In this article, let’s look at PLM and Evolution of BOMs.
PLM and Evolution of BOMs (Bill of Materials) across the Product Life Cycle
In the world of Product Lifecycle Management (PLM), the Bill of Materials (BOM) plays a critical role in connecting design intent with the downstream execution of manufacturing, sourcing, and service operations.
However, a BOM is not a static artifact. It evolves as a product moves from ideation to design, through production and into the aftermarket. Each stage of the lifecycle demands a different flavor of BOM—tailored to the context, purpose, and audience involved.
In this article, let’s explore different types of BOMs encountered throughout the product engineering journey and how PLM systems help manage the evolution of BOMs seamlessly across disciplines and departments.
What is a BOM?
A Bill of Materials (BOM) is a structured list of parts, assemblies, and components required to build a product. It contains part numbers, descriptions, quantities, unit of measure, and often metadata like material, supplier, lifecycle status, and cost.
Evolution of BOMs: From DBOM to SBOM
Here’s how BOMs typically evolve across the product lifecycle:
1. DBOM (Design BOM) – Early Concept Stage
- Created by industrial or conceptual designers
- Focused on product structure and functions
- Informal, creative, and unvalidated
- Used for feasibility analysis and stakeholder reviews
⬇️ Transitions into
2. EBOM (Engineering BOM) – Detailed Design Stage
- Created by engineering teams using CAD and PLM tools
- Contains actual part numbers and specifications
- Focuses on what the product is (design intent)
- Validated through simulations, testing, and design reviews
⬇️ Transformed into
3. MBOM (Manufacturing BOM) – Manufacturing Planning Stage
- Created in collaboration with manufacturing and process engineers
- Includes everything needed for assembly: fasteners, consumables, tools
- Structured according to how the product is built (assembly steps)
- Synchronized with routings, work orders, and ERP systems
⬇️ Localized into
4. Plant BOM – Plant-Specific Execution
- Tailored version of MBOM for a specific factory or plant
- Reflects local sourcing, tools, and regulations
- Includes supplier alternates, local packaging materials
- Used on the shop floor for actual production execution
⬇️ Derived for
5. SBOM (Service BOM) – Aftermarket and Service
- Simplified view of the product with only serviceable components
- Used by field service teams, spare parts distributors, and warranty teams
- May include exploded views, part replacements, and service kits
- Tied to As-Maintained configuration of serialized products in the field
At each stage, the BOM is enriched, restructured, or filtered depending on the context:
- DBOM to EBOM = Add engineering detail
- EBOM to MBOM = Add manufacturing process logic
- MBOM to Plant BOM = Localize and optimize for plant operations
- Plant BOM to SBOM = Filter for serviceability and field use
Beyond these core BOMs, companies may use specialized BOMs:
- Supply-Chain (or Procurement) BOM – a subset of the EBOM/MBOM used for supply and purchasing, often communicated to suppliers.
- Sales BOM – a sales or kit BOM (often called SBOM in some contexts) listing the product and its components as sold to a customer (usually before final assembly); used for quoting and order configuration.
This is normally not handled in serial after manufacturing; instead it exists early as part of product definition for sales or CPQ, or as a parallel branch. In an engineer-to-order process, sales BOM/configuration often precedes manufacturing. A more appropriate sequence would be to introduce the Sales/BOM view around the same time as the EBOM (to drive quotes). That said, in simpler make-to-stock products, a Sales BOM may simply mirror the final EBOM/MBOM. But as a general process, Sales BOM is typically prepared in parallel (or from variants) rather than strictly afterward.
- As‑Maintained (As-Serviced) BOM – the actual configuration of a specific installed product over time, reflecting any field upgrades or repairs (essentially an “as-built” BOM updated by service history..
Example for each type of Bill of Material (BOM) :
Each example aligns with a specific BOM’s role in the product life cycle of a car—let’s say a hybrid SUV as the base product.
1. Design BOM (DBOM)
Example: Lithium-ion Battery Module (Part #LI-BAT-4000) Listed in the DBOM during the concept phase to define the energy storage unit required to meet the vehicle’s range and power goals.
2. Engineering BOM (EBOM)
Example: Front Suspension Assembly – Version 3.1 (Part #FS-V3.1) Defined by the engineering team with detailed part specs, tolerances, and CAD model references. Includes items like strut, control arm, and bushings as designed.
3. Manufacturing BOM (MBOM)
Example: HVAC System with Pre-Assembled Duct Units (Assembly #HVAC-MFG-001) Tailored for the assembly line. Includes manufacturing-specific details like glue, fasteners, and tooling instructions not present in the EBOM.
4. Plant BOM
Example: Infotainment System Variant for EU Market (Assembly #INFO-PLANT-EU) Includes components localized for compliance (e.g., GPS maps for EU, different language packs) that are specific to the European production facility.
5. Service BOM
Example: Hybrid Battery Service Kit (Kit #SERV-BAT-KIT01) Contains parts and subassemblies needed to service or replace the hybrid battery in a dealership or authorized service center.
6. Supply Chain or Procurement BOM
Example: Rear Axle Assembly – Procurement View (BOM #PROC-AXLE-002) Shows supplier-specific components, part numbers, lead times, preferred vendors, and alternate sources for parts like bearings and shafts.
7. Sales BOM
Example: Premium Interior Package (Sales Kit #PREM-INT-PACK) Configurable option in the dealership system including leather seats, ambient lighting, and upgraded dashboard—all shown as a single SKU in sales but broken into multiple parts in backend systems.
8. As-Maintained or As-Serviced BOM
Example: VIN ABC123456789 – As-Maintained BOM Tracks the exact parts and serial numbers installed or replaced in a specific vehicle (e.g., brake caliper replaced in Jan 2024, infotainment system updated in Aug 2024).
Key Aspects of BOM Management in PLM:
- Accurate Product Definition: A BOM provides a comprehensive list of all components, their quantities, and specifications, ensuring a clear and consistent understanding of the product’s structure.
- Collaboration and Communication: PLM systems facilitate collaboration among different teams by providing a central repository for BOM data, enabling efficient information sharing and communication.
- Change Management: BOMs are not static; they evolve as products change. PLM systems help track and manage changes to BOMs, ensuring that everyone is working with the latest version.
- Cost Estimation and Analysis: BOMs are used to calculate material costs, labor costs, and other expenses associated with producing a product, enabling better cost control and optimization.
- Manufacturing and Supply Chain Integration: BOMs are crucial for planning manufacturing processes, managing inventory, and coordinating with suppliers.
- Compliance: BOMs help ensure that products meet regulatory standards and industry requirements.
- Data Quality: PLM systems help ensure the accuracy and consistency of BOM data, reducing errors and rework.
- Engineering to Manufacturing Transition: The transition from an Engineering Bill of Materials (EBOM) to a Manufacturing Bill of Materials (MBOM) is streamlined, ensuring that the manufacturing department has a clear and accurate blueprint for production.
Benefits of Effective BOM Management in PLM:
- Reduced Costs: By optimizing material usage, reducing errors, and streamlining processes, BOM management can significantly reduce manufacturing costs.
- Improved Quality: Accurate BOM data helps ensure that products are manufactured to the correct specifications, improving product quality.
- Faster Time to Market: By streamlining product development and manufacturing processes, BOM management can help organizations get products to market faster.
- Enhanced Collaboration: A centralized PLM system with BOM management promotes better communication and collaboration among different teams.
- Better Decision Making: Accurate and up-to-date BOM data enables better decision-making throughout the product lifecycle.
How PLM Enables BOM Harmonization
The biggest challenge with managing different BOMs is ensuring that they stay in sync and reflect the same product reality. PLM systems provide the backbone for:
- BOM synchronization between design, manufacturing, and service
- Change management and version control
- Configuration and variant management
- Cross-functional collaboration (engineering, manufacturing, sourcing, service)
- Traceability across the lifecycle
Modern PLM platforms offer BOM management capabilities that span disciplines, allowing stakeholders to work from a shared source of truth while viewing the BOM from their own lens.
Conclusion
A BOM is much more than a list of parts—it’s a living, evolving structure that carries the DNA of the product across its lifecycle. From initial sketches on a design board to assembly lines, warehouses, and field repairs, different types of BOMs serve different audiences with different needs.
Understanding how these BOMs evolve—and how PLM systems help manage them—is key to building products that are not just manufacturable, but also serviceable, customizable, and sustainable. For engineering and operations leaders, investing in BOM maturity and PLM integration is no longer optional—it’s foundational to digital transformation.
MechiSpike can be of great help to your organization to consult you on anything and everything related to PLM, Engineering and IT Digital. Click here to know more about us.
For Corporates :
MechiSpike can be of great help to your organization to help you improve your PLM ROI and 30% Savings, be it the hiring cost in staffing or setting up an ODC.
We do this with efficient planning, organizing and controlling Product Master data with seamless data exchange among Engineering, Manufacturing and Enterprise systems.
Why MechiSpike :
Niche Expertise in Engineering & IT
Our Speed of Hiring, Cost Optimized Solutions and Global Presence.
RightSourcing is ‘Better Outsourcing’, given to ‘NICHE EXPERTS’.
Click here to know how we can actually help you with our Proven Methodologies.
For PLM Careers :
Learn More | Earn More | Grow More
Interactive UI : Every Application will get a response with a recruiter contact details and the applicant will get a notification at each phase until the applicant is positioned well with our 15+ global clients in India, USA & Germany.
Candidate Referral Program : Refer a candidate and earn INR 25,000.
Mechispike Solutions Pvt Ltd is a PLM focused company, having all kinds of PLM projects to enable employee career growth and add value to clients. We can position you better with our 15+ global clients in India, USA & Germany.
We believe in “Grow Together” and “Employee First” culture.
Dream more than a Job. Grow your PLM Career to the Fullest with MechiSpike
Click Here to explore our Job Openings.
Subscribe Now :
Our mission : To equip you with the knowledge and tools you need to drive value, streamline operations, and maximize return on investment from your PLM initiatives.
PLM ROI Newsletter will guide you through a comprehensive roadmap to help you unlock the full potential of your PLM investment.
We are committed to be your trusted source of knowledge and support throughout your PLM journey. Our team of experts and thought leaders will bring you actionable insights, best practices, case studies, and the latest trends in PLM.
Subscribe Now to get this weekly series delivered into your Inbox directly, as and when we publish it.
To your PLM success!
Warm regards,
