Toyota Boshoku USA Reduces Bill of Materials Process from Weeks to Days
Better Data Loading Leads to Efficient Processes
Case Study – Manufacturing
Toyota Boshoku USA‘s Engineering, Sales, and Manufacturing landscape is a complex web of interactions, requiring constant, accurate updates to its Oracle EBS Bill of Materials data.
The Client
Toyota Boshoku USA, part of the global Toyota Boshoku manufacturing group.
The Challenge
Toyota relied on multiple systems to manage Bill of Materials (BOM) data: an engineering system, an ordering system, and Oracle EBS. Manually processing manufacturing BOMs across all three caused duplicated effort and introduced risk to essential inventory data.
Rather than eliminate any of these systems, Toyota set out to migrate its manufacturing BOM master data into Oracle EBS and use it as the system of record, feeding data to the ordering system from there. But the engineering system’s complexity meant BOM details still had to be updated manually before loading into any system.
The result: it took Toyota 3-4 weeks just to get engineering BOM data into its ordering system and Oracle EBS. Further investigation revealed most plants were also maintaining a separate Excel BOM alongside the data already loaded into their systems, adding yet another layer of duplication.
The Solution
Toyota needed a tool that could extract engineering BOM data directly into Oracle, cutting manual effort and reducing inventory errors. After meeting with the More4apps team to understand these pain points, Toyota implemented the More4apps BOM Wizard from the EBS Toolbox.
The BOM Wizard eliminated the need for a separate Excel file altogether, since changes upload directly into Oracle. This let Toyota streamline the flow of data from its engineering system straight into Oracle EBS.
The Results
After rolling out the solution at its first plant, Toyota saw the impact immediately. End users cut BOM entry time from 3-4 weeks down to 3-4 days. Pleased with the results, Toyota began evaluating additional More4apps tools to expand time savings across its broader workforce.