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[IMP] Multilevel BoM updates
closes #12182 Signed-off-by: Zachary Straub (zst) <[email protected]>
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=============================
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Manage semi-finished products
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=============================
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===============
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Multilevel BoMs
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===============
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A *semi-finished product*, also known as a *subassembly*, is a manufactured product that is used as
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a component in another product's bill of materials (BoM). Semi-finished products are used to
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simplify complex :abbr:`BoMs (Bills of Materials)` or to more accurately represent a manufacturing
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flow. A :abbr:`BoM (Bill of Materials)` that contains semi-finished products is referred to as a
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*multilevel BoM*, where the main *top-level product* and its subassemblies are distinguished.
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.. |BOM| replace:: :abbr:`BoM (Bill of Materials)`
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.. |BOMs| replace:: :abbr:`BoMs (Bills of Materials)`
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Configure semi-finished products
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================================
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Use a multilevel bill of materials (BoM) when a manufactured product is part of another assembly.
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This method nests |BOMs| within other |BOMs|, organizing complex products while simplifying
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manufacturing by defining each procurement and production step separately.
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To set up a multilevel :abbr:`BoM (Bill of Materials)`, the top-level product and semi-finished
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products must be configured. Therefore, the first step is to create the semi-finished products and
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their :abbr:`BoMs (Bills of Materials)`.
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Sublevel |BOMs| (subassemblies or semifinished products) streamline these production workflows, and
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are beneficial when the subassembly is used across multiple finished products (meaning they'd appear
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on multiple top-level |BOMs|). The more complicated a product is to build or procure, the more value
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a multilevel |BOM| can provide.
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.. seealso::
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:doc:`../basic_setup/bill_configuration`
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Create a multilevel BoM
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=======================
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To set up a multilevel |BOM|, the top-level product and sublevel products's |BOMs| must be created.
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If starting from scratch, build the |BOMs| from the bottom up. Start with the lowest-level product
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|BOMs|, then include those products as components in higher-level |BOMs|.
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For example, a printed circuit board (PCB) for a custom keyboard would be composed of hundreds of
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electronic components, such as transistors, resistors, and capacitors. Instead of listing all of
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those components out, a sublevel product and |BOM| for `PCB` is created, to track the quantities of
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transistors and other small components, without needing to overcrowd the toplevel |BOM| for custom
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keyboard with listing them. Instead, the custom keyboard's |BOM| consists of an assortment of
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components and sublevel |BOMs| alike, like keycaps, switches, the PCB, and keyboard plate.
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.. image:: sub_assemblies/semifinished-product-bom.png
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:align: center
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:alt: A bill of materials for a semi-finished product.
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:doc:`Learn how to build a simple bill of materials <../basic_setup/bill_configuration>`. For the
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PCB, this would include the transistors, resistors, and other components.
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Create the top-level bill of materials (BoM)
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============================================
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.. image:: sub_assemblies/sublevel-bom.png
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:alt: A bill of materials for a PCB.
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After the semi-finished products are fully configured, navigate to :menuselection:`Manufacturing
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--> Products --> Products`. Then, :guilabel:`Create` the top-level product. Configure the product's
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specifications as desired, and be sure to :guilabel:`Save`.
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After the sublevel products (like the PCB, keycaps, and keyboard plate) are fully configured, create
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the top-level product by navigating to :menuselection:`Manufacturing --> Products --> Products`, and
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then selecting :guilabel:`New`. From here, configure the product's specifications as needed.
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Once the top-level product is configured, click the :guilabel:`Bill of Materials` smart button on
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the product form, then click :guilabel:`Create` to make a :abbr:`BoM (Bill of Materials)` for the
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top-level product. Then, simply add the semi-finished products to this :abbr:`BoM (Bill of
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Materials)`, along with any other necessary components.
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Once the top-level product (the keyboard) is configured, click the :guilabel:`Bill of Materials`
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smart button on the product form, and then select :guilabel:`New` to make a |BOM| for the top-level
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product. Add the sublevel products to this |BOM|, along with any other necessary components.
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.. image:: sub_assemblies/custom-computer-bom.png
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:align: center
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:alt: A bill of materials for a top-level product, containing a subassembly component.
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.. image:: sub_assemblies/top-level-bom.png
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:alt: A bill of materials for a keyboard, containing a bill of materials for a PCB.
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Manage production planning
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==========================
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There are several methods to manage manufacturing order automation for products with multilevel
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:abbr:`BoMs (Bills of Materials)`.
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The two options below are two of the best ways to manage manufacturing order automation for products
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with multilevel |BOMs|.
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.. note::
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Semi-finished products are specifically used to manage manufacturable products with multilevel
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BoMs. If a BoM is being created simply to organize components or bundle sellable products,
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using :doc:`Kits <kit_shipping>` is the more appropriate option.
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Complex |BOMs| are specifically used to manage products that require manufactured components. If
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a BoM is being created to organize components or bundle sellable products, :doc:`use a kit
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<kit_shipping>` instead.
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To automatically trigger manufacturing orders for semi-finished products after confirming a
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manufacturing order for the main product, there are two options:
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To automatically trigger manufacturing orders for sublevel products after confirming a manufacturing
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order for the main product, there are two options:
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- **Option 1 (recommended):** Create *Reordering Rules* for the semi-finished products and set both
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the minimum and maximum desired stock quantities to `0`.
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- **Option 1 (recommended):** Create *Reordering Rules* for the sublevel products and set both the
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minimum and maximum needed stock quantities to `0`.
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- **Option 2:** Activate the :guilabel:`Replenish on Order (MTO)` and :guilabel:`Manufacture` routes
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under the :guilabel:`Inventory` tab of the sublevel product's product form.
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.. seealso::
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:doc:`../../purchase/products/reordering`
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:doc:`../../inventory/warehouses_storage/replenishment/mto`
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- **Option 2:** Activate the :guilabel:`Replenish on Order (MTO)` and :guilabel:`Manufacture`
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routes under the :guilabel:`Inventory` tab of the semi-finished product's product form.
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Option 1 is more flexible than Option 2 and is therefore recommended. Reordering rules do not
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directly link demand to replenishment, and therefore allow stocks to be unreserved and redirected
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to other orders, if necessary. The Replenish on Order (MTO) route creates a unique link between the
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semi-finished and top-level products, exclusively reserving quantities for the confirmed top-level
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manufacturing order.
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Regardless of the method chosen, semi-finished products must be fully manufactured before
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manufacturing can begin on the top-level product.
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Option 1 is more flexible than Option 2 and is recommended. Reordering rules do not directly link
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demand to replenishment, allowing stock to be unreserved and reassigned as needed. The Replenish on
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Order (MTO) route, however, uniquely links sublevel and top-level products, reserving quantities for
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the confirmed top-level manufacturing order.
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.. image:: sub_assemblies/semifinished-on-mo.png
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:align: center
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:alt: A manufacturing order for a top-level product.
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In both methods, sublevel products must be fully manufactured before starting the top-level product.
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