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BOM - Checklist & Material Deviations

 · 4 min · Romeu Gonçalves

On-the-Fly Adjustments

Checklist BOM Protocol V11.2
In modern manufacturing, flexibility is key, but it must be balanced with control. That's why our new MES version includes now a powerful new feature: "Material Deviation for Checklist and Bill of Material".

In the industrial equipment industry, it’s not uncommon for operators, during the assembly of parts (guided by a Checklist), to have to make unforeseen changes, such as modifying certain Items of the Checklist or even replacing a component or adjusting the quantity to be used.

BOM - Checklist & Material Deviations Overview

In Critical Manufacturing MES, a BOM can be associated with a Checklist, where each component to be assembled is assigned to specific Checklist Items, ensuring that a defined sequence is followed during the assembly process (Although it's always possible to configure some Checklist Items to be executed at any point during the process) During these operations the end user can on the fly request some changes as shown below:

  • Add/Change/Remove Checklist Items
  • Add/Change/Remove BOM Items

Material Deviation
Material Deviation

However, these change requests are not immediately implemented. They need first to be reviewed and either approved or rejected through a Material Deviation protocol. Therefore, this protocol must be also assigned to the Checklist to enable this functionality.

Configuration Highlights

Multiple MES entities contribute to the configuration of this feature, so let's take a look at each of them.

  • Bill of Material configuration

BOM
BOM

Create (or import into MES) the Bill of Material. This entity offers various options, but the most important properties for this use case are the BOM scope, the products with their respective consumption quantities, and the assembly process step."

  • Protocol Setup

A protocol of Scope “Material Deviation” must be created to Review and then either approve or reject the changes requested. Its flow chart can be minimal, with a single approval state, or more elaborate with multiple states and approval levels.

Protocol
Protocol

  • Data Collection and Data Collection Limit Set Optionally, create a Data Collection and a Data Collection Limit Set to capture process data during assembly process

  • Checklist Configuration

Checklist
Checklist
Create a LongRunning checklist for the material transaction and assign all previously configured entities to it, as illustrated above. For specific Checklist Items, define the components to be consumed during the process, and for others, or the same items, configure the data to be collected

  • Context Tables

For the Assembly Step, fill the context tables for BOM, Data Collection and Checklist

Demo

Benefits

CM MES Features like this one bring meaningful benefits across all levels of users in Critical Manufacturing MES:

  • Enhanced Flexibility During Assembly: Operators can request changes “on the fly” without completely stopping production, adapting to unforeseen adjustments smoothly.

  • Controlled Change Management: All requested deviations are reviewed and either approved or rejected via the Material Deviation protocol, ensuring changes are tracked and authorized before implementation.

  • Single GUI for all operations: With the integration of BOMs, protocols, Checklists, and optional data collection, documents and technical drawing, MES users can perform all tasks without switching between different features

Final Thoughts

The new Material Deviation feature for Checklists and BOMs brings the perfect balance between flexibility and control in modern manufacturing. Operators gain the freedom to adapt to real-world changes on the shop floor, while managers retain oversight and traceability through a structured approval process

Author

Hi! My name is José Romeu Bogas Gonçalves. 😉

I’ve been with Critical Manufacturing since 2018, starting out as an MES Consultant. Earlier this year, I stepped into the recently created Advocate & Architecture team. My role sits at the intersection of technology, communication, and strategy. Making sure solutions are technically sound and that everyone understands how to use or build them.

You can check me on LinkedIn

Skills: MES Consultant | System Testing | System Modeling | User Training | Content Creating

Romeu Gonçalves
Architecture & Advocacy | MES