Detailed Design Package - Build4ScaleOnline BOM tools: o Build and generate BOMs in a standard...

BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org www.build4scale.org

DetailedDesignPackageModule2ABillofMaterialsandBillofProcess

BOMandBOPU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org

o Eventhesimplestproductsaretypicallycomplexinstructureo Ifbillofmaterials(BOM),billofprocess(BOP),andengineeringdrawingsarenotcrystalcleartotheinnovatorandthemanufacturer,itcanresultwastedmoneyand/orproductsthatareimproperlyconstructed

o It’scrucialtoknowtheanswersto:— Whatandhowmanycomponentsformtheproduct?— Whatarethesteps/sequenceforfabricaJngtheproduct?— HowcantheproductconJnuetobeproducedeffecJvelyasitscomplexityincreases?

Whyisthismoduleimportant?Mo1va1on

o LearningobjecJveso Producthierarchy,billofmaterials(BOM)o Processplanning,rouJngsheet,billofprocess(BOP)o Engineeringdrawing:— Componentlevel— Assemblylevel— InterpreJngengineeringdrawings

o Casestudies

ModuleOutline

o LO1:IdenJfyproducthierarchyandassemblyplano LO2:Developappropriateprocessplanforcomponentso LO3:Assessengineeringdrawingsforcomponents

LearningObjec1ves

o TherelaJonshipbetweenBOM,BOP,andengineeringdrawingso BasicterminologyofBOM,BOP,andengineeringdrawingso SomeexisJngonlinetoolstoassistincreaJngaBOMandaBOPo HowtomanageBOMgeneraJonforcomplexproducts

WhatThisModuleAddresses

HowtheyallrelateBOP,BOM,AndDrawings

These3blocksmustbeconsideredsimultaneously!

EngineeringandAssemblyDrawing

BillofMaterials(BOM)

BillofProcess(BOP)

Engineeringandassemblydrawingprovides:o VisualrepresentaJonofproductandcomponentso Fit,tolerances,andassemblyspecificaJons

BillofProcess(BOP)

Billofprocess(BOP)addresses:o Processesthatproducetheproductandtheirsequenceo SpecificaJonsandparametersofeachprocessstep

BillofProcess(BOP)

Howtheyallrelate

Billofmaterials(BOM)addresses:o Componentsformingtheproducto ProducJonJmepercomponent

BOP,BOM,AndDrawings

BillofProcess(BOP)

o Billofmaterials(BOM):ListsquanJJesofcomponents,ingredients,andmaterialsrequiredtomakeaproduct

o Integratesproducthierarchythroughparent/childdelineaJonLevelsofaproduct:o Parent:Enditem(orfinalproduct)o Children:Rawmaterials,components,andsub-assembliesDemandmaydependonproductlevels:o Parent:Independentdemand(externaltothesystem)o Children:Dependentdemand(internaltothesystem)—Demandforanitemdependsonthedemandforitems”higherup”onthetheBOM

BasicsBillOfMaterials

TheBOMprovidesinforma1onabout:o RelaJonshipbetweenitemsatdifferentlevelso QuanJtyofeachitemo LeadTimeofeachitem

Example-ProducthierarchyBillOfMaterials

Parent(enditem)

Children

Laptop

MonitorQuanJty:1

LeadTime:2weeks

ProcessorQuanJty:1

LeadTime:3weeks

KeyboardQuanJty:1

LeadTime:2weeks

KeysQuanJty:104

LeadTime:1week

CasingQuanJty:1

LeadTime:2days

RawMaterials

Low-levelcoding(LLC):o AnumberthatidenJfiesthelowestlevelatwhichaspecificitemexistsintheBOM

o AllowsforeasilycompuJngtherequirementsofanitemexisJngatdifferentlevelsoftheBOM

BOMprocessor:o EssenJalcomponentinmostcommercialpackages;maintainstheBOMandautomaJcallyassignsLLCs

o IsessenJalforproductswithlargeBOMs(e.g.,automobileswithapproximately30,000components)

BOMgeneraConcomponentsBillOfMaterials

Example–Lowerlevelcoding

o ItemGcanbecodedasLevel2(underB)orLevel3(underE)o LLCconvenJonhasitcodedasLevel3

BillOfMaterials

ParentChildren

CQuanJty:1

LeadTime:2days

BQuanJty:1

LeadTime:1week

Level0

Level1

Level2

GQuanJty:2

LeadTime:5days

Level3

EQuanJty:1

LeadTime:2days

FQuanJty:1

LeadTime:4days

DQuanJty:1

LeadTime:6days

HQuanJty:1

LeadTime:5days

GQuanJty:1

LeadTime:5days

OnlineBOMtools:o BuildandgenerateBOMsinastandarduser-friendlyenvironment

o ScantheBOMforduplicatesorredundantpartso GenerateBOMgraphicalrepresentaJonso EnablecollaboraJonacrossanorganizaJonExamples:DragonStandardBOMisafreechromeextensionforcreaJngBOMs.CommercialsoluJonsincludeArenaSoluJons’ProductLifecycleManagement(PLM),MouserElectronics’Forte,andIQMSEnterpriseResourcePlanning(ERP)sohware.

BillOfMaterialsTools

Example–BOMsoFwareBillOfMaterials

o ProcessplanningistypicallydocumentedonarouJngsheet,alsoknownasabillofprocess(BOP)

Processplanningorganizestheseproduc1on-relatedelements:o MethodsofproducJono Toolingo Fixtureso Machineryo SequenceofoperaJonso ProcessingJmeofoperaJonso Assemblymethods

BasicsProcessPlanning

Factorstobeconsideredduringprocessplanning:o Dimensions/sizeo Surfacefinisho Geometricshapeo Toleranceo Materialbeingprocessedo Productvalueandurgencyo ManufacturingcapabiliJesandresourcesavailable

KeyconsideraConsProcessPlanning

ExampleProcessPlanning

Source:hips://www.slideshare.net/GuhanM/process-planning-34794073

o Represent3Dobjectsin2DbyprojecJngtheobject’sshapeontoaplane

Example-ComponentlevelEngineeringDrawings

Correspondingsec1onalview(demonstra1nginternalfeatures)

Indicateswherethesec1onwas

3Dviewofacomponent

Example–Internalfeatures

EngineeringDrawings

o RepresentinternalfeaturesofcomponentsusingsecJonalviewso ThisisimportanttodisJnguishbetweenhollowcomponentsandsolidcomponents

Dimensionaltolerances:o Definedastheallowableerrorsonaspecificdimensiono Typicallyexpressedasarangeofvalues(i.e.,thediameterofaholeisexpressedas“3.5inches±0.02,”whichmeansthattheholeisacceptableaslongasitsactualmanufactureddiameterisbetween3.48and3.52inchesindiameter)

DimensionaltolerancesEngineeringDrawings

o RepresenJngdimensionaltolerancesonacomponent’sdrawing

IntroducContodimensionaltolerancesEngineeringDrawings

+0.2-0.140 0.1 mm40mm

40.239.9 mm

Moredetailedexampleshere-hLps://www.nmri.go.jp/eng/khirata/metalwork/basic/accuracy/index_e.html

Geometrictolerances:o Definedastheallowableerrorsonshapes,locaJons,andprofiles(asopposedtosizeordimensionaltolerances)

o Specifiedonengineeringdrawingsasaboxwithaleaderconnectedtothefeatureofinterest

Geometrictolerances

EngineeringDrawings

Maintypesofgeometrictolerances

EngineeringDrawings

o Thisfeaturecontrolframeisreadas:"Thespecifiedfeaturemustlieperpendicularwithinatolerancezoneof0.05diameteratthemaximummaterialcondi1on,withrespecttodatumaxisC

o Inotherwords,thisplacesalimitontheamountofvariaJoninperpendicularitybetweenthefeatureaxisandthedatumaxis.Inadrawing,thisfeaturecontrolframewouldaccompanydimensionaltolerancesthatcontrolthefeaturesizeandposiJon 25

Example-Geometrictolerances

EngineeringDrawings

Source:hips://www.joshuanava.biz/engineering-4/geometric-tolerancing.html

Example–FlatnessgeometrictoleranceEngineeringDrawings

Engineeringdrawingindica1ngdesiredflatnessoutcome

Translatesinto

Parallelplanes

ToleranceZone

<0.001

Manufacturedproductwithinspecifica1onsoftheengineeringdrawing

Informa1ononanengineeringdrawingor“blueprint”:o Titleo Versiono Materialo ProjecJontypeo Unitso Scaleo Other(i.e.,assemblyinstrucJons,intellectualproperty,tolerances)

HowtointerpretthemEngineeringDrawings

Example-InterpreCngtheblueprintEngineeringDrawings

o AssemblydrawingsareengineeringdrawingrepresentaJonsoftheBOM

Example–AssembliesEngineeringDrawings

Enlargedonnextslide

Example–Assemblies(cont.)EngineeringDrawings

Example1-IniCalwastepipebracketBOPAssemblyMap

PreAsm Pipe Pipe Clamp

Clamp cdi Upper Clamp

Lower Clamp

Screw flip

Washer Nut cdi Driver Wrench

tighten

Clamp clamp

Drill Motor

Drill Pilot

Scribe tool

Mark Loc

Drill Motor

Drill Pilot

unclamp Alodine Prime

Measure

New Clecos

Cleco Plier

Remove Clecos

Scribe Mark Loc

Measure Mark Loc

Driver Loosen Rem Nuts

Rem Screws

Rem Wshrs

Rem Clamp

cdi Rem Pipe

Rem Angle

Unclamp Pipe

Rem Upr

Pipe Angle

Clamp Cleco

Drill Motor

Drill Full

Insert Cleco

Cleco Pliers

Drill Motor

Drill Full

Rem Harness

Rem Pipe Ang

Debur Tool

Debur Rag Wipe Solvent

Cleco Pliers

X 2 X 2

X 2 X 2 X 2

X 2 X 2 X 2 X 2

X 2 X 2

Harness Angle

Clamp Cleco

Cleco Insert Cleco

X 2 X 2

X 2 X 2 X 2 X 2

X 2 X 16

Get Inspector

Inspect Holes

X 8 X 8 X 8

Example2BOPAssemblyMap

Example3–CarAssemblyLineBOPAssemblyMap

ExampleEngineeringDrawing

Example–BOMonanengineeringdrawingBillOfMaterials

ExampleBOP,BOM,AndDrawings

BasePlateAssembly

1.BearingMounJngPad

2.MotorMounJngPad

3.MainFrame

4.AngleMounJngBrackets

5.CrossSupports

8.MotorMounJngPad

TheseitemscorrespondtothelinenumberintheBOM

onpreviousslide 36

Background:o HyperionisdevelopingaLEDbulbthatwillreplacetheconvenJonalhigh-intensitydischarge(HID),metalhalide,andhigh-pressuresodiumbulbsusedinornamentalsidewalklamps.ThebulbreferredtohereastheB1hasdevelopedthroughtwomajoriteraJons,theB1-aandtheB1-b,withnumerousdevelopmentiteraJonsbetweentheversions

Casestudy1–LEDlightbulbBOM/BOP

Note:ThroughouttheBuild4Scalemodules,we’llincludeproductcasestudiesthatillustratewhatonecompanyexperiencedastheyweredevelopingtheirproducts.Wehavechangedthecompanynameandanonymizedtheirproduct,butwehopethattheir

experiencewillhelpyouavoidthepipallstheyencounteredandshedlightonthelessonstheylearnedalongtheway.

o UsingtheBOM,HyperionwasabletoidenJfywhichcomponentswouldprovidethemostoverallvalueforproductcostreducJonanddesignopJmizaJon.

o InsteadoflookingateverysinglecomponentintheBOM,HyperionwasabletofocusitsaienJononafewcomponentsthatwouldgreatlyaffectcostandJme

o Inthiscase,theBOMwasusedtoidenJfycomponenthierarchybasedonthefuncJon,materials,andcostofproducJon

o HyperionwasabletoclearlyidenJfythefanassemblyasaprimetargetforcostreducJonwithapercentageoftotalcostatscaleof43.2%

Casestudy1–LEDlightbulb(cont.)BillOfMaterials

FanAssembly

o BycodingtheirproducJonintoarunninglistofprocesses(orBOP)andtrackingiteraJonsusingversioncontrol,thecompanydocumentedchangesintheirprototypeproducJonprocessestolaterbecarriedintoamanufacturingiteraJon

o TheBOPandtheBOMarethefoundaJonuponwhichfurtherproductdevelopmentcanbebuiltfromprototypetomanufacturing.TheywillbeaconJnuoustrunkofinformaJonrunningthroughallfutureiteraJons

Casestudy1–LEDlightbulb(cont.)

BillOfProcess

o AstheteambeganproducJonofthelampendcap,thequanJtyofproducJonbegantodictatethemanufacturingprocess

o Thedecisioncamedowntothemanufacturingprocessthathadthelowestcost

o IniJalprototypingwascompletedattheLosAngelesAdvancedCleantechIncubator(LACI)PrototypingCentertoallowforrapiditeraJondevelopment

Casestudy1–LEDlightbulb(cont.)ManufacturingProcess

o AsthedemonstraJonsiteswerecomingonline,HyperionmovedproducJontoasiliconmoldcastcontractortohandletheincreasedquanJJes

Casestudy1–LEDlightbulb(cont.)ManufacturingProcess

NumberofPartsNeeded

ManufacturingProcess

Produc1onSite

1-100 3DPrinJng PrototypingCenter

50-500 SiliconMoldCasJng Contractor

2,000-10,000 InjecJonMolding Contractor

Somanytradeoffs—howdoyouevaluate?Materialtradeoffs:o DifferentmaterialsrequiredifferenttoolsandproducJonprocesses,eachwiththeirowntrade-offs

o Reducedcostofmaterialsmaymeanhigherper-piecepricewithvolumeifthenewmaterialrequiresamoreexpensiveproducJonprocess

o Morerobustmaterialsmayrequirelargerinvestmentintoolingandcapitalequipment

o Lighterweightdoesnotnecessarilymeanlessmaterial

SeeModule3BformoredetailsonmaterialselecCon

TradeoffsScale-UpEffectsOnBOM/BOP

Manufacturingprocesstradeoffs:o Lowervolumesrequiredifferentmanufacturingprocesstocontroltoolingandcapitalequipmentinvestments

o SwitchtohighvolumewithlesstaktJmeprocessmayrequiremajorinvestmentincapitalequipmentbutlowerper-piecepriceoverJme

SeeModule3Cformoredetailsonmanufacturingprocesses

Tradeoffs(cont.)Scale-UpEffectsOnBOM/BOP

1.DeterminetheoperaJngenvironment:Industrial/powerplants—thelampwouldexperiencehightemperaturesandvibraJon

2.SummarizeandprioriJzethefuncJonalneedsbasedontheoperaJngenvironment(ideallyquanJfyneeds):— a.Structurallystrong— b.Operateathighheat(500–700°C)

— c.CosteffecJve

3.ExploreyourmaterialopJonsbasedonavailability,generalcost,weight,manufacturability,etc.DetermineopJonstobe:— Polycarbonate—  StainlessSteel

Casestudy2-OutdoorLEDretrofitbulbMaterialSelec1on

FanCenterBodySupport

Casestudy2-OutdoorLEDretrofitbulb(cont.)MaterialSelec1on

4.WithmaterialselecJonnarroweddownevaluateeachbasedonthreecriteriainstep2

o Stainlesssteel-NotasairacJvebecauseofhighercostandweightbutsJllpreferredduetostrengthandoperaJoninheat

5.Finaldecision:BecauseoftheuniqueoperaJngcondiJons,wepreferredstainlesssteel

o Polycarbonate-AiracJvebecauseit'slowerinweightandcostbutthesearesecondaryfactors

Material Opera1ngT(°C) Strength Weight Cost

Polycarbonate 100 Lower Lighter Lower

Stainlesssteel 800 Higher Heavier Higher

Keydeterminingfactorsarecircledbelow:

o TheuseofmaterialsandmanufacturingprocessisnotonlydictatedbyvolumebutalsobytolerancerequirementsanddesignprioriJes

Note:DefiniJonofprocessesfoundonthenextpage

Scale-UpEffectsOnBOM/BOP

SeeModule3Band3Cformoredetails

Material LowVolume MediumVolume HighVolume

Higherper-piececost,Low-costtooling

Lowerper-piececost,Highertoolingcost

Lowestper-piececost,Highercapitalequipment,

toolingcost

Metal MachinefromBillet,AddiJveMfg

SohTooling(CasJng)

HardTooling(StampingDie,Extrusion)

Plas1c MachinefromBillet,AddiJveMfg

RotaJonalMolding,BlowMolding,Thermoforming

InjecJonMolding,Extrusion,Pultrusion

Composite HandLayup,AddiJveMfg

RTM,VARTM,CompressionMolding

InjecJonMolding,Pultrusion,Filament

Winding

o  Resintransfermolding(RTM)isanincreasinglycommonformofmolding,usingliquidcompositehips://www.azom.com/arJcle.aspx?ArJcleID=8620

o VacuumAssistedResinTransferMolding(VARTM)orVacuumInjectedMolding(VIM)isaclosedmold,outofautoclave(OOA)compositemanufacturingprocesships://en.wikipedia.org/wiki/Vacuum_assisted_resin_transfer_molding

o  PultrusionisaconJnuousprocessformanufactureofcompositematerialswithconstantcross-secJonhips://en.wikipedia.org/wiki/Pultrusion

o Handlay-upisamoldingprocesswherefiberreinforcementsareplacedbyhandthenwetwithresinhip://www.coremt.com/processes/hand-lay-up/

o  CompressionmoldingisaformingprocessinwhichaplasJcmaterialisplaceddirectlyintoaheatedmetalmold,thenissohenedbytheheat,andforcedtoconformtotheshapeofthemoldasthemoldclosesoncemoldingiscompletedexcessflashareremoved,in-ordertogetbestfinishhips://en.wikipedia.org/wiki/Compression_molding

DescripConofMoldingMethodsScale-UpEffectsOnBOM/BOP

ControllingvariabilityinBOMandBOP:o Addstocost,complexityo Impactsqualitycontrol,inventoryreadiness,partstracking,suppliercontracts

Partsplanning:o Considerapartstrackingsystem(forinventoryordering/controlandqualitytraceability)

o Highlyrecommendaplanforeachpart!Processdocumenta1on:o Workflowprocessmapping(valuestreammapping)o ISOprocessdocumentaJon

KeyconsideraConsScale-UpEffectsOnBOM/BOP

SummaryScale-UpEffectsOnBOM/BOP

o Generalmoldingresourceguidehip://www.plasJcmoulding.ca/techniques/compression_moulding.htm

Resources

Glossary

Module 2A

BOM – Bill of Materials is a list of the raw materials, sub-assemblies, intermediate assemblies,

sub-components, parts and the quantities of each needed to manufacture an end product.

BOP – Bill of Process is a best practices template for production comprised of detailed plans

explaining the manufacturing processes for a particular product. Within these plans resides in-

depth information on machinery, plant resources, equipment layout, configurations, tools, and

instructions.

Engineering Drawings are a type of technical drawing is used to fully and clearly define

requirements for engineered items.

Assembly Drawings show how different parts go together, identify those parts by number, and

have a parts list,

Routing Sheet in a manufacturing or production unit defines the exact process by which a

product is to be manufactured or a service is to be delivered.

Product Hierarchy is the decomposition of a product showing the relationship between parts.

This is used in conjunction with the BOM which additionally shows all

critical product information including lists the raw materials, assemblies, components, parts

and the quantities of each needed to manufacture a product.

LLC - Low-Level Coding refers to the lowest level code of the item used in BOM. The low level

code is registered to each item, and is used to perform a level-by-level explosion.

BOM Processor is data management system that organizes the specifications of product

assemblies and structures used in manufacturing and related industries. Essential component

in most commercial software packages; maintains the BOM and automatically assigns Lowest-

Level Coding (LLCs) — The BOM processor is essential for products with large BOMs (e.g.,

automobiles include approximately 30,000 components)

Process Planning is a plan of how your parts will be produced, what machines to use and in

what order, to achieve the correct tolerances etc. It involves strategic decisions and careful

analysis with production engineers and expertise in order to plan and adapt the production of

every single component.

Orthographic Projection is a means of representing three-dimensional objects in two

dimensions.

Dimensional Tolerances is the permissible limit or limits of variation in: a physical dimension; a measured value or physical property of a material, manufactured object, system, or service; other measured values (such as temperature, humidity, etc.); in engineering and safety, a physical distance or space (tolerance); in mechanical engineering the space (such as between a bolt and a nut or a hole, etc.)

Component Level Design involves the selection, maintenance, design and construction of smaller parts for a larger machine/assembly. This includes selecting, qualifying, approving, documentation, and managing the purchasing of components and direct material required to produce an end product.

Component engineering also involves product lifecycle management plan when a component is going to be obsolete or to analyze the form–fit–functionality changes in the component.

Geometric Tolerances (GD&T) is a system for defining and communicating engineering

tolerances. It uses a symbolic language on engineering drawings and computer-generated

three-dimensional solid models that explicitly describes nominal geometry and its allowable

variation.

Material Properties is an intensive, often quantitative, property of some material

Mechanical Properties is the response of the material to force and load.

Physical Properties is any property that is measurable, whose value describes a state of

a physical system. Physical properties are often referred to as observables.

Thermal Properties is the reaction of the material in the presence of heat or cold.

Electrical Properties is the ability of a material to transmit, store, or impede electricity.

Optical Properties is the ability of the material to transmit, reflect, or absorb light.

Environmental Properties are the ability of the material to maintain performance in its

application environment.

Hardness is the resistance of a material to indentation.

Young's Modulus also known as the elastic modulus, is a measure of the stiffness of a solid

material.

Stainless Steel is a steel alloy with a minimum of 10.5% chromium content by mass. Stainless steel is notable for its corrosion resistance, and it is widely used for food handling and cutlery among many other applications.

Polycarbonates are a group of thermoplastic polymers containing carbonate groups in their

chemical structures. Polycarbonates used in engineering are strong, tough materials, and some

grades are optically transparent.

Resin Transfer Moulding (RTM) is an increasingly common form of molding, using liquid

composites.

Vacuum Assisted Resin Transfer Molding (VARTM) is a closed mold, out of autoclave (OOA)

composite manufacturing process.

Pultrusion is a continuous process for manufacture of composite materials with constant cross-

section.

Hand lay-Up is a molding process where fiber reinforcements are placed by hand then wet with

resin.

Compression Molding is a method of molding in which the molding material, generally

preheated, is first placed in an open, heated mould cavity.

Detailed Design Package - Build4ScaleOnline BOM tools: o Build and generate BOMs in a standard...

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