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This article explains how to set up and use the BOM Picking function in ELAM Solutions. A BOM step allows operators to pick multiple components in a single step, guided by a Bill of Materials. Each component can be confirmed via a KBS module (Pick to Light), a SmartTower, or by scanning the component’s barcode.

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What is BOM Picking?

BOM Picking is a guided picking process based on a Bill of Materials (BOM). Each BOM contains a list of components with their part ID, name, scan code, and required quantity. A single BOM step in a flowchart covers all positions of the BOM – the operator works through each component one by one within that step, without needing a separate flowchart step per part.

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Step 1: Create a BOM

Before you can use BOM Picking in a flowchart, you need to create at least one BOM.

1. In the ELAM Administration, navigate to Components in the left menu.
2. The Component Overview opens. Click the BOM Overview button in the top right corner to switch to the BOM view.
3. Click + New BOM.
4. Enter a Name for the BOM (required field).
5. Click + Assign Component to add components to the BOM.
6. For each component, select the Component ID from the dropdown and set the required Quantity. The position is assigned automatically and can be reordered by drag and drop.
7. Click Save.

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Note: Components must be created in ELAM before they can be assigned to a BOM. Each component has a unique Component ID and a scan code used for verification during picking. A KBS module or SmartTower can be assigned to a component directly in the Component settings.

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Step 2: Add a BOM Step to a Flowchart

1. Open or create a flowchart under Flowcharts.
2. Switch to Edit Mode.
3. From the step palette on the left, drag the BOM step (clipboard icon) into your flowchart canvas.
4. Connect it between the Start and End OK nodes.
5. Click on the BOM step to open the BOM Details panel on the right.

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Step 3: Configure the BOM Step

The BOM Details panel has the following fields:

• Name: The display name shown in the ELAM Assistant.
• Source: Defines where the BOM data comes from. Two options are available:

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Source: ELAM BOM

With this option, a BOM that was created directly in ELAM Solutions is used (under Components → BOM Overview). The BOM is used exactly as it is currently configured – its component list, quantities, and positions are fixed at the time of execution.

• BOM: Select the desired BOM from the dropdown.

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Source: Import BOM

With this option, the BOM data is transmitted to ELAM by the ERP system. The ERP system sends the BOM list as part of the order data. In the BOM step, you enter a BOM Name that identifies which BOM from the ERP order should be used for this step.

• BOM Name (required): Enter the name that identifies the BOM within the ERP order. This name must exactly match the BOM name transmitted by the ERP system.

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Note: Import BOM requires a configured ERP Connector in ELAM. The BOM data is provided by the ERP system via the assigned order. If no matching BOM name is found in the order data, the picking list will appear empty in the ELAM Assistant.

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• Picking Mode: Choose between two modes:
  • Sequential: The operator picks components one by one in defined order. Each position is highlighted individually.
  • Parallel: All components are shown at once and can be confirmed in any order.

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Recommendation: Use Sequential for error-critical assemblies where order matters, and Parallel for simple picking tasks where the operator can work freely.

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Step 4: Release and Assign the Flowchart

1. Click Save to save your changes.
2. Click Publish to release the flowchart version.
3. Assign the flowchart to a variant or station via Assignments.

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BOM Picking in the ELAM Assistant

When the operator starts the assigned variant, the BOM Picking step is displayed as a table with the columns: No., Component ID, Component Name, Scan Code, Quantity, and Status. The currently active position is highlighted in blue.

Each component can be confirmed in one of the following ways:

• KBS Module (Pick to Light): The KBS module assigned to the component lights up. The operator picks the part and confirms via the module button.
• SmartTower: The SmartTower assigned to the component opens the correct drawer. The operator picks the part and confirms via the SmartTower.
• Scan: The operator scans the barcode of the component. ELAM verifies the scan code and confirms the position automatically if it matches.

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Note: The Manual OK (MOK) button allows an operator to manually override a picking position without scan or module confirmation. This is a manual override and is not equivalent to a regular OK as confirmed by a tool or hardware module. Use MOK only when a hardware confirmation is not possible.

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Once all positions are confirmed, the BOM step completes and the flowchart advances to the next step.

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Preview and Test

You can simulate the BOM step directly from the flowchart editor by clicking Preview in the BOM Details panel. This opens the ELAM Assistant in simulation mode.

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Note: When using Import BOM, the picking list will be empty in simulation mode since no live ERP order data is available during a simulation.

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FAQ

What is the difference between ELAM BOM and Import BOM?

ELAM BOM uses a component list that you configure and manage directly in ELAM Solutions. The BOM is used as currently set up. Import BOM uses a component list that is transmitted to ELAM by the ERP system as part of an order, identified by the BOM Name configured in the step.

Can a single BOM step cover multiple components?

Yes. A single BOM step processes all components defined in the BOM. The operator picks each position within the same step without needing additional flowchart steps per component.

Which hardware can be used for picking confirmation?

KBS modules (Pick to Light), SmartTower modules, and barcode scanning are all supported. The hardware must be assigned to the respective component in the Component settings.

What is Manual OK (MOK) and when should it be used?

Manual OK is a manual override that allows confirming a picking position without hardware or scan confirmation. It is not the same as a regular OK confirmed by a tool or module. MOK should only be used when normal confirmation is not possible.

Can the order of BOM positions be changed?

Yes. In the BOM editor (ELAM BOM), positions can be reordered using drag and drop. For Import BOM, the order is determined by the ERP system.

Can I use the same BOM in multiple flowcharts?

Yes. An ELAM BOM is reusable and can be assigned to as many BOM steps as needed across different flowcharts.