Configure and Use Phantom BOMs

A phantom bill of materials (BOM) represents a group of components used within a parent item but not manufactured or stocked as a separate subassembly.

When GoldFinch creates a work order for the parent item, it replaces the phantom BOM line with the phantom BOM’s underlying components. Those components become material requirements on the parent work order.

Before you begin: Confirm that the parent manufactured item, its item formula, and any applicable item routings have been configured.

Configure the Phantom BOM Item

Create or open the item that will represent the phantom BOM.

1. Set the Item Type to Service.
2. Select the Phantom BOM field.
3. Complete any other required item information.
4. Save the item.

Important: GoldFinch requires phantom BOM items to use the Service item type. Because a phantom BOM is not stocked separately, it should not be configured as an inventory item.

Create the Phantom BOM’s Item Formula

Create an item formula for the phantom BOM item and add the components represented by that phantom structure.

Components may include:

• Raw materials
• Packaging materials
• Purchased components
• Other component items used by the parent product

Enter the quantity and unit of measure required for each component.

If a component should be associated with a particular production operation, enter a Link to Operation No. on the item formula line.

Add the Phantom BOM to the Parent Item

Open the item formula for the parent manufactured item.

1. Add the phantom BOM item as a component.
2. Enter the required quantity.
3. If applicable, enter a Link to Operation No.
4. Save the parent item formula.

The operation number entered on the parent formula line can serve as the default routing operation for components expanded from the phantom BOM.

How GoldFinch Expands a Phantom BOM

When a work order is created for the parent item, GoldFinch:

1. Reads the parent item formula.
2. Identifies formula lines marked as phantom BOM items.
3. Replaces each phantom BOM line with its underlying formula components.
4. Calculates the required component quantities.
5. Adds the underlying components to the parent work order.
6. Links those components to the applicable routing operations.

The phantom BOM item itself is not treated as a separately stocked component on the work order.

Link Components to Routing Operations

The Link to Operation No. determines where a component appears within the parent item’s production routing.

GoldFinch evaluates operation links as follows:

• If an underlying phantom component has a valid Link to Operation No. that exists in the parent routing, GoldFinch uses that operation.
• If the component does not have a valid operation link, GoldFinch uses the operation assigned to the phantom BOM line on the parent formula.
• If no applicable operation is specified, review the resulting work order and assign the component according to your production process.

Example

Assume the parent item has the following routing:

The parent item formula contains:

The phantom BOM formula contains:

When GoldFinch expands the phantom BOM:

Verify the Work Order

After creating a work order that includes a phantom BOM, review it before releasing or processing it.

Confirm that:

• The phantom BOM item has been replaced by its underlying components.
• All expected components appear on the work order.
• Required quantities reflect the parent work order quantity.
• Units of measure are correct.
• Components are linked to the correct routing operations.
• No duplicate or unexpected component lines were created.
• Material availability and allocations are reasonable.

Updating a Phantom BOM

Changes to a phantom BOM formula affect work orders created or refreshed after the change, subject to the applicable formula version and work order status.

Before changing a phantom BOM that is already in use:

• Review the effective formula version.
• Determine whether existing open work orders should retain their current components.
• Test the revised structure before applying it to active production.
• Refresh only the work orders that should receive the updated formula information.

Troubleshooting

The phantom item appears instead of its components

Confirm that:

• The Phantom BOM field is selected on the item.
• The item uses the required Service item type.
• An active item formula exists for the phantom BOM.
• The phantom BOM is included in the applicable parent formula version.

Phantom components do not appear

Confirm that:

• The phantom BOM formula contains active component lines.
• The correct parent formula and formula version are being used.
• Component quantities and units of measure are valid.
• The work order was created or refreshed after updating the formula.

Components appear under the wrong operation

Review:

• The Link to Operation No. on each phantom BOM component.
• The default operation assigned to the phantom BOM line on the parent formula.
• The operation numbers defined in the parent item routing.

A component-level operation must correspond to an operation available in the parent routing. Otherwise, GoldFinch uses the applicable default operation from the phantom BOM line.