Harmonizing EBOM to MBOM Discrepancies During Electric Vehicle Ramp
An Electric Vehicle (EV) original equipment manufacturer ramping up a new dual motor SUV platform across two high volume vehicle assembly plants.
Run on Sama · Traceability & Product Data
The challenge
Frequent Engineering BOM (EBOM) updates released by R&D; (such as battery busbar revisions and harness routing updates) were out of sync with plant Manufacturing BOMs (MBOMs).
Plant manufacturing engineers relied on weekly spreadsheet reconciliations, leading to assembly line part shortages and line stoppage.
Engineering Change Orders (ECOs) took up to 3 weeks to manually reconcile across plant MBOMs, resulting in $1.8M in obsolete component write offs.
How Sama solves it
Multi Domain BOM Dashboard Integration
Sama centralizes CAD derived EBOMs and plant specific MBOMs into a single real time synchronization cockpit.
Real Time Discrepancy Detection Engine
Automatically highlights part number mismatches, quantity deltas, and revision discrepancies between engineering and manufacturing.
Visual Part Dependency Tree Mapping
Renders interactive part dependency trees showing how changes to battery modules ripple into structural brackets and wiring harnesses.
Automated ECO Line Item Impact Analysis
Computes exact line item revision deltas and alerts manufacturing engineers to pending engineering change releases.
One Click MBOM Alignment Dispatch
Propagates approved engineering changes directly to plant ERP and MES execution systems without manual data re entry.
The outcome
- ECO reconciliation and MBOM update cycle time slashed
- 0 weeksECO reconciliation and MBOM update cycle time slashed
- BOM mismatch related assembly line stoppages reduced
- 0%BOM mismatch related assembly line stoppages reduced
ECO reconciliation and MBOM update cycle time slashed from 3 weeks to under 4 hours.
BOM mismatch related assembly line stoppages reduced by 94% during platform launch.
Scrap and obsolete component inventory write offs reduced by $1.4M.
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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