Key Takeaways
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The legacy Bill of Materials (BOM) process ensures all lift design updates are accurately tracked before manufacture.
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Clear feedback loops between design and production reduce version errors and duplicated part numbers.
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Introducing connected digital tools like Airtable and Asana strengthens data integrity and real-time visibility across departments.
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Continuous improvement helps ensure that every bespoke Sesame lift meets consistent quality and accessibility standards.
Introduction: The Problem and the Solution
In bespoke lift engineering, even minor data inconsistencies in a Bill of Materials can lead to wasted hours, rework, or miscommunication between teams. Historically, lift manufacturers have struggled with version control, outdated drawings, duplicated parts, and manual spreadsheet errors that disrupt production.
At Sesame Access, this challenge is solved through a disciplined Legacy BOM process that connects design, drawing review, and production in a single workflow. By aligning 3D models, drawings, and BOM data through structured reviews, Sesame eliminates ambiguity, increases build precision, and protects project timelines.
What is the Legacy BOM Process and Why It Matters
The Legacy BOM is an internal tool that lists every component, finish, and subassembly needed to manufacture a bespoke platform lift. It ensures data from the 3D model stage through final surface treatment remains consistent and traceable.
When combined with structured drawing reviews, it helps identify where seemingly small changes, such as finish colour or galvanisation method, can affect assembly time or part compatibility.
This workflow complements related systems such as Issues Raised During Drawing Delivery and Finishing BOM Integration & Surface Treatment Communication, ensuring cross-department consistency.
Whether applied to the Wellington Lift, Richmond Rising Platform Lift, or Cambridge Part M Lift, this framework keeps every bespoke lift aligned to the same manufacturing standard.
How Drawing Reviews Strengthen BOM Data Integrity
The design team discovered that subtle differences in notation, like “painted” versus “galvanised”, could take up to six hours to correct across all assemblies. By capturing such updates through a shared review process, Sesame ensures accuracy without overloading designers or delaying production.
Every drawing review now includes an estimated time to implement changes, allowing teams to prioritise the most critical updates and maintain workflow efficiency.
Digital Tools for Process Control
To minimise manual data handling, Sesame is introducing modern process-control tools that link design and manufacturing environments.
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Airtable acts as a live relational database, replacing static Excel sheets.
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Asana integrates task tracking and automated alerts when a BOM revision is made.
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Python scripting and AI-assisted validation help clean and reconcile data before it reaches procurement.
This digital ecosystem enhances transparency, ensures that engineers are notified of every revision, and prevents missing components or outdated assemblies during production.
Real-World Impact
Applying this structured approach has delivered measurable results. In internal trials across several bespoke lift projects:
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Revision cycle times were reduced by approximately 35%, enabling faster design approvals.
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Duplicated part entries dropped by over 40% after database automation.
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Communication delays between design and production teams decreased by nearly 50%, leading to smoother manufacturing handovers.
These tangible improvements underline how the legacy BOM framework supports the consistent delivery of complex lifts such as the Pimlico Lift and Kensington Stairlift.
Integrating Continuous Improvement
This process is part of a broader engineering ecosystem linking the Legacy BOM Collaboration Process, drawing management, and finishing integration.
By maintaining digital traceability, Sesame ensures each project benefits from the lessons of the last—reducing rework, improving forecasting, and strengthening overall quality assurance.
Frequently Asked Questions (FAQ)
1. What is a Legacy BOM in lift manufacturing?
It’s a structured database that lists every component and material used in a lift, ensuring traceability and accuracy from design to production.
2. Why is BOM data integrity important?
Accurate BOM data prevents part duplication, reduces assembly errors, and ensures consistent design replication across projects.
3. What causes drawing revision mistakes?
Human error, outdated file versions, or lack of cross-department alerts can cause inconsistencies in drawings and BOMs.
4. How does Sesame prevent BOM errors?
Through linked tools like Airtable, Asana, and structured review meetings, each change is logged, reviewed, and approved before production begins.
5. How long does it take to fix BOM errors?
Depending on the project size, corrections can take several hours, but the improved process has reduced average revision time by 35%.
6. How does the digital process reduce human error?
Automation tools clean and check data, ensuring engineers work from verified, current information without relying on manual updates.
7. What happens when a drawing revision affects existing parts?
Changes trigger alerts in Asana, prompting engineers to confirm updates and ensure correct components are ordered.
8. Can AI be used to manage BOM data?
Yes. AI-driven validation scripts are being trialled to detect duplicates and ensure that every part aligns with current assembly drawings.
9. What is the role of surface treatment communication in this process?
It ensures materials, coatings, and finishes are aligned across departments, linking with the surface treatment protocols discussed in the Knowledge Hub.
10. How can clients benefit from this process?
Clients receive lifts with reduced risk of error, shorter delivery times, and full traceability from concept to installation.
To discuss your upcoming accessibility or heritage lift project, book a Teams meeting with one of our Project Managers.