MODULE 1: PRODUCTION SYSTEMS LABWORK
PRODUCT AND PROCESS DESIGN
PROCESSES AND PRODUCTION SYSTEMS LABORATORY
DEPARTMENT OF MECHANICAL AND INDUSTRIAL
ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITAS GADJAH MADA
YOGYAKARTA
2025
CHAPTER I
PRODUCT AND PROCESS DESIGN
1.1 Practicum Objectives
The following are the objectives of the practical work for module 1,
chapter 1.
1. Able to understand the workflow and significance of process design
for a product
2. Able to create process design based on a product's requirements
3. Able to understand material flow analysis methods for production
design
1.2 List of Materials
In carrying out the manufacturing process, product design is required as a
stage in the company's operational process.
1. Bill of Materials (BOM)
a. BOM tree
b. BOM list
2. Part List
3. Assembly Chart
4. Operation Process Chart (OPC)
5. Route Sheet
1.3 Material
1.3.1 Bills of Material
Bills of Materials (BOM) is a list of raw materials, sub-assemblies,
components, their description, and the quantities required to manufacture a
final product. BOM serves as a communication tool between
manufacturing partners or within a single factory. It is commonly linked to
production orders, where issuing the BOM can generate:
● Purchase orders for components in stock, and
● Material requests for components not in stock.
Uses of Bill of Materials :
1. In Design for Manufacturing (DFM), BOM is used to identify all
components required to assemble the product, along with the
necessary assembly processes.
2. In Requirements Planning, BOM supports Material Requirements
Planning (MRP) by specifying parts to be ordered, where order
quantities correspond to those defined in the BOM.
3. In Assembly, BOM determines the sequence and timing of
assembly operations for each component.
4. In Computer-Aided Design (CAD), BOM facilitates product design
during engineering processes.
Bill of Materials structures can be either BOM Tree or BOM List:
A. BOM Tree
The BOM Tree functions to define an element's structure through
hierarchical levels. Levels are sequenced starting from the
highest-order component in the product assembly. The product is then
decomposed into modules (sub-assemblies that form a single product).
Bom provide product structure :
● Parents: items above given level
● Children: items below given level
Each module is further broken down iteratively until reaching
indivisible components. Below is an example of a BOM Tree:
Figure 1.1 BOM Tree
The structure of the BOM tree is shown in the following figure.
Figure 1.2 Structure BOM Tree
From Figure 1.2, it can be observed that the air flow regulator is
the final product to be manufactured, therefore it is placed at Level 0.
The number 10000 is the part number containing four zero digits
because there are four levels in the BOM tree.
The numbering system for BOM tree components operates as
follows. Using the body assembly at Level 3 as an example:
a. The first digit follows its parent (the air flow regulator).
b. The second digit is assigned number 1, corresponding to
its upper level (the main assembly).
c. The third digit is assigned number 2 because the body
assembly is the second part in its branch.
For identical parts used in multiple locations or more than once, their
hierarchy levels will be standardized to match the lowest occurrence
level within the BOM tree structure.
B. BOM List
The BOM List represents a list BOM structure displaying all items
required to build the final product. It serves to identify components for
procurement planning and production decisions. While containing
identical component data to the BOM Tree, the BOM List facilitates
make-or-buy determinations. This format offers configurable variations
tailored to operational needs. Below is an example BOM List for the
air flow regulator:
Figure 1.3 BoM List
The inclusion of the chart header at the top is an important aspect in
creating the BoM list, as shown in Figure 3. The difference between a
BoM list and a BoM tree is that the BoM list contains information to
determine whether to make or buy. Make and buy are pieces of
information used to identify whether a part needs to be manufactured
or purchased.
Uses of the Bill of Materials list:
a. Provides details on the components required to produce a
product.
b. Identifies the number of items that make up a finished
product.
c. Determines which components need to be manufactured
or purchased.
In creating a BoM list, there are several aspects that need to be
considered, including:
a. Determine the part code numbering, as each company
has its own specific format for part codes. Since every
company has different standards, the numbering system
must be established accordingly.
b. Understand the product structure and component levels
before they are formed. It is important to know which
parts need to be assembled first and which parts are final
components.
c. Understand the processes involved in the components
(e.g., welding, painting, machining).
d. Determine whether the component will be purchased or
manufactured.
e. Perform checks and ensure that the BoM is correct.
1.3.2 Part List
Figure 1.4 Part List
A part list is a document containing components and/or parts used to
manufacture a specific product. It serves to identify materials required for
procurement and production decisions. Only components at the lowest
level are listed. For example, the part list for manufacturing an air flow
regulator is shown in the table below :
Table 1.1 Different between BoM List and Part List
BoM List Part List
Part list records items at the
All parts (components) in the BOM
lowest hierarchy level or the
tree are documented, including
smallest indivisible components
assemblies.
used in product assembly.
1.3.3 Assembly Chart
An Assembly Chart (or assembly map) is a graphical representation
of the sequential flow of components from individual parts and
sub-assemblies to the complete product assembly. By definition, it
visualizes relationships between components assembled into the final
product. This chart serves to Display a product's constituent components
and Define the sequence of assembly operations. Consequently, it
facilitates understanding of:
1. Product component structure
2. Methods for joining components
3. Sub-assembly constituent parts
4. Component flow into assemblies
5. Interdependencies between components and
sub-assemblies
6. Assembly sequence order
7. Preliminary material flow patterns
8. Comprehensive assembly process overview
Symbol legend in Assembly Charts:
a. Circle: Represents assembly operations
b. Square: Denotes inspection points
Figure 1.5 Assembly Chart
1.3.4 Operation Process Chart (OPC)
An Operation Process Chart (OPC) is a process map illustrating the
sequence of operations and inspections that components undergo from raw
material to finished or semi-finished products. Key OPC construction
principles include: Starting at the upper-right with components for the first
assembly operation. Listing at the bottom are Component numbers (per
BOM), Machining types and Processing times. Featuring a header section
and summary detailing about Activity types, Total activities and Time
allocations. Symbol Legend in OPC are Square for Inspection activity and
Circle for Operation activity.
Figure 1.6 OPC
As an example, according to Figure 1.6 The seat ring with number
component 11221 is positioned below it, followed by its processing steps
are cutting, shaping, and inspecting, with a processing time of 23 seconds.
Another critical consideration is that if lines overlap in the diagram, they
must be rendered as shown in Figure 1.7.
Figure 1.7 Collision OPC
1.3.5 Route Sheet
A route sheet is a document listing the sequence of operations
required to complete a component. Each route sheet details the specific
manufacturing operations needed for a single part or assembly. Route sheet
calculations determine the number of machines or production equipment
required to meet target output quantities, accounting for scrap percentages,
machine/equipment capacity, and plant efficiency.
Figure 1.8 Route Sheet for Air Regulator
REFERENCES
Tompkins, J. A., White, J. A., Bozer, Y. A., & Tanchoco, J. M. A. (2010).
Facilities planning. John Wiley & Sons.
