Managing Formula Revisions by Configuring Batch Yields

A Batch Yield, as defined on a Part's Edit BOM form, determines the total quantity of the formula that will be produced as a result of the formula. In DEACOM, users may choose between two different options for how the system will calculate batch yields on BOM revisions:

Calculated - indicates the system will automatically determine the batch yield either in weight or volume amounts based on the weight, volume and quantity information for all parts on the bill of material.
Specified - indicates the yield will be manually entered by the uses and needs to the be the sum of the quantity on all bill of material lines.

BOMs can be scaled in order to produce the Batch Yield specified. For example, if the natural batch yield was 97 lbs, and it needs to be 100 lbs, click the "Scale BOM" button on the Edit BOM form, enter the new yield on the Scale Formula form and then click "Save" and "Exit". Note: When using this option, the system will round the results based on the BOM decimals specified in Inventory Options. BOM Lines can also be flagged with Non-Scalable Quantities. If checked, this indicates that the entered quantity for this BOM line will be used regardless of the batch size. (It will be used in full in the first finish of a job, preventing multiple finishes of a job.) In addition, viewing a BOM and changing the batch yield will leave the non-scalable items at the entered quantity in stock units.

Notes:

When a revision is marked as "Regulatory", the "Batch Yield Calc" must be set to specified and the "Batch Yield" must be set to "1". For more information, refer to the Additional Considerations sections further down the page.
The item master property tab contains a flag, "Restrict Job Quantity to Batch Yield". If checked, and adding a new line for this item to a production job, the "Quantity" specified will default to the Batch Size on the Revision selected, and this quantity will not be allowed to be modified (grey out). Also, since items may have multiple BOMs, when the Revision is changed on the job line, the quantity will change to that revision's Batch Yield and will not be allowed to be modified (grey out). If no revision is selected, the job quantity is forced to be zero and does not allow the user to modify it (grey out). Business Case: Customer required a process to restrict job quantities to certain validated Batch Sizes. One item may have non-incremental quantities allowed for production, and they are not allowed to deviate from these quantities (ex. FINI1 can only be made in quantities of 3000, 6000, 10000, and no other quantity is allowed).

Configuration

The default "Batch Yield Calc." needs to be defined in Inventory Options. The options are the same as on a Part's Edit BOM form, defined in the Business Case above. All other requirements are the same as detailed in the Configuration section of the Adding and Modifying BOM Revisions page.

Process

Configuring Batch Yields

When adding or modifying a BOM Revision,

Follow the steps to add a BOM as detailed on the page linked above.
Navigate to the General tab of the Edit Bill of Materials form and make a selection from the "Batch Yield Calc." pick list.
- If "Calculated" is selected, the "Batch Yield" field will be grayed out, as the system is performing the calculations automatically.
- If "Specified" is selected, the "Batch Yield" field will be editable, as the user is defining the quantity.
Click "Save" and "Exit" once all details have been entered to commit the changes and close the form.

If the BOM should be scaled in order to produce the Batch Yield specified:

On the Edit Bill of Material form, click the "Scale BOM" button to open the Scale Formula form.
Enter a quantity in the "New Batch Yield" form and click "Save". The system will automatically adjust the Quantities for all Parts listed on the BOM to match the new Batch Yield entered.
On the Edit Bill of Materials form, click "Save" and "Exit" to commit the changes and close the form.

Additional Considerations

Configuring Regulatory Bills of Materials

Some purchased components will be directly represented on the regulatory form, because they are a pure regulatory component having an assigned CAS number, for example. For these components, the values for component-based variables are entered directly to the user-defined fields of the component part, and used in user calculations to determine their effect on the physical properties of the parent part.

Other purchased components will not be directly represented on the regulatory form, because they are composed of multiple regulatory components, each having their own assigned CAS number, for example. For these components, a regulatory bill of materials (BOM) is entered instead of entering the values on the item master of the purchased component.

A regulatory BOM for a purchased part is entered in much the same way that a formula is entered for a manufactured product, with minor differences. The sub-component parts can either be entered during BOM creation or in advance, possibly copied from other parts. A part entered purely for use in a regulatory BOM can be marked as not purchasable, not salable, and not manufactured to prevent its use in any of those modules. It also might be in its own unique category of SDS parts, rather than in categories with purchased parts. The component-based variable data for the SDS will be stored in the user-defined fields of these regulatory parts, and will be available, through the use of the TABLE macro tag, to the part forms for top-level formulas. (Section 3 of SDS)

To enter a regulatory BOM:

Navigate to Inventory > Item Master and enter pre-filters to view a list of items that include the purchased part that needs the regulatory BOM.
Select the part and click the "Edit BOM" button.
On the General tab, set the BOM to be Active, Default, and on the Regulatory tab select the Regulatory flag. Regulatory BOMs are not used for costing purposes, the sum of the cost of the components do not roll up to the parent part, and do not contribute to the results of user calculations. Regulatory BOMs are also fixed to produce one unit of weight or volume of the purchased part, and the non-reportable sub-components do not have to be listed.

As an example, consider a purchased component that is made up of two reportable sub-components. By weight, it is made up of 50% sub-component A and 30% sub-component B. The remaining 20% is listed as non-reportable by the vendor, on their SDS. The regulatory BOM should have one line for 0.5 pounds of A, and a second line for 0.3 pounds of B, with no third line. The "Batch Yield Calculation" should be set to Calculated, and the "Batch Yield" will be fixed at 1, as a feature of regulatory BOMs. The revision can be named “SDS” to distinguish it from other formulas to be used in production.

To further clarify the batch yield on the regulatory BOM - it is set to calculated with a batch yield of 1 because regulatory BOMs do not have to be complete. The setting of calculated and a batch yield of 1 facilitates the ability to have non-complete formulas as seen in the example above where there are only 2 reportable sub-components totalling 80%.

Note: The Inventory > Options > Printing tab flag "Summarize Regulatory BOM" is considered when gathering regulatory information for part label printing. If checked, regulatory BOMs will be summarized, specifically the bo_bomfor value will be '0'. If unchecked, the bo_bomfor will display the right number. The box is checked by default. Unchecking the box is useful when printing nutrition labels where the it is necessary that the bo_bomfor = pr_id in order to print the ingredients list.

Configuring BOM Weight & Volume Roll-Ups

Changes made to the current volume or quantity of items on the bill of materials will roll-up to the unit volume and unit weight fields on the properties tab of the item master, provided the "Roll up weight/volume from BOM" flag is set on the item master properties tab. If the flag is unchecked, changes to the bill of materials will not roll-up.