Digitizing Boiler Manufacturing Project Workflows
Eliminated a 4-hour BOM-to-dispatch cycle through a single connected workflow, replacing 7 manual spreadsheets and streamlining approvals.
An engineering firm managing boiler manufacturing projects ran every stage BOM items, material orders, shipping groups, and release documents across separate Excel files.
- A missed revision number at any point broke the downstream process, causing errors that surfaced only at fabrication or dispatch
- The cycle from BOM to final PMS, SL, and release document took 4 hours per project run.
The PMS & SL is a Product Manufacturing Schedule and Shipping List management tool that gives engineering teams a single place to manage everything from BOM items to dispatch documents. The foundation starts with a master item list loaded from the client's existing data before project work begins, and each is handled by multiple engineers through one connected workflow.
- Projects are set up with a code and broken into major product assemblies covering engineering and erection scope
- Drawings are registered with auto-generated reference numbers capturing project, category, size, order sequence, and revision
- A Bill of Materials (BOM) is built against each drawing the complete list of every item required, covering material spec, dimensions, weight, and quantity
- Material orders are raised against BOM items for externally sourced raw materials and components as per specifications
- BOM items are grouped into labeled shipping units with total weight for packing and sent together
- All shipping units across the project are consolidated into a single dispatch list
- A Document Release Advice (DRA) is the formal sign-off document that confirms a release is ready for dispatch, is issued through a Drafter, Checker, and Approver and feeds into the procurement team
| Impact Metric | Before | After |
|---|---|---|
BOM-to-dispatch cycle time | 4 hours | ~5 mins |
Revision mismatch errors | Recurring | Eliminated |
Manual document handoffs | 7 separate Excel files | 1 connected workflow |
Dispatch approval back-and-forth time | 3–4 days | 1 day |
Stages requiring manual data re-entry | 5 per project cycle | 0 |
This workflow helps multiple teams from engineering to procurement in an EPC organization to manage their suppliers with BOM, raw material indent requirements, DRA, revisions, and other operations from their head office to the site.
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