150% BOM, EBOM, MBOM and BOR in PLM explained

Overcomplete structure, 150% BOM, EBOM, MBOM, BOR, PDM, PLM, these words come up in every working group, and rarely does everyone mean the same thing. Here is the landscape in plain language, plus the answer to the question that matters most. What do you really need in order to sell?

Where each bill of materials lives

Landscape from the CAD 150% assembly in PDM via EBOM and configurator to the 100% order structure, with MBOM and BOR optional in PLM or ERP — The configurator does not replace this landscape. It reads it, and fills it per order.

The overcomplete structure (150%)

CAD and PLM hold the generic, overcomplete model. That is the structure containing all options and variants, often called the 150% structure. No physical product ever looks exactly like it, it is the collection of everything that can be. In PLM it lives as items with article numbers at various BOM levels. Options and variants attach through variant conditions or an Options & Variants mechanism. The configurator resolves from 150% to 100% per order. Precisely this product, with real article numbers and dimensions.

The EBOM, the engineering bill of materials

The EBOM describes the product as designed. Functionally grouped, properly numbered. It lives in PDM or PLM and is the source the configurator draws from. For configure-to-order this is the structure that matters. A reliable EBOM plus stable article numbers is all you need to start.

The MBOM, the manufacturing BOM (optional in PLM)

The MBOM describes the product as built. Build sequence, purchased parts, semi-finished goods, phantom assemblies. Some companies manage it in PLM (with an EBOM-to-MBOM transformation); others let the ERP derive it. Both are fine, it differs per company, and the configurator works with either.

The BOR, operations and hours (optional in PLM)

The BOR (bill of resources, also bill of routing) describes how things get made. Which operations, on which machines, with how much time per step. Captured in PLM it becomes reusable per module, the 300 and the 400 drawer block share one routing with a different saw length. Often the BOR lives in the ERP. That is fine too. What matters is that the configurator can include the hours in the cost price.

PDM or PLM?

PDM manages the CAD files, with versions, permissions, check-in and check-out. It knows which file is the right one. PLM is the process. Lifecycle, BOMs, changes, releases and workflows across departments. In short, PDM guards files and PLM guards agreements.

Start where you are

A perfect PLM setup is not a precondition for selling. A reliable EBOM and stable article numbers suffice; MBOM and BOR can follow later, or simply stay in the ERP.

Pre-engineer or parametric? Three ways to deliver an assembly

Three ways to deliver an assembly: pre-engineered with own numbers and drawings, pre-generated with family tables, and parametric at sale via design automation — In PLM terms they together form the 150% structure, and every order resolves to a 100% BOM.

Pre-engineerA handful of variants? Engineer them out, with an own number, drawing and BOM per variant. In CAD these are called configurations, on the drawing the classic tabulated drawing.
Pre-generateMany sizes with critical features (holes, recesses)? Keep the parametric model in CAD and batch-generate a series of sizes with the family table (Creo) or design table (SolidWorks). The configurator picks the right one per order.
Parametric at saleOne free dimension without features (profiles, skirtings, trims)? The dimension follows from the order. The system outputs a cut length and BOM without a CAD round-trip. Industry calls this design automation.

The decision rule is simple. Few variants → pre-engineer · many sizes with features → pre-generate · one free dimension without features → parametric. The trap is dogma. Engineering everything out yields thousands of articles, making everything parametric yields fragile automation. The mix keeps it manageable.

How much drawing does your sales process need?

Four levels, pick the lowest rung that sells.

Level 0, no drawing. Price, quote and BOM. Many configurators pay for themselves right here.
Level 1, an automatic 2D dimension drawing. Views with main dimensions, generated from the choices. Often exactly what the customer and the permit require, at a fraction of 3D.
Level 2, light 3D in sales. Stretched profiles and surfaces show the product and catch gross collisions, without a CAD link.
Level 3, CAD builds the assembly. After the order an automated step turns the choices into the complete 3D model under the project number, with collision checking and drawings.

Whichever level you pick, manage geometry in one place. A second 3D brain inside the configurator is guaranteed to fall behind.

PDM guards files, PLM guards agreements, and the configurator only writes the per-order list.

Frequently asked questions

What is a 150% BOM (overcomplete structure)?

The 150% BOM or overcomplete structure is the generic product model containing all options and variants, more than ever comes together in one physical product. It lives in PLM as items with variant conditions. At every order the configurator resolves it to a 100% BOM. Precisely this product, with real article numbers.

What is the difference between EBOM and MBOM?

The EBOM (engineering bill of materials) describes the product as designed. Functionally grouped. The MBOM (manufacturing BOM) describes it as built. Build order, purchased parts and semi-finished goods. The EBOM lives in PDM or PLM. The MBOM in PLM or in the ERP, it differs per company.

What is a BOR (bill of resources)?

The BOR describes how manufacturing happens. Operations, machines and hours per step. Captured per module it becomes reusable, variants share the same routing with different dimensions. The BOR lives in PLM or ERP. For the configurator what matters is that hours flow into the cost price.

What is the difference between PDM and PLM?

PDM manages CAD files, with versions, permissions, check-in and check-out. PLM is the process around it. Lifecycle, BOMs, changes, releases and workflows across departments. PDM guards files, PLM guards agreements.

Do I need a fully configured PLM system for a configurator?

No. A reliable EBOM and stable article numbers are enough to start. MBOM and BOR can follow later or stay in the ERP. Start where you are. A perfect PLM setup is not a precondition for selling.

Where the 150% structure, EBOM, MBOM and BOR live