Complex Configuration & Option Variant BOM Governance
A luxury commercial coach and specialized vehicle builder offering over 2,500 customizable options, seating layouts, powertrain configurations, and interior trims.
Run on Sama · Traceability & Product Data
The challenge
Configuring custom vehicle builds required manual interpretation of complex 150 page option compatibility matrices and 150% BOMs.
Sales orders with invalid option combinations slipped through to the shop floor, resulting in missing wiring harnesses and stopped assembly lines.
Engineers spent 40% of their time manually reviewing custom customer orders to resolve option rule conflicts.
How Sama solves it
150% Master Configurable BOM Architecture
Sama manages complex 150% master BOM structures with embedded Boolean logic and option code dependency rules.
Automated 100% Single Vehicle BOM Resolution
Instantly resolves sales option selections into an accurate, complete 100% build BOM for individual custom vehicle orders.
Real Time Option Conflict & Incompatibility Flagging
Detects mutually exclusive option choices and missing prerequisite components at the point of order entry.
Option Variant Cost & Weight Rollup
Calculates precise vehicle weight, center of gravity, and component cost dynamically based on selected option packages.
Automated Work Order Traveler Generation
Dispatches customized station by station assembly travelers and kitting lists to the factory floor.
The outcome
- custom vehicle order BOM validation time reduced
- 0 dayscustom vehicle order BOM validation time reduced
- elimination of invalid option combinations and missing harness
- 0%elimination of invalid option combinations and missing harness
Custom vehicle order BOM validation time reduced from 4 days to 3 seconds.
100% elimination of invalid option combinations and missing harness errors on the assembly line.
Reduced custom vehicle engineering order processing costs by 65%.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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