150% BOM refers to a comprehensive bill of materials that includes all possible components, assemblies, and options for a product. It represents a "maximum configuration" that serves as the basis for subtractive configuration. In subtractive configuration, specific product variants are created by removing (or "subtracting") components from this master list that are not required for the desired product.
The 150% BOM is particularly useful for handling complex product lines with multiple options and variants. It allows manufacturers to define all possible configurations in a single structure, ensuring that every potential feature or component is accounted for. However, the 150% BOM is not intended to be built as-is, as it often contains mutually exclusive options (e.g., two different engine types for a car).
Examples
Aircraft Seating - A 150% BOM for an aircraft seat might include all possible options, such as seat widths (normal, narrow), upholstery materials (leather, fabric, synthetic), integrated features (USB ports, screens, reclining mechanisms), and accessories (headrests, footrests, tray tables).
Modular Furniture - A 150% BOM for an office desk might list all available configurations, such as tabletop finishes (wood, glass, laminate), frame colors (black, white, metallic), optional features (cable trays, height adjustment mechanisms), and add-ons like drawers or shelves.
Automobiles - A 150% BOM for a car might include all available options, such as multiple engine types (diesel, hybrid, electric), interior trims (leather, fabric), and additional features (sunroof, heated seats).
Boolean algebra and 150% BOMs
The 150% BOM often relies on Boolean algebra to manage the logical relationships between components and options. For example, rules such as "if Option A is selected, then Option B must be excluded" or "Option C requires Option D" can be expressed using Boolean logic. This ensures that only valid configurations are generated by applying logical operations to the 150% BOM, preventing incompatible combinations of components.