PYMAC BOM BASIC EDUCATION

PYMAC BASIC EDUCATION
BOM MODULE

Prepared by: PC div
YEVN-18th April 2013


CONTENT
1. BOM introduction
2. Organization Structure
3. SU code
4. Item Number & Item key
5. Concept of SU
6. Manufacturing process & BOM
7. Data Item Definition
8. Item Class
9. Item Status
10.Revision Notice and Effective date
11.Stock Location
12.Work Center
13.Load sum code
14.Operation/ work flow


INTRODUCTION TO BOM MODULE
WHAT IS BOM???

 BOM : BILL of Material
 Function of BOM module : Provide fundamental info about :
1. Item Information, Product structure
2. Location of Itiem in Plat form/ Stock point/ Work Center

3. Supplier & User of each Itiem.
4. MRP information and Manufacturing Engineer Info.
[MAIN FUNCTION ]
[ SUPPLEMENT FUNCTION ]

OP

BOM
PP

Bill Of Material
(DE& ME info)

Order Processing

Production Plan

I-0P

MRP
CP
Material Requirements
Planning

Capacity Plan

CC

BOM provide fundamental for other modules.

IC
Inventory Management
Cost Control

VICS

PUR/IA
Unit Cost Registration

Oversea Purchase

Vehicles Control

Our goal: Ensure BOM accuracy rate 100%


Title

BOM Basic Education

Sub Title

1. ORGANIZATION STRUTURE

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div


Title

BOM Basic Education

Sub Title

2. S/U code

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div

YEVN Standard Definition of
S/U CODE & P/F CODE
Customer
Customer

7xxx

9140

9130
9150

⑤IGN COIL

③ST MOTOR

9120

④UNIT

S/P
S/P

Ign coil

Pouring

②STATOR

Stator

P/F
P/F

P001

MOTOR

Stator

Pouring

Stator

Manual
Insert

9900

Coil

1xxx~

Armature

Coil

winding

⑥Non-Process

4xxx

Unit
Winding

Winding

MOTOR

①ROTOR

SMT
Stator

9110
ROTOR

ROTOR

Pulsar
Armature

Vendor
Vendor


Title

BOM Basic Education

Sub Title

2. S/U code

YEVN PYMAC -III
YEVN-18

Total 7 digits :

th

Apr 2013

Made by: PC div

0 0 0 □□□□

YEVN Standard Definition of
S/U CODE

Source of part

In-House

S/U

91xx 　　　

Comment
xx = alpha-numeric
(0,1,…9,a,b,…y)

Manufacturing

Vendor

99xx
1xxx 　

*except i,o,q,z

　

Example

Plant : 91xx
* If increase the factory, use 92xx …

Non Process : 99xx

Overseas Vendor : 1xxx~2xxx
Same as above

Purchasing

Local Vendor : 3xxx ~ 4xxx

4xxx

Vendor
Purchasing

5xxx

Same as above

Vendor : 5xxx

7xxx

Same as above

Customer : 7xxx

- Indirect , Others -

Customer


Title

BOM Basic Education

Sub Title

2. S/U code

SU_CODE

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div

SU NAME

1000

YAMAHA MOTOR ELECTRONICS JAPAN

1001

YAMAHA MOTOR ELECTRONICS INDONESIA

Oversea

1002

YAMAHA MOTOR ELECTRONICS TAIWAN

vendors

1003

YAMAHA MOTOR COMMERCIAL TRADING (SHINGHAI) CO.,LTD.

3001

KYOSHIN VIETNAM CO.,LTD

3002

ASTI ELECTRONICS CORP HCM

3003

DRACO PCB PUBLIC CO.,LTD.

3004

ASTI ELECTRONICS HANOI CORP.,

3005

KYOEI MANUFACTURING CO., LTD

5001

NAGOYA INDUSTRIAL EQIPMENT CO.,LTD

5002

LONG SON CO., LTD

5003

DUY HUNG IMC CO., LTD

5004

NITTO DENKO CO., LTD

5005

HA SON

9110

ROTOR ASSY

9120

STATOR ASSY

9130

STARTING MOTOR ASSY

9140

IGNITION COIL ASSY

9150

CDI UNIT ASSY

9900

NON PROCESS

7001

YAMAHA MOTOR VIET NAM

7002

PART CENTER YAMAHA MOTOR VIETNAM

7003

YAMAHA MOTOR ELECTRONICS THAILAN

7004

YAMAHA MOTOR ELECTRONICS TAIWAN

7005

YMAC

Local
vendors

Indirect
vendors

In- house
manufacturing

Customer


Title

BOM Basic Education

Sub Title

YEVN PYMAC -III
YEVN-18

3. PYMAC ITEM

th

Apr 2013

Made by: PC div

1.Item Number & 　 Item Master ( For Normal Parts)

PYMAC-Ⅲ DE Item Number/ Item Master
Example:
Ordinary part No.

New-BASE (R&D)
Part Number

5VT-H1450-01

OOO-OOOOO-OO
Part No. system is defined by YGK

10 digits

Color Indication No.also defined by YGK
5VT-H1450-00-0080

Item Number
　　　　

OOO-OOOOO-OO

- OO - 8O
Normally 　　　　　

R&D Parts Number

14 digits
10+2+2

Item Master

Process

OOO-OOOOO-OO

- OO - OO 　

　　　　

Item Number of BOM

22 digits

OOOO
Supplier

　

OOOO
User

　　　　

10+2+2+4+4
　 / 　 Code

　 When Supplier is same to User

　　　　　　　　 Manufacturing

　 When Supplier is different to User 　　≠　　　　　 Transportation

5VT-H1450-00-00-80-9110-9110


Title

Sub Title

BOM Basic Education

3. PYMAC ITEM

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div


Title

BOM Basic Education

Sub Title

3. PYMAC ITEM

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div

Item Number & 　 Item Master ( For Raw Materials)
PYMAC only control raw materials that we can calculate consumption for producing 1 FGS.

Example: Magnet wire, Resin, Hose, Cord High tension, Solder
Pymac Item No

 Pymac Item Name

Kind or material

SUPPLIER

USER

D0100-00001

CORD HIGH TENSION

D

1018

9140

D0200-00001

HOSE

D

1001

9140

A0100-00001

MAGNET WIRE

A

1015

9120

A0100-00002

MAGNET WIRE

A

1015

9120

A0100-00001

MAGNET WIRE

A
YEVN,

1006

9120

A0200-00001

MAGNET WIRE

A

1006

9130

A0200-00003

MAGNET WIRE

A

1006

9130

A0200-00002

MAGNET WIRE

A

1006

9130

A0100-00002

MAGNET WIRE

A

1006

9120

A0200-00004

MAGNET WIRE

A

1006

9140

A0200-00005

MAGNET WIRE

A

1006

9140

A0200-00006

MAGNET WIRE

A

1028

9140

C0100-00001

EPOXY - ST MOTOR

C

1018

9130

C0200-00001

EPOXY RESIN K-8174(A)

C

1018

9130

C0200-00002

EPOXY RESIN K-8174(B)

C

1018

9130

C0100-00002

EPOXY(adhesive) SOMAR

C

1018

9110

C0100-00003

EPOXY RESIN

C

1019

9130

C0200-00003

EXPOXY RESIN (A)

C

1029

9140

C0200-00004

EXPOXY RESIN (B)

C

1029

9140

B0100-00001

SOLDER PASTE

B

1021

9150

C0200-00005

UE-947A

C

1027

9150

C0200-00006

UE-947B

C

1027

9150

B0200-00002

SOLDER BAR

B

5010

9150

Item No is decided by
not YGK


Title

Sub Title

BOM Basic Education

YEVN PYMAC -III
YEVN-18

4. CONCEPT OF S/U

th

Apr 2013

Shop and Vendor
S/U definition
.

S: Supplier
U: User
.

　 tock

　 lat

Work Center

　 orm

　 oint

( W/C)

(P/F)
　

　

(S/P)
　

　

　　　 ---express Manufacturing Level
First = Platform 　　　　
S/U Condition

Center = Shop or Vendor 　　　　
End = Stock Point 　　　　

　　 Receiving Parts --- Platform 　　　　
　　 Assembly after Parts Machining --- Shop or Vendor

　　 Stock Point for Finished Goods, Waiting for Shipping 　　　　
　　　　　　　　

Made by: PC div


Title

BOM Basic Education

Sub Title

YEVN PYMAC -III

5. MANUFACTURING PROCESS AND BOM

YEVN-18

th

Apr 2013

BOM
BOMDisplay
Displaywith
withManufacturing
ManufacturingProcess
Process
Manufacturing Process

S/U: 3005

Parts

　 / 　　

9110

5TN-85559-00

　 / 　

-00-80

Shop

　 / 　

　

BOM

(S 　 U)

　 / 　

　

(S≠U)

Shop

　 / 　

　

(S 　 U)

　　　

4

3
　

5VT-H1450-01-00-80-9110-9110

　　　　　 Manufacturing at 9110

5TN-H555A-21-00-80-9110-9110

　　　　　 Manufacturing at 9110

5TN-85559-00-00-80-3005-9110
　

5TN-85559-00-00-80-3005-3005

　　　　　 Transfer from 3005 to 9110
　　　　　 Manufacturing at 3005

Made by: PC div


Title
Sub Title

BOM Basic Education

YEVN PYMAC -III
YEVN-18

6. DATA ITEM DEFINITION

Item Type

1
Standard Item

Item Class

2
Built through Item

1
Raw materials

Apr 2013

Made by: PC div

3
Reference Item

2
Parts

th

3
Manufacturing

5
Manufacturing group (CKD)

Group (CBU)

Itiem Status

2
Pilot production

MRP demand Policy

1

3
First Production

4

Mass production

2

3

6

7

Discontinue of

Service

Production

Parts

4

8
Deletion

5

6

code
Prod Planning Item

Manual Control Item

Automated

Early Stage automated again

Again Plan Item

Order Policy

D

F

S

Code
Lot for lot

Fixed ordered Q’ty

Specified Standard

On order fixed
Item

GRP Item

9
Impossible to manufacture

Title

BOM Basic Education

Sub Title

7. ITEM CLASS

Catagory

YEVN PYMAC -III
YEVN-18

th

Apr 2013

ITEM CLASS

Example

1

Raw material

A0100-00001 MAGNET WIRE

2

Normal Part

5TN-85559-00-00-80 ROTOR

Made by: PC div


Title

BOM Basic Education

Sub Title

YEVN PYMAC -III
YEVN-18

8. ITEM STATUS

th

Apr 2013

Made by: PC div

Item Status changing steps
Check existing in
PROPAC/G-FAST part master

System processing :automatic by monthly

For Service part
　
Service
part

　

　

　

　

　
Impossible

Pilot

First

Mass

Production

Production

Production

Delete

manufacturing

　
Discontinued

Mass delete

production

2times/year

Non Service part item

Utilize
by

Pilot production
Order

Check sheet

Rejection of

for the initial

Die, Mold and JIG

Supply part

another system

or manual operation


Title

Sub Title

BOM Basic Education

YEVN PYMAC -III
YEVN-18

9. REVISION NOTICE

th

Apr 2013

Made by: PC div

Two types of Revision (Technical/Manufacturing)
Priority

Technical

The highest priority apply for initial production

A

revision

revision to be applied

B1
Revision

Manufacturing

as soon as New parts are available

B2

when Old part stock has been used

D

deal with procedural changes only

B1

revision

BOM Revision
BOM revision has two types of data,
Effective date and revision No..

Effective
Date

+

Revision
Number

Example;
Technical
revision

=When new parts will start
production (Supply) / or
finish to use old parts.

Use technical revision number
for technical revision.
Otherwise, use ‘Original’ revision
number for manufacturing revision.

Manufacturing
revision

5TP5A25
(upon YGK rule)

143Z1A1
(arbitrary No.)

5TL5525
Numeric:
Local R&D

Title

Sub Title

BOM Basic Education

YEVN PYMAC -III
YEVN-18

9. REVISION NOTICE

th

Apr 2013

Out/In Date & Rev.No.

Mar.
31
1DB-H591A-01

Old part

Same date

Apr.
1

YYYY MM DD

OUT

Out effective date: 20130401
IN

1DB-H591A-02

Out Rev.No: 1DB1A00

New part
YYYY MM DD

In effective date: 20130401
In Rev.No: 1DB1A00

Same Rev. No.

Out effective date…
From this day, old part will be not effective
** = Old part will be effective until one day before

Made by: PC div


Title

BOM Basic Education

Sub Title

9. BOM FOR PP & MRP

YEVN PYMAC -III
YEVN-18

Production Plan
Production Plan
(PP)
(PP)

Material Requirement Planning
Material Requirement Planning
(MRP)
(MRP)

3 Plan (Output)
3 Plan (Output)

+/- 0:zero Production
+/- 0:zero Production

th

Apr 2013

Made by: PC div

Organization Master (definition of S/U code , etc. )

BOM

Item master, Product Structure

Order by required Item / Time / Quantity
　 Depend on Order policy, Demand policy and Lead Time 　

Receive/ Manufacture/ Delivery Plan ( also Extra order)

Strictly upon the production schedule
　　　　　　　

Manufacturing result report (Inventory, Inventory on order)
Inventory Control
Inventory Control
　　　　
　　　　

Receiving report / Completion report / Safety stock
　　　　　　　　　　　　　　　
　　　　　　　　　　　　　　


Title

BOM Basic Education

Sub Title

10. MRP ( Material requirement plan)

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Master Production
Schedule (MPS)

Gross required
Manufacturing

Quantity calculation

Gross required
Quantity

Order
(Start date)

BOM
　　　

Preceding
Calculation

Inventory
Lead time

　　　
Inventory on

　　　　　　

Calculation of
Net required quantity

Order
　　　

Order policy
　　　　

Manufacturing

Net required

Order
(Paying out date)

Quantity
Lot sizing

Made by: PC div


Title

BOM Basic Education

Sub Title

10. MRP ( Material requirement plan)

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div

MRP information provide all Pur parameters:
　 Order policy, Demand policy and Lead Time, Packing Capacity, Stock Location, etc

MRP demand policy

Load sum code

MRP demand policy

Order Policy

MOQ

MOQ

Packing capacity


Title

BOM Basic Education

Sub Title

11. STOCK LOCATION

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div

YEVN Standard Definition of
Stock Location code
Category

Stock Loc.

Stock Location (P/F, S/P)

axx

Comment
x = alpha-numeric
(0,1,…9,a,b,…y) *except i,o,q,z

SU_code

Location(P/F)

Location(S/P)

ROTOR ASSY Line

A**

A**

STATOR ASSY

STATOR ASSY Line

B**

B**

　

　

COIL ASSY Line

C**

C**

　

　

PULSER

D**

D**

STARTING MOTOR ASSY Line

E**

E**

STATOR Line

F**

F**

ARMATURE Line

G**

G**

IGNITION COIL ASSY

IGNITION COIL ASSY

H**

H**

　

IGNITION COIL COMP

J**

J**

UNIT ASSY

CDI UNIT ASSY

K**

K**

　

　

CIRCUIT BOARD ASSY

L**

L**

　

　

SMT

M**

M**

NON PROCESS

-

N**

N**

9110
9120

9130

SU_name

ROTOR ASSY

STARTING MOTOR ASSY

　

　

　

　

9140
　
9150

9900

WC_name

ED
D
I
EC
D
T
O
N

1 digit : W/C

2 digit : Area
1~3 > P/F
4~5 > Room
6~7 > Old Factory
8~9 > Line
A~Z > S/P

3 digit : Detail
- Shelf, Area, …


Title

BOM Basic Education

Sub Title

YEVN PYMAC -III
YEVN-18

12. LOAD SUM CODE

YEVN Standard Definition of

th

Apr 2013

Used
Usedby

by summarized
summarizedProduction
ProductionPlanning,
Planning,
Sequence
Sequenceof
ofProduction
Productionschedule.
schedule.

Load Sum code

Category

Load Sum

All

Comment
x = numeric

a1x

(0,1,…9)

* : 0-9
SU_code

SU_name

WC_name

Load_sum_code

9110

ROTOR ASSY

ROTOR ASSY Line

A11

9120

STATOR ASSY

STATOR ASSY Line

B11

　

　

COIL ASSY Line

C11

　

　

9130
　

STARTING MOTOR ASSY
　

ED
D
I
C
DE

PULSER

D11

STARTING MOTOR ASSY Line

E11

STATOR Line

F11

ARMATURE Line

G11

IGNITION COIL ASSY

IGNITION COIL ASSY

H11

　

IGNITION COIL COMP

J11

UNIT ASSY

CDI UNIT ASSY

K11

　

　

CIRCUIT BOARD ASSY

L11

　

　

SMT

M11

NON PROCESS

-

　
9140
　
9150

9900

　

-

Made by: PC div


Title

BOM Basic Education

Sub Title

YEVN PYMAC -III
YEVN-18

13. WORK CENTER

YEVN Standard Definition of

th

Apr 2013

Made by: PC div

Used
Usedby
bySummarize
Summarizecapacity,
capacity,MRP
MRPInformation
Information‘s‘skey
key

Input work center code

Category

Input W/C

All

a01

Comment
a = alpha-numeric
(User Definable)

SU_code

SU_name

WC_name

9110

ROTOR ASSY

ROTOR ASSY Line1

A01

9120

STATOR ASSY

STATOR ASSY Line1

B01

　

　

COIL ASSY Line2

C01

　

　

PULSER

D01

STARTING MOTOR ASSY Line1

E01

STATOR Line1

F01

ARMATURE Line1

G01

IGNITION COIL ASSY

H01

　

IGNITION COIL COMP

J01

UNIT ASSY

CDI UNIT ASSY

K01

　

　

CIRCUIT BOARD ASSY

L01

　

　

SMT

M01

NON PROCESS

-

9130

STARTING MOTOR ASSY

　

　

　

　

9140
　
9150

9900

IGNITION COIL ASSY

ED
D
I
C
DE

Input _WC

-

Title

BOM Basic Education

Sub Title

14. Operation : How to input BOM

YEVN PYMAC -III
YEVN-18

th

Apr 2013

Made by: PC div

　 Current operation 　
1)
1)Gathering
Gatheringinformation
information

2)
2)Making
MakingBOM
BOMfor
forProd.
Prod.

3)
3)Check
Check//Approval
Approval

No double check operation

PC

Drawing

4)
4)Input
InputBOM
BOM

No process of approval
R/N
　 Mistake of input
PC receive “Drawing” and “R/N” from

　 Mistake of R/N

PC gather information from

QA div. After that think of BOM for

　 Mistake of qty. info

each div. and it takes long time

Manufacturing.

Input “PS_table.xls”

to collect completely. Sometimes by oral.

Lots of problems can be happened!!!

　 PYMAC operation 　
1)
1)Gathering
Gatheringinformation
information

2)
2)Making
MakingBOM
BOMfor
forProd.
Prod.

PC

Drawing

　　

3)

3)Check
Check//Approval
Approval

PC

　　　

Add info

Item Master

4)
4)Input
InputBOM
BOM

Item Master

Add info
Item Master

R/N
Registration
Format

Registration
Format

Registration

PIC must check its contents

Based on the information of

Format

and sigh it

registration format, input these
Info to PYMAC BOM module.

「 Registration format for “ Item master”/ “BOM” 「

Double check operation

must be sent around each div. and it’s easy to gather info.

And BOM accuracy will be high.


Title

BOM Basic Education

Sub Title

14. WORK FLOW: How to input BOM

YEVN PYMAC -III

YEVN-18

th

Apr 2013

Made by: PC div