3

Module

BILL OF MATERIAL (BOM)

I. Objectives
The objectives of the practicum are:
1. To make an Assembly Chart (AC)
2. To make a product structure
3. Explain step by step of Bill of Material (BOM) making process.

II. Literature Review

A. Assembly Chart
An assembly chart, which is sometimes called a gozinto chart, maps
how a product’s parts go together and the order in which they are
assembled. Detailed instructions for all major parts of the product and all
assembly and subassembly operations and inspections are included on the
chart (Venkataraman & Pinto, 2017).
6 mm
8 mm

9 mm

Komponen 1 10 mm
A
SSSA
-1 12 mm
Komponen 2
B
SSA-
1
Komponen 3
C
SA-1

Komponen 4
D
A-1
Komponen 5
E

Komponen 6
F
SSSA
Komponen 7 -2
G SSA-
SSA-
22
Komponen 8
H SA-2 A-2
Komponen 9
I

Komponen 10
J

Komponen 11
SA-3 A-3
K

Source: (Apple, 1977)

Figure 3.1 Assembly Chart Example
Drawing rules:
a. Diameter of the components is 6 mm,
b. Diameter of the sub-assembly is 7 to 11 mm, and
c. Diameter of the assembly is 12 mm.

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B. The Product Structure and Bill of Materials (BOM)

A Bill of Materials (BOM) contains a listing of all of the assemblies,
subassemblies, parts, and raw materials that are needed to produce one unit
of a finished product (Stevenson & Chuong, 2014). Heizer and Reinder
(2013) stated that one way a bill of material defines a product is by
providing a product structure. A product structure tree is useful in
illustrating how the bill of materials is used to determine the quantities of
each of the ingredients (requirements) needed to obtain a desired number
of end items (Stevenson & Chuong, 2014). Specifically, the Bill of
Materials structure contains not only the composition of the components,
but also the completion of the finished product. Bill of material function is
as a network or network that describes the relationship of parent (parent
product) to the component. Here is the use of Bill of Materials (Arif, 2016):
1. Needed as input in planning and control of production activity.
2. Without Bill of Materials it is impossible to implement MRP.

III. Tables
PRODUCT STRUCTURE
OBJECT NAME :

MAPPED BY : Now

MAPPED DATE : Proposed

THE WAY OF MAPPING :

Level

FINISHED
0
PRODUCT

W M
W M

A2 C4 1

W M W M

A1 C3 2

W M W M

C1 C2 3

Figure 3.2 Example of The Product Structures

Where:
W = Numbering
M = Required number

Table 3.1 Example of Bill of Material

Component
Level Description Code Quantity Units
No.
1 .1.. Assembly 2 A2 1 piece
2 ..2. Assembly 1 A1 1 piece

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IV. Procedures
The following is a picture of the components of a train toy, the picture
will be used to make assemble charts and product structures with the Bill of
Material table. Following are the steps to make an assembly chart, product
structure, and Bill of Material (BOM)

Figure 3.3 Toy Train View Drawing

Figure 3.4 Toy Train Exploded View

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Assembly Chart
1. The following is information about the code and number of components and
list of an assembly of a toy train. Use this information to make assembly
charts, product structure, and bill of materials.

Table 3.2 Component’s Code and Quantity

Index Code Components Quantity (unit)
1 TB Train Body 1
2 S Stack 1
3 W Wheel 4
4 LA Linkage Arm 2
5 WP Wheel Peg 4
6 CC Cow Catcher 1
7 LP Linkage Peg 4
8 HP Hitch Peg 1
9 HM Hitch Magnet 1

Tabel 3.3 List of Assembly

Name Assembly
A5 S + A4
A4 CC + A3
A3 SA2 + A2
A2 WP + A1
A1 TB + SA1
SA2 HM + HP
SA1 LP + SSA1
SSA1 LA + W

2. The first step in making a train toy assembly chart is to write sequentially
from the first component assembled into the last component assembled. Code
and component names are written in circles with a diameter of 6 mm.

Wheel
W

Linkage Arm
LA

Linkage Peg
LP

Train Body
TB

Wheel Peg
WP

Hitch Peg
HP

Hitch Magnet
HM

Cow Catcher
CC

Stack
S

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3. The first component assembled on the train toy is the Wheel (W) and Linkage
Arm (LA) components, the two components are connected by a line to a circle
with a diameter of 9 forming Sub-Sub-Assembly 1 (SSA-1).

Wheel
W
SSA
-1
Linkage Arm
LA

Linkage Peg
LP

Train Body
TB

Wheel Peg
WP

Hitch Peg
HP

Hitch Magnet
HM

Cow Catcher
CC

Stack
S

4. Next, the components Sub-sub-Assembly 1 (SSA-1) are assembled with the

Linkage Peg (LP) component. Both components are connected by a line to a
circle with a diameter of 10 mm and form Sub-Assembly 1 (SA-1).

Wheel
W
SSA
-1
Linkage Arm
LA
SA-1

Linkage Peg
LP

Train Body
TB

Wheel Peg
WP

Hitch Peg
HP

Hitch Magnet
HM

Cow Catcher
CC

Stack
S

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5. After that, the components Sub-Assembly1 (SA-1) are assembled with the
Train Body (TB) component. Both components are connected by a line to a
circle with diameter of 12 mm and form Assembly 1 (A-1).

Wheel
W
SSA
-1
Linkage Arm
LA
SA-1

Linkage Peg
LP
A-1

Train Body
TB

Wheel Peg
WP

Hitch Peg
HP

Hitch Magnet
HM

Cow Catcher
CC

Stack
S

6. The next stage is the components Assembly1 (A-1) are assembled with the
Wheel Peg (WP) component. Both components are connected by a line to a
circle with diameter of 12 mm and form Assembly 2 (A-2).

Wheel
W
SSA
-1
Linkage Arm
LA
SA-1

Linkage Peg
LP
A-1

Train Body
TB

Wheel Peg
WP A-2

Hitch Peg
HP

Hitch Magnet
HM

Cow Catcher
CC

Stack
S

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7. After that, the Hitch Peg (HP) and Hitch Magnet (HM) components are
assembled. Both components are connected by a line to a circle with diameter
of 10 mm and form Sub-Assembly 2.

Wheel
W
SSA
-1
Linkage Arm
LA
SA-1

Linkage Peg
LP
A-1

Train Body
TB

Wheel Peg
WP A-2

Hitch Peg
HP

SA-2
Hitch Magnet
HM

Cow Catcher
CC

Stack
S

8. The next step in assembling train toys is assembling Sub-Assembly 2 (SA-2)

components with Cow Catcher component, both components are connected
by a line to a circle with diameter of 12 mm and form Assembly 3 (A-3).

Wheel
W
SSA
-1
Linkage Arm
LA
SA-1

Linkage Peg
LP
A-1

Train Body
TB

Wheel Peg
WP A-2

Hitch Peg
HP

SA-2 A-3
Hitch Magnet
HM

Cow Catcher
CC

Stack
S

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9. After Assembly 3 (A-3) is formed, the next step is to assemble the Cow
Catcher (CC) component with Assembly 3 (A-3). The combination of the two
components forms Assembly 4 (A-4).

W Wheel
SSA
-1
LA Linkage Arm
SA-1

LP Linkage Peg
A-1

TB Train Body

WP Wheel Peg A-2

HP Hitch Peg

SA-2 A-3

HM Hitch Magnet

CC Cow Catcher A-4

S Stack

10. The final step in assembling train toy is by assembling the Stack (S)
component with a combination of Assembly 4 (A-4) components. The two
are connected by a line leading to a circle with a diameter of 12 mm and
forming Assembly 5 (A-5), namely finished goods toys.
W Wheel
SSA
-1
LA Linkage Arm
SA-1

LP Linkage Peg
A-1

TB Train Body

WP Wheel Peg A-2

HP Hitch Peg

SA-2 A-3

HM Hitch Magnet

CC Cow Catcher A-4

S Stack A-5

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Product Structure
After making the assembly chart, the next step is to make the product
structure of the train toy. Following are the steps in making product's structure:
1. The following is the product structure of a train toy, the value of w means
numbering and the value of m means the number of requirements for the
component. Component numbering begins with components located on the
right side of the structure

Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level
W : Numbering
M : Req. Numbering Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

2 1 15 1

Cow
Assembly 3 2
Catcher

3 4 1214 1
Sub-
Assembly 2 3
Assembly 2
4 1 11 4 12
13 1 1413 1
Hitch
Assembly 1 Wheel Peg Hitch Peg 4
Magnet

5 4 10 1
Sub-
Train Body 5
Assembly 1

6 2 9 4
Sub-sub Linkage
6
Assembly 1 Peg

7 4 8 2
Linkage 7
Wheel
Arm

2. First, In product's structure, there is a level of assembly arranged sequentially

starting from level 0, namely finished goods in the form of a train toy.

Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

3. Next, level 1 in the product structure contains components that form finished
goods at level 0. The two components are Stack and Assembly 4.

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Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

4. The next step is to arrange level 2 which contains the components that form
Assembly 4 at level 1. The components that make up Assembly 4 are Cow
Catcher and assembly 3.
Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

2 1 15 1

Cow
Assembly 3 2
Catcher

5. Then level 3 is arranged based on the components that form Assembly 3 on

level 2. The two components that form Assembly 3 are Sub-Assembly 2 and
Assembly 2.

Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

2 1 15 1

Cow
Assembly 3 2
Catcher

3 4 14 1
Sub-
Assembly 2 3
Assembly 2

12

6. The next step is to arrange level 4 based on the components that form
Assembly 2 and Sub-Assembly 2 on level 3, the two components that form
Assembly 2 are Wheel Peg and Assembly 1 while the Sub-Assembly is
formed by components of Hitch Peg and Hitch Magnet

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Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

2 1 15 1

Cow
Assembly 3 2
Catcher

3 4 14
12 1
Sub-
Assembly 2 3
Assembly 2

4 1 11 4 12
13 1 13
14 1
Hitch
Assembly 1 Wheel Peg Hitch Peg 4
Magnet

7. After that level 5 is arranged based on the components that form Assembly 1
at the previous level. Assembly 1 is formed by the components of Train Body
and Sub-Assembly 1.

Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

2 1 15 1

Cow
Assembly 3 2
Catcher

3 4 14
12 1
Sub-
Assembly 2 3
Assembly 2

4 1 11 4 12
13 1 13
14 1
Hitch
Assembly 1 Wheel Peg Hitch Peg 4
Magnet

5 4 10 1
Sub-
Train Body 5
Assembly 1

8. Next, at level 6 there are components that form Sub-Assembly 1 at the

previous level, the components that form Sub-Assembly 1 are Sub-sub
Assembly 1 and train body.

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Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

2 1 15 1

Cow
Assembly 3 2
Catcher

3 4 14
12 1
Sub-
Assembly 2 3
Assembly 2

4 1 11 4 12
13 1 14
13 1
Hitch
Assembly 1 Wheel Peg Hitch Peg 4
Magnet

5 4 10 1
Sub-
Train Body 5
Assembly 1

6 2 9 4
Sub-sub Linkage
6
Assembly 1 Peg

9. Level 7 is the last level of train toy product's structure, at level 7 there are
components that form Sub-sub Assembly 1. Both components are Wheel and
Linkage Arm. Components contained in level 7 are the first components
assembled in the train toy assembly.

Product Structure
OBJECT NAME : TOY TRAIN
MAPPED BY : POA ## Now
MAPPED DATE : MM - DD - YYYY Proposed
THE WAY OF MAPPING :1
Level

Finished
0
Goods

1 1 16 1

Assembly 4 Stack 1

2 1 15 1

Cow
Assembly 3 2
Catcher

3 4 12
14 1
Sub-
Assembly 2 3
Assembly 2

4 1 11 4 13
12 1 14
13 1
Hitch
Assembly 1 Wheel Peg Hitch Peg 4
Magnet

5 4 10 1
Sub-
Train Body 5
Assembly 1

6 2 9 4
Sub-sub Linkage
6
Assembly 1 Peg

7 4 8 2
Linkage 7
Wheel
Arm

Bill Of Material (BOM)

The Following are the steps in making a Bill of Material (BOM):
1. Bill of material can be made based on product's structure that has been made
in the previous stage. The following is a table of Bill of Materials (BOM).

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Component No. Level Description Code Quantity Units

2. Enter the components of the assembly in accordance with the numbering

given on product's structure. Like the example below, the first component is
Assembly 4 which is at level 1 with the required number 1.

Component No. Level Description Code Quantity Units

1 .1…… Assembly 4 A-4 1 Piece

3. After that enter the second component on product's structure, the second
component is assembly 3 which is at level 2 with the required number 1.

Component No. Level Description Code Quantity Units

1 .1…… Assembly 4 A-4 1 Piece
2 ..2….. Assembly 3 A-3 1 Piece

4. After that, continue to input all existing components in sequence according to

numbering on product's structure, level, description, and quantity.
Component code information can be seen in the Table 3.2.

Component
Level Description Code Quantity Units
No.
1 .1…… Assembly 4 A-4 1 Piece
2 ..2….. Assembly 3 A-3 1 Piece
3 ..3…. Assembly 2 A-2 4 Pieces
4 …4… Assembly 1 A-1 1 Piece
5 ….5.. Sub Assembly 1 SA-1 4 Pieces
6 …..6. Sub-sub Assembly 1 SSA-1 1 Piece
7 ……7 Wheel W 4 Pieces
8 ……7 Linkage Arm LA 2 Pieces
9 …..6. Linkage Peg LP 4 Pieces
10 ….5.. Train Body TB 1 Piece
11 …4… Wheel Peg WP 4 Pieces
12 ..3…. Sub Assembly 2 SA-2 1 Piece
13 …4… Hitch Peg HP 1 Piece
14 …4… Hitch Magnet HM 1 Piece
15 ..2….. Cow Catcher CC 1 Piece
16 .1…… Stack S 1 Piece

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