Creating Manufacturing Order
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Creating Manufacturing Order involves selecting the manufacture item (bill of material) that has been requested by the customer. By doing so, you can see the raw material and the steps involved in the manufacturing of the item and begin the manufacturing process.
The manufacturing order process involves various status indicators that help manage the entire lifecycle of the manufacturing order. Each status represents a different stage in the order's progression, providing valuable insights into the current production state of the item.
When entering a manufacturing order, you'll begin by entering essential header-level information, such as the manufacture item, store, order qty, order date, and production offset qty. Once the basics are set, you can proceed to see the bill of material details and manufacture the item.
MO Header
Manufacturing Order Type
Select the type of order. The available options are: Manufacture and Disassemble.
MO Header
Manufacture Item Number
Search and select an item that is being manufactured. Once selected, the raw goods of its BOM will automatically be fetched below in MO Lines.
MO Header
Manufacture Order Qty
Enter a quantity that is being manufactured.
MO Header
Project/Class
This field allows you to assign a Project/Class to the MO.
MO Header
Store
Select the store this item is being manufactured in.
MO Header
Schedule Date
Select the date this manufacturing order is scheduled to be manufactured.
MO Header
Production Offset Qty
Enter the production offset quantity in this field. The quantity entered here will post the transaction in shrinkage/swell offset account and will affect the final quantity produced.
MO Header
Disassemble Offset Account
MO Header
Bill Of Material
Select a Bill of Material for the item being manufactured.
MO Header
Memo
This field allows you to add any additional information or notes to the manufacturing order.
MO Header
Assign To
This field allows you to assign this order to a user, if required.
Other
Default Finished Goods Location
This field allows you to select the default location at which the finished goods will be stored after production.
Other
PPE Notes
This field allows you to add specific instructions or information related to Personal Protective Equipment (PPE) that should be followed during the manufacturing or assembly of the product.
Other
Default Raw Material Location
This field allows you to select the default location from which the raw materials will be picked for production.
Other
Instruction
This field allows you to add any instructions related to the manufacturing process.
Custom Fields
Custom Fields
This will allow you to enter data in the custom fields defined for the manufacture order entity. This feature provides the flexibility to capture and store additional information relevant to the manufacture order, tailoring the system to your unique business requirements. Please note that if the custom field mapping has been created with BOM custom fields entity, the values entered in the BOM will be displayed in the custom fields.
Linked Orders
Sales Order
This tab shows the details of any sales order linked to this manufacturing order.
Linked Orders
Purchase Order
This tab shows the details of any purchase order linked to this manufacturing order.
Options
Quick Produce
This function performs the quick produce function, automating all the intermediate processes.
Options
Link Order
This option allows you to establish a connection between the line items in the manufacture order and the line items of one or more sales orders. This linkage enables seamless coordination and tracking between the production and sales processes, streamlining order fulfillment and enhancing efficiency.
Options
Quick Disassemble
This function performs the quick disassemble function, automating all the intermediate processes.
Options
Show Dependencies
Shows the details list of the raw materials required to produce this manufacturing order.
Options
Show Transactions
Show the Journal Transactional View for the manufacturing order.
Options
Print Pick Sheet
Prints the pick sheet corresponding to the wave created for the order.
Options
Add To Email Queue
Adds the manufacturing order to the email queue for sending at a later time.
Options
Create Duplicate
Creates a new, duplicate order for the manufacturing order.
Options
Create PO for Selected Lines
Creates a purchase order for the selected item lines of the manufacturing order.
Options
Void
Voids the manufacturing order. Voided orders are deleted permanently from the system.
Once the basics are set, the raw materials corresponding to the bill of material will be retrieved in the details section of the manufacture order.
Open/Released
Default Vendor
This is an editable field that allows you to select a default vendor for the raw material.
Open/Released
Description
This field displays the description of the item.
Open/Released
Factor
This is the total quantity of the raw material. This comes from the “Manufacture Qty” field.
Open/Released
Force Sub MO(s)
If this field is enabled, sub MOs will be created for all the manufacturing items whose raw material is also manufacturable, irrespective of available inventory.
Open/Released
Item
This is the unique identifier for the item.
Open/Released
Is Manufacturable?
If this raw material item is manufacturable, then this box will be checked. Click on the "Flask" icon under this column to open the respective bill of material. Please note that upon releasing an MO, for the quantities that are not available to be picked, sub-MOs will be auto-generated for manufacturable items.
Open/Released
Instructions
This is an editable field that shows the manufacturing instructions for the raw material.
Open/Released
One Time Item?
Check this box if this item is only consumed once during the manufacturing process, regardless of the quantity being produced.
Open/Released
Per Qty
This field shows the raw good quantity required to produce one manufactured item.
Open/Released
Prevent Sub Mo?
If this box is checked for a manufacturable raw material, the sub MO will not be created.
Open/Released
Raw Material Location
This field shows the location from where the raw material will be consumed.
Open/Released
Ref#
This field displays the Sub MO number (if any) related to the Manufacture Order. You can click on the Sub MO number to view the manufacturing order subform.
Open/Released
To Pick
This field displays the total raw good quantity required for this MO (Per Qty*Factor).
Open/Released
Type
Specifies the type of item, such as inventory, non-inventory, etc.
Open/Released
Unit Cost
This field allows you to enter a unit cost for service or labor-type items.
Open/Released
UOM
Specifies the unit of measure for the item (liter, unit, kilogram, etc.).
In Picking
Action
Click this icon to open a window that will let you pick a line.
In Picking
Description
This is the description of the item in the wave.
In Picking
ItemNumber#
The unique identifier of the item in the wave.
In Picking
Order#
This field shows the manufacturing order number.
In Picking
Qty Allocated
This field shows the item quantity that is allocated.
In Picking
Qty Picked
This field shows the item quantity picked for the line. If it is equal to Qty Allocated, then the line will be in Picked status.
In Picking
Status
This field displays the status of the line.
In Picking
Status
This field displays the status of the wave.
In Picking
Store
This field shows the store associated with the wave.
In Picking
Wave Qty
This field shows the quantity of the line on the wave. This is different from the “Qty Allocated” column because if a line is unallocated, its quantity will appear under “Wave Qty”, not “Qty Allocated”.
Work In Progress
Production Date
This field allows you to select the date of production for the manufacturing order.
Work In Progress
Destination Location
This field allows you to select the location where the finished products are to be stored.
Work In Progress
Raw Materials Consumed
This section displays the details of the materials used to produce the finished good.
Click "Add Items" to add any additional item(s). This option is especially useful when you want to add a service or labor item to the order.
After adding the header info and items, click on the "Save" button to create a manufacturing order. You can use the "Save & New" dropdown option to save their current manufacturing order and redirect to a new, blank order creation page.
The system will automatically assign a unique number to the sales order in the format of MO-M000001, where "MO" denotes the sales store code and 1 denotes a sequential series. This number will be displayed on the top left corner of the page. Once this number is generated, it becomes a permanent identifier and cannot be altered.
The MO Lines Context View in XoroERP's MO module offers a set of right-click options that streamline the MO creation and management process. Here’s a brief overview of each option:
Copy to All: Replicates the selected line item's details across all MO lines, saving time and ensuring consistency.
Copy to Selected: Copies the selected MO line item’s details to specific, selected MO lines for targeted updates.
Delete: Removes the selected MO line item from the Manufacturing Order.
Item Details: Provides a detailed, read-only view of the selected item, including specifications and BOM.
Inventory Info: Offers comprehensive inventory details for the selected item, such as stock levels and warehouse locations.
A sub-MO is a child MO created for a raw material that is also manufacturable. So, when a manufacturable raw material is short, a sub-MO is created to fulfill the raw material and produce the final product. This allows for a hierarchical breakdown of the production process, enabling efficient tracking of individual components.
The "Enable Force Sub MO(s)" setting under the Manufacturing tab in App Config introduces a new checkbox in the Manufacture Order module. When this checkbox is checked, users are granted the ability to force the creation of sub-MOs for all manufacturing items whose raw materials are also manufacturable.
If this option is enabled, the child MOs will always be created even if the inventory is available. If this is unchecked, then the sub-MOs won’t be created if the inventory is available.
The auto-creation of Sub MOs can be restricted for particular manufacturable Items, even when the “Force Sub MO” App Config or the toggle in the MO is true.
This functionality is useful in cases when the Sub MOs would ideally be created for the raw materials of MO, but the user wants to prevent the Sub MOs for some or all of the raw materials.
For this purpose, ‘Prevent Sub MO‘ column has been added in the Bill Of Material and Manufacturing Order modules.
Please Note:
This check has a higher priority than the “Force Sub MO” checkbox on the MO header level.
This checkbox is only enabled for raw material lines that are manufacturable. If this field is checked, then this will not auto-create sub MOs for this line if inventory is short while releasing.
How does it work?
In the manufacturing order, enable this flag for a BOM Item.
Go to the Manufacture Order module and add the Bill of Material.
‘Prevent Sub MO’ column is added to the MO Item level. It will be auto-checked if this flag is true for that bill of material line.
Enable the “Force Sub MO(s)” flag.
Create MO with the ‘Prevent Sub Mo?’ flag true.
It will not create the Sub-MO for the line for which Prevent Sub Mo flag is true even when Enable Force Sub MO(s) flag is enabled.
The Priority of the ‘Prevent Sub MO’ flag is the highest.
Please note that this may impact the auto producible function as the picking stage may not be completed due to insufficient inventory of these items.
A Manufacturing Order (MO) goes through the entire production cycle of an item. It begins by selecting the item to manufacture and retrieving the necessary raw materials from its Bill of Materials (BOM). It then goes through a picking stage where those raw goods are picked from their locations. The item is manufactured and put away into a designated location.
To begin with the manufacturing process, click on the "Release" button to release the manufacturing order.
Once the order is released, click on "Start Picking" to commence the picking process.
To fulfill all the items in the manufacturing order, click "Fulfill". To fulfill specific item(s), click on the cart under the "Action" column. After picking all the items, click "Pick Complete" to finalize the picking process.
The manufacturing order will then enter the "Work In Progress" state. Select the "Production Date" and "Destination Location," and click "Produce" to complete the production process.
This will result in the production of finished goods, and the manufacturing order status will be updated to "Produced".
Open: A newly created MO is in open status and the raw goods cannot be waved yet.
Released: Once an MO’s quantities and raw materials are finalized they can be released in preparation for picking.
In Picking: The MO’s raw goods have been allocated and are being picked in this stage.
Work In Progress: The picking of raw goods is complete and manufacturing for this item is taking place.
Produced: The raw goods are entirely consumed and the newly manufactured item is finished.
Disassembled: This status indicates that the manufactured item has been taken apart or broken down into its individual components.
After a manufacturing order (MO) is released, a new field called "Qty To Produce" becomes available in the header section of the MO.
This field allows you to modify the quantity to be produced for that specific MO. When the Qty to Produce is updated for a manufacturing order, you get an option to create a separate MO for the remaining Qty.
To update the "Qty To Produce" field, follow the steps below:
Click on the "Edit" option next to the "Qty To Produce" field. This will enable the quantity field for editing.
Enter the new quantity and click "Update".
Upon clicking "Update", a pop-up window will appear. In this window, you will see a toggle button labeled "Create new MO for the remaining qty (Old qty to Produce – New qty to Produce)?". This option lets you decide whether to create a new MO for the remaining quantity that results from the change.
If you enable this toggle button, a new MO will be created. The quantity for this new MO will be the difference between the old quantity to produce and the new quantity to produce (i.e., Old qty to Produce – New qty to Produce).
Click "OK" to update the producible quantity and create a new MO, if applicable.
The new MO will be linked with SO in case the MO has been created from a Sales Order.
XoroERP offers the ability to add multiple batch numbers and lot numbers for finished items during MO production, allowing for detailed tracking and management of inventory. This is particularly useful for scenarios where the raw material is stored across different locations, and you want to produce the finished goods at different locations as well.
To utilize this feature, please enable the app config, "Use raw materials lot and batch number for finished good item".
Enable the above-mentioned app config.
Create a manufacturing order, proceed with releasing the order, complete the picking process, and transition to the "Work In Progress" stage.
Click on the newly introduced "Edit LPN" button. It's important to note that this button will only be available if the raw material is in multiple locations.
This will redirect you to the Edit LPN screen. Users can easily add or remove lots and batches using the intuitive +/- buttons, ensuring precise control over inventory quantities. ** It is important to note while you can add as many lots as you want, the quantity sum of all the lots should be equal to the quantity to be produced.
To store the finished goods at the same location, simply click "Save" without altering any information. If you intend to place the finished goods in a different location, adjust the LPN and Batch number details before clicking "Save".
To void a manufacture order, open the manufacture order and go to Options > Void.
Please Note: Make sure that the status of the Manufacturing Order is ‘Open’ or ‘Released’ as you cannot void a ‘Produced’ Manufacturing Order.
If you must undo a Produced MO, then the correct way to do it is to create inventory adjustments. Create a negative adjustment for the produced goods and a positive adjustment(s) for all the raw materials that were incorrectly consumed.
This field allows you to select an disassemble offset account. The account will be used as an offset account for the transactions in disasseble manufacture orders. Please note that you can select a default offset account under the app config, ".
