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A Bill of Materials (BOM) is essential for efficient manufacturing, but outdated BOMs lead to production errors, material shortages, and costly rework. Integrating shop floor systems (like Manufacturing Execution Systems) with Enterprise Resource Planning (ERP) and Product Lifecycle Management (PLM) software ensures real-time BOM updates, keeping operations aligned. In this article, we’ll explore how modern shop floor systems optimize BOM management, reduce waste, and improve production efficiency.
Integrate ERP & PLM for Real-Time BOM Updates
Manufacturing Execution Systems (MES) need to link directly with Enterprise Resource Planning (ERP) and Product Lifecycle Management (PLM) software to ensure real-time data exchange. Shop floor systems capture live production data (machine performance, work orders, quality checks, etc.), which ERP systems use for planning, costing, and forecasting. With the integration, any changes to BOMs (managed in ERP) automatically update on the shop floor, preventing outdated instructions and reducing manual errors. This eliminates outdated paper documents, enhances communication across teams, and ensures everyone—from procurement to production—is always working with the latest data.
Operators Always Have Up-to-Date Work Instructions
BOM changes impact operators directly. If they follow outdated instructions, they may use incorrect parts or procedures, leading to defects, rework, or safety issues.
With Digital Work Instructions synced with ERP systems, operators receive instant updates when BOMs change. This helps:
- Eliminate Paper Instructions – Reducing confusion caused by outdated printed BOMs.
- Ensure Standardized Assembly – Operators always follow the latest approved processes.
- Reduce Training Time – New employees quickly follow step-by-step, visual instructions.
- Capture Live Feedback – Operators can flag errors or suggest improvements directly from the workstation.
Prevent Material Shortages with Real-Time Inventory Tracking
A BOM update often involves changes to required materials. Connected shop floor systems automatically adjust inventory tracking in response to these changes by:
- Providing immediate visibility into current stock levels, clearly indicating which new components must be ordered.
- Utilizing barcode and RFID scanning to ensure only correct materials are used at each production stage.
- Alerting procurement teams instantly when stock levels are low, preventing shortages that could halt production.
Beyond addressing shortages, these systems incorporate error-proofing mechanisms, such as smart assembly tools, torque validation, and barcode scanning, which help prevent incorrect part usage, reduce costly rework, and increase product quality.
Maintain Version Control and Full Traceability
Each revision of the BOM must be accurately recorded and easily traceable. Shop floor systems include built-in version control, documenting all changes with timestamps, approval records, and revision notes.
This detailed tracking lets teams quickly identify which BOM version corresponds to a specific production batch, easily revert to an earlier version if necessary, and demonstrate compliance during audits or quality checks. This eliminates uncertainty, ensures regulatory compliance, and strengthens accountability across the organization.
BOM Updates Are Only as Good as Their Execution
BOM updates are a natural part of manufacturing, but the quality of their execution determines whether your production stays on schedule or experiences costly disruptions. A connected shop floor ensures each update is recorded, synchronized, and immediately applied, keeping operators, procurement teams, and engineers consistently aligned.
If errors related to BOM updates are hurting production, investing in a connected shop floor solution like PICO can help. PICO integrates seamlessly with ERP and PLM software, ensuring each BOM update instantly reaches your shop floor.
Next Steps
- Learn more about ERP and MES integrations, and why you need both: MES vs. ERP: Do I Need Both In My Factory?
- See all the business systems that PICO integrates with: Integrations for a connected factory
- Want to see how PICO MES eliminates BOM errors? Schedule a live demo today.
