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🛋️ Madrid Sofa: BOM Simulation & Setup

This guide simulates how to fully define and structure a Madrid Sofa in CushionsERP using raw materials, sub-assemblies, and final BOMs.

✅ 1. Define Raw Materials

These are the lowest-level components (foam, fabric, zippers, etc.)

Go to: Products/Services → New Product

Create entries like:

HR Foam 40D – Seat
Fabric – Outdoor Grade A
Polyester Thread
Zipper YKK 60cm
Velcro Tape
Plastic Bag (Rain Cover)

For each item:

Type: Product
Nature: Purchasable
Stock management: Enabled
Unit: (e.g., meters, pcs, kg)

🧮 *You may reflect loss directly in BOM quantities (e.g., add 5% extra to cover waste).*

✅ 2. Define Sub-Assemblies (Components)

These are intermediate items assembled from raw materials:

Mattress Cushion
Back Cushion
Pillow
Rain Cover

For each:

Type: Product
Nature: Manufacturable
Stock Management: Enabled
Assign a BOM (see Step 4)

✅ 3. Define the Finished Good

Create product: Madrid Sofa

Type: Product
Nature: Manufacturable
Stock: Managed
Selling: Enabled (if sold directly)
Unit: pcs

✅ 4. Create BOMs

Go to: MRP → Bill of Materials Create a new BOM for each manufacturable item.

📌 BOM A: Mattress Cushion

* HR Foam 40D – Seat → 2 pcs

Fabric – Outdoor → 3 m
Polyester Thread → 50 m
Zipper YKK 60cm → 2 pcs
*(Apply 5–10% loss if needed manually)*

📌 BOM B: Back Cushion

* HR Foam 40D – Back → 1 pcs

Fabric – Outdoor → 2 m
Polyester Thread → 30 m

📌 BOM C: Rain Cover

* Plastic Bag → 1 pcs

Velcro Tape → 2 m
Thread → 10 m

📌 BOM D: Madrid Sofa (Final Assembly)

* Mattress Cushion → 1

Back Cushion → 1
Pillow → 2
Rain Cover → 1

🔁 Cushions supports multi-level BOMs by referencing component BOMs in the final product's BOM.

✅ 5. (Optional) Add Suppliers & Prices

For each raw material:

Go to Product → Suppliers
Add:
- Supplier reference
- Purchase price
- Minimum quantity or delay (optional)

✅ 6. (Optional) Create Manufacturing Order

Once BOMs are created:

Go to Manufacturing → New Order
Select Madrid Sofa
System calculates all components recursively
Execute the MO to deduct materials and add finished stock

✅ Summary: Structure Modeled

🧱 Raw Materials → Stock-managed, purchased
🧩 Sub-Assemblies → Each with its own BOM
🛋️ Finished Good → Final BOM uses subcomponents
💰 *Optional*: Supplier pricing, inventory links

→ Next: Product Lot Number Guidance

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