BILL OF MATERIALS AUTOMATION

Adi Y. Nugroho

June 22nd, 2013

SYSM 6309: Advanced Requirements EngineeringSummer 2013

Table of Content• Background• Process Flow and Description• Situation and Description• Input and Output BOM Format• Problems• Solution• Implementation Aspect• Cost Estimation and Comparison• Summary

Background

• Engineering team had to deliver Bill of Materials (BOM) for sales and project team based on solution requirement and final design output.

• Bill of Materials must used products described on solution document and match with final microwave design.

Process FlowHigh Level Solution

Agreed with The Customer

Site Acquisition and Development

Nominal Microwave Design

Line of Sight Survey LOS Confirm? Final Microwave Design

Bill of MaterialsDocuments

Yes

No

Process DescriptionSolution Requirement

High Level Design + Products

Site AcquisitionNominal Design Line of Sight Survey

Final Design Bill of Materials

Engineering Scope

Situation1. Every site has unique BOM since it might has different parameters:

– Number of links• Related to indoor unit type that will be used: 2/5/20 slots.

– Link specifications:• Antenna diameter size: 1/2/4/6 feet• Antenna type: Std (Standard)/HP (High Power)• Radio Frequency: 11/15/23/28/38 GHz• Radio modulation: 4/16/64/126/256/512 QAM• Capacity: 30/60/125/200/350 Mbps• Link specification example:

– 15GHz 064T/16 ANT0.6 HP (not all sites has the same spec!)

– Antenna placement location• Antenna location: rooftop or tower• Related to radio cable size that will be used. Cable length size: 1 - 400 feet

Situation2. Total number of sites: 6000 sites nationwide. 3. BOM must have accuracy with maximum error tolerance 1%4. Timeline: 2 months5. Maximum number of resources 2 engineers.

Situation Description

Site

LinkEven though these two sites have same condition (they have 2 links), it does not mean the BOM will be same.The link spec might be different so is the antenna location. -One site can have high tower and the other site can be roof top.-One link can have MLTN28/2X 194T/64X-140 spec and the other can have 2010 28 064T/16-20 spec.

Input BOM FormatSite name 1 Site name 2 Antenna model 1 Antenna model 2 Antenna

height (ft) 1Antenna height (ft) 2

Frequency (MHz)

Radio model 1 Radio model 2

Site392 Site191 ANT2 0.6 28 HPX (TR) ANT2 0.6 28 HPX (TR) 93 140 27922 MLTN28/2X 194T/64X-140 MLTN28/2X 194T/64X-140Site645 Site187 ANT2 0.6 11 HPX (TR) ANT2 0.6 11 HPX (TR) 108 67 11200 TN11/2X 279T/512X HP-210 TN11/2X 279T/512X HP-210Site627 Site606 ANT2 0.3 28 HP (TR) ANT2 0.6 28 HP (TR) 112 91 27922 MLTN28/2X 225T/128X-80 MLTN28/2X 225T/128X-80Site279 Site031 ANT2 0.6 28 HP (TR) ANT2 0.6 28 HP (TR) 168 82 27922 MLTN28/2X 248T/64X-90 MLTN28/2X 248T/64X-90Site606 Site599 ANT2 0.6 28 HP (TR) ANT2 0.6 28 HP (TR) 82 86 27922 2010 28 064T/16-20 2010 28 064T/16-20Site012 Site522 ANT2 0.6 18 HP (TR) ANT2 0.6 18 HP (TR) 154 25 18700 2010 18 064T/16-20 2010 18 064T/16-20Site269 Site467 ANT2 0.6 11 HP (TR) ANT2 0.6 11 HP (TR) 80 88 11200 TN11/2X 225T/128X HP-80 TN11/2X 225T/128X HP-80Site522 Site462 ANT2 0.6 11 HP (TR) ANT2 0.6 11 HP (TR) 88 87 11200 TN11/2X 194T/64X St-70 TN11/2X 194T/64X St-70Site424 Site462 ANT2 0.3 28 HP (TR) ANT2 0.3 28 HP (TR) 81 127 27922 MLTN28/2X 143T/64X-40 MLTN28/2X 143T/64X-40Site391 Site390 ANT2 0.6 28 HP (TR) ANT2 0.3 28 HP (TR) 71 127 27922 2010 28 064T/16-20 2010 28 064T/16-20Site462 Site673 ANT2 0.6 11 HPX (TR) ANT2 0.6 11 HPX (TR) 127 220 11200 TN11/2X 194T/64X St-135 TN11/2X 194T/64X St-135Site442 Site462 ANT2 0.6 11 HP (TR) ANT2 0.6 11 HP (TR) 72 82 11200 TN11/2X 131T/16X St-35 TN11/2X 131T/16X St-35Site396 Site394 ANT2 0.6 18 HP (TR) ANT2 0.6 18 HP (TR) 115 89 18700 TN18/2X 194T/64X HP-65 TN18/2X 194T/64X HP-65Site394 Site021 ANT2 0.3 28 HP (TR) ANT2 0.3 28 HP (TR) 89 127 27922 2010 28 064T/16-20 2010 28 064T/16-20Site380 Site394 ANT2 0.3 28 HP (TR) ANT2 0.3 28 HP (TR) 88 89 27922 2010 28 064T/16-20 2010 28 064T/16-20

Output BOM Format

Site001

Site002

Site003

Site004

Site005

Site006

Site007

Site008

Site009

Site010

Dummy Front, 265mm 1 1 1 1 2 1 1FAU4 Fan unit 1 1 1 2010 18, Subband 31 1 2010 18, Subband 35 1 1 2010 28, Subband 52 2010 28, Subband 54 30 Mbps Capacity 2 2 2 1 1 1 1 2 60 Mbps Capacity (60 Mbps Includes 30 Mbps) 2 2 3 2 200 Mbps capacity (200 Mbps Includes 30,60,125 Mbps 2 4 4 2350 Mbps Capacity (350 Mbps Includes 30,60,125,200 Mbps 4 2 21+1 Radio Protection 1 1 1 1 1 1 Ethernet switching on NPU3C 1 1 1 1 2 1 2 1 1Adaptive Modulation (per MMU2 H) 4 2 2 4 7 5 1 8 4 4XPIC For TDM/Ethernet (per 2 Radio Terminals) 2 2 2 2 22010 R1 Basic SW License 1 1 1 Grounding Kit For 10mm RF Cable 12 4 4 8 18 8 0 24 12 86p C R4 with NPU3C kit 1 1 1 1 2 1 12p B R4 w NPU3C Kit 1 1 1 Cable Clamp kit, 10mm (Ø3/8"), 50 pcs 8 2 2 4 12 4 0 16 8 418 GHz RAU2 X, Subband 31 1 18 GHz RAU2 X HP, Subband 31 2 18 GHz RAU2 X, Subband 35 2 18 GHz RAU2 X HP, Subband 35 3 1 RAU2 X 28, Subband 52 2 3 2 RAU2 X 28, Subband 54 2 2 2 3 11 GHz RAU2 X HP, Subband 22 2 211 GHz RAU2 X HP, Subband 23 2 11 GHz RAU2 X HP, Subband 26 2 11 GHz RAU2 X HP, Subband 27 2 MMU2 H kit 4 2 2 4 6 4 8 4 4Cable Clamp Kit 50 (50 pcs) 2 1 1 Coax cable reel, 100m 4 6 8 4

Site001

Site002

Site003

Site004

Site005

Site006

Site007

Site008

Site009

Site010

Coax cable reel, 300m Coax cable reel, 50m 2 2 4 4 4TRX MM 1000Base-SX LC-SFP -40/+85C Optical Transc. /SFP GB-LX 1310nm SM, LC duplex 2 2 2 ETU3, 2xGbE (SFP) + 2x1000-BaseT 1 1 2010 Power Cable, 100m 2010 Power Cable, 50m 1 1 2010 Power Cable, 70m 1 6p DC Cable, 5m 1 1 1 1 2 1 1Alignment test cable, 1.5m (5ft) 1 1 1 1 1 1 1 1 1 1LC-LC Outdoor Fiber, 100m LC-LC Outdoor Fiber, 50m 1 1 LC-LC Outdoor Fiber, 70m 1 XPIC 2xRJ45,0.3M 2 2 2 2 22p DC Cable, 5m 1 1 1 DC power cable Dummy front, 49mm 1 1 1 1 2 1 12 pcs N-type connector and 1 pcs adaptor 4 2 2 4 6 4 8 4 4Dummy Front, 115mm short 1 1 1 1 1 2 1 1Radio cable bracket (2 pos) 2 1 1 2 3 2 4 2 211 GHz 3 ft HPX antenna 1 111 GHz 2 ft HPX antenna 1 1 1 18 GHz 2 ft HPX antenna 1 1 118 GHz 2 ft HP antenna 1 1 1 1 1 1 2 28 GHz 2 ft HPX antenna 1 28 GHz 2 ft HP antenna 1 1 2 1 28 GHz 1 ft HPX antenna 1 28 GHz 1 ft HP antenna 1 1 18 GHz Asym. Power splitter 1 28 GHz Asym. Power splitter 1 1 1 1 1 AMP 2POS CONN 1982299-3 KEY ON TWO SIDES 1 1 1 1 2 1 0 2 1 1TYCO CONT 13AWG FE, R927837-5 2 2 2 2 4 2 0 4 2 2

Problems• Huge effort to finish the work with limited resources.

– Rough Calculation:• 6000 : 2 engineer = 3000 sites/2 month/engineer

= 65 sites/day/engineer– Supposed 1 engineer can finish 1 site BOM within 15

minutes with 8 working hours per day, it will take 4 months to complete the work.

• Human error probability is high for repetition work.

• Difficulties to track the document if there are some changes or revision during BOM generation process.

Solution

• BOM generator automation is needed to produce the BOM faster, less errors, more accurate, consistent, easy to track, and convenient for all end users.

Implementation Aspects

• In order to create this automation, a programmer with competence in .NET and C# language, SQL database, and web programming is needed.

• The programmer resource will be taken from internship since the project duration is only 1-2 months.

• The programmer must collaborate with Subject Matter Expert (SME) to produce the correct algorithm for all automation processes.

Cost Estimation and Comparison

Up to 85% cost reduction!

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SUMMARY

• Engineering team had to deliver BOM for sales and project team based on solution requirement and final design output.

• After analyzing all possible risks, we found 3 major problems that must be handled.

• BOM generator automation is proposed as a solution for the problems.

• Based on rough cost estimation, the tool is not only will speed up the process but it can reduce the operational cost up to 85% as well.

Thank You