP ULTRAFLEX
manufacture?

1. PRIMASLIT Series

Duplex Slitter Rewinder Machines- Compact

PRIMASLIT FL- 13000

PRIMASLIT RL- 14000

2. ULTRASLIT Series

Duplex Slitter Rewinder Machines- Separate Unwind

ULTRASLIT OHP- 15000

ULTRASLIT FSU- 16000

3. ROBOSLIT Series

Dual Turret Slitter Rewinder Machines- Compact

ROBOSLIT RL- 17000

Dual Turret Slitter Rewinder Machines- Separate

Unwind

ROBOSLIT OHP- 18000

ROBOSLIT FSU- 19000

4. ROBOSLIT PLUS Series

Dual Turret Slitter Rewinder Machines- Fully Loaded

ROBOSLIT OHP- 18100

ROBOSLIT FSU- 19100

5. DRM REV- 11000

Doctoring Rewinding Machine- Reversible

6. WIR REV- 12000

Web Inspection Rewinder- Reversible

7. Trim Winder

Duplex Slitter Rewinder series for PRIMASLIT and

ULTRASLIT series

Dual Turret Slitter Rewinder series for ROBOSLIT and

ROBOSLIT PLUS series.

8. MAXISLIT Series

Surface Winder

MAXISLIT RL- 24000

ROQ and ROL List for Stock
Consumption
ROQ- Reorder Quantity

ROL- Reorder Level

These refer to the yearly projections for standard machines through Master BOM including optional features.

The objectives of ROQ and ROL: 1) To develop machines in a timely fashion, 2) To reduce machine dispatch lead time as a result, 3)
To reduce the price of items bought in large quantity, hence at discounted rates from a commercial point of view, 4) To not delay
manufacturing as machine parts would already be there in stock at the store.

How does ROQ and ROL work?

The BOM team receives a Machine Projection List from the Management for manufacturing for that year. This List is forwarded to the
purchase HOD. The Management and Purchase Head decide how much ROQ and ROL quantity to keep.

What role does the Design Team have here?

The Design Team gives the quantity of ROQ and ROL for stock consumption to the Purchase Department via Master BOM once a year
at the start of the financial year.
SALES DESIGN INPUT (DI)

The Sales Design Input, also known as simply DI (Design

Input), is a document created by the Design team and
provided further to the Sales department.

First, the SALES DI number, Machine Model and Series

Number are mentioned.

It is created in an Excel Sheet and consists of 1) Machine

Specification details such as Material Data, and Material
Thickness Range. 2) Machine Data consisting of Unwind
Section, Main Section, Cutter and Trim Extraction Section,
and Rewind Section. 3) Electronics details are also
mentioned.

Furthermore, upgrades included if any are also highlighted

similar to how it’s earlier done in the Technical
Specifications document in the form of Included Features.

Design Change if any is also noted here at the end.