• A Bill of Materials (BOM) is a comprehensive list of all the components, parts, and raw materials needed to manufacture a product or assemble a finished good. It provides a detailed breakdown of everything required to build a product, including the quantities, specifications, and costs of each item.

  • The BOM is an essential document in manufacturing and production management because it enables manufacturers to determine the total cost of a product, plan production schedules, and manage inventory levels. It also helps ensure that the right parts and components are available at the right time, so that production runs smoothly and efficiently.

• Creating a bill of materials involves several steps:

1. Identify the finished product: Determine the final product that you intend to manufacture or assemble.

2. Determine the structure: Identify the components, sub-assemblies, and raw materials needed to build the product.

3. Determine quantities: Determine the quantity of each component and raw material required to build the product.

4. Determine costs: Calculate the cost of each item, including shipping, handling, and taxes.

5. Compile the list: Put all of the information together in a spreadsheet, database, or other document.

6. Maintain and update: Keep the BOM up-to-date as you make changes to the product design, add or remove components, or update costs.

• Overall, the bill of materials is a vital tool for managing the production process and ensuring that products are built on time, on budget, and to the required specifications.

1. For this Checkpoint, you will be performing the role of an Industry 3.0 (i3.0) Automatic Saw Operator

   • Note: If you are physically unable to complete the following tasks for whatever reason, please let the instructor know and we'll have you do something else!

2. Using one of the Tormach Auto-Feed Bandsaws in the MET Cutting Lab, do the following:

   • Locate 1" 6061-T6 AL Square Bar

   • As needed (not required), utilize Systems Approach tools/methods/techniques to understand how the saw operates:

     1. System-Module-Component Breakdown

     2. Sequential Function Chart (SFC)

     3. Power-Work-Control (PWC) / Energy-Material-Information (EMI) Charts

     4. Displacement Step Diagram (DSD)

   • As needed during setup & operation of the saw, troubleshoot & resolve minor malfunctions or problems that arise

     1. Consult the Tormach AF-50 Autofeed Bandsaw Operator's Manual

     2. DO NOT DISASSEMBLE THE SAW WITHOUT INSTRUCTOR PERMISSION/DIRECTION

   • Load the square bar in the autofeed bandsaw:

     1. Setup the saw to cut 1.25" (+/- 1/16") long pieces

        • Perform a test cut & adjust as needed to prepare for an automated run of more parts: 

          • Deburr all sharp edges of the piece

     2. Perform a run of 3 parts to cut automatically (for a grand total of 4 pieces for this assignment)

        • Deburr all sharp edges of each piece

        • Inspect the cut quality/dimension to the specified tolerance

     3. Record and document:

        • Setup Time (How long it took you to get ready to cut)

        • Cycle Time (How long it took you to cut each piece)

        • Post-Processing Time (How long it took you to inspect & deburr each piece)

     4. Bring the pieces to your instructor to verify quality & be used to make parts at a later date

Once done, upload documentation of your progress (text/pictures/gifs/videos) to your previously-created "Saw Operator" project page on your portfolio website, including:

2. • You performing all operations of making the pieces (ID, setup, measure/layout, cutting, deburring, inspecting)

   • A table showing your setup, cycle, and post-processing times

   • Descriptions/summaries of what you did/learned