150% BOM

A 150% BOM is a product structure that contains all possible components, assemblies, and options for a product family — including mutually exclusive combinations that cannot appear together in any single buildable variant. It represents a “maximum configuration” that serves as the master structure from which specific product variants are derived by removing the components not required.

The term “150%” reflects that the structure exceeds any one realizable product: it contains more than 100% of what any single variant needs.

The 150% BOM is particularly useful for products with high variant diversity driven by a stable set of options and rules. It allows engineers to define all possible configurations in one central structure. However, it is not intended to be built as-is — it deliberately contains mutually exclusive options, such as a diesel engine and an electric drivetrain for the same vehicle model.

How the 150% BOM is used

The 150% BOM is the foundation of subtractive configuration Subtractive Configuration (səb-ˈtrak-tiv kən-ˌfi-gyə-ˈrā-shən) n. Subtractive configuration starts from a 150% BOM containing all possible options and removes components not needed for a specific variant. Common in automotive and ERP. . Instead of defining each variant from scratch, engineers define the full universe of possible options once. Individual variants are then created by applying configuration rules that remove mutually exclusive or inapplicable components from this master list.

This approach is widely used in SAP (via LO-VC — Logistics Variant Configuration) and other ERP systems. The configuration rules — expressed using Boolean algebra Boolean Algebra (ˈbü-lē-ən ˈal-ji-brə) n. Boolean algebra provides the logical operators (AND, OR, NOT) used to define valid product configurations and constraints in variant management and CPQ. — determine which components from the 150% BOM are included in a specific variant’s BOM (the 100% BOM).

Examples

• Automobiles — A 150% BOM for a car model includes all available engine types (diesel, hybrid, electric), all interior trim options (leather, Alcantara, fabric), and all optional features (sunroof, heated seats, adaptive cruise control). No single car contains all of these.
• Aircraft seating — A 150% BOM for an aircraft seat includes all seat width options (standard, narrow), all upholstery materials (leather, fabric, synthetic), and all integrated features (USB ports, screens, reclining mechanisms). The airline selects a valid combination per cabin configuration.
• Modular furniture — A 150% BOM for an office desk lists all available tabletop finishes (wood, glass, laminate), frame colors (black, white, silver), and optional accessories (cable trays, height adjustment mechanisms, drawer units).

Boolean algebra and the 150% BOM

The 150% BOM works in conjunction with Boolean algebra Boolean Algebra (ˈbü-lē-ən ˈal-ji-brə) n. Boolean algebra provides the logical operators (AND, OR, NOT) used to define valid product configurations and constraints in variant management and CPQ. -based constraint rules to ensure that only valid variants are derived. Rules such as:

• “If [Electric Drivetrain] is selected, then [Exhaust System] must be excluded.”
• “If [Sunroof] is selected, then [Reinforced Roof Structure] must be included.”

These rules are applied when a specific product variant is being configured, automatically filtering the 150% BOM down to the 100% BOM for that variant.

Frequently asked questions