Formula
A formula: a bill of material for process manufacturing, with ingredient types, batch yield, catch weight and co-products and by-products.
What it is for
The formula works like a Bill Of Material, with the same lines, rules and approval, and adds:
- Batch Yield: the share of good output, starting at 100 and never 0. The manufacturing order copies it.
- Ingredient Type on each line. A Compensating line must name its Active Ingredient and a Factor above zero. Active ingredients are balanced by batch on the manufacturing order.
- Co-Products & By-Products: other items that come out.
- Default Vendor for a subcontracting usage, required then and cleared otherwise.
The formula number is also its BOM number, so a Manufacturing Order of category Process Order picks it in the same Bom/Formula field. Clone is allowed.
Note: the manufacturing order does not bring over the formula's co-products and by-products today; see the questions report.
Every field in plain words
Header
| Field | What it means | What to put |
|---|---|---|
| Potency Required | Potency required. | Filled in |
| Factor | Factor for a compensating ingredient. | Above zero |
| Formula | The formula code. | Cannot be changed once saved. Required |
| Usage | The usage. | Pick one. Required |
| Alternate | This is an alternate BOM for the same item and dates. | Set when you confirm it on Save |
| Alternate Precedence | Its precedence among alternates. | Counted by the system. Filled in by the system |
| Tag | A tag. | Optional |
| Item | The item made. | An item made with this usage's type. Locked after Create. Required |
| Item Variant | The variant made, if any. | Locked after Create |
| Name | Its name. | Filled in |
| Unit | The BOM unit of the item. | From the item |
| Quantity | The quantity the lines are for. | Starts at 1; above zero. Required |
| Standard Cost | Sum of the lines' Standard Cost. | Calculated |
| Valid From | Valid from. | A date. Required |
| Valid To | Valid until. | A date, not before Valid From. Required |
| Routing | The routing. | Pick a routing of the item |
| Batch Yield | The share of good output, in percent. | Starts at 100; not 0 |
| Project | A project the BOM is for. | Then each line needs a Project Category |
| Catch Weight Unit | Catch weight unit. | Formulas |
| Catch Weight Quantity | Catch weight quantity. | Formulas |
| Approved By | Who approved. | Pick a person |
| Approved | Approved. Manufacturing orders offer only approved BOMs. | Tick when approved; set by the approval when one is configured |
| Site | The site. | Hidden for a subcontracting usage. Required |
| Authorization Key | An authorization key from system administration, recorded on the record. | Usually empty |
| Version | A version label. | Any text |
| Default Vendor | The subcontractor. | Required for a subcontracting usage |
| Name | Its name. | Filled in |
BOM Lines
One line per ingredient.
| Field | What it means | What to put |
|---|---|---|
| Ingredient Type | For formulas: Active, Compensating and so on. | Pick one; None by default |
| Item No | A component. | Pick an item |
| Item Variant | Its variant. | Required for a variant item when the setting says so |
| Name | Its name. | Filled in |
| Unit | The unit. | Pick one. Required |
| Quantity | How much, for the BOM Quantity. | Above zero |
| Fixed | The quantity does not grow with the order quantity. | Tick for a fixed amount |
| Utilized Quantity | How many units one quantity serves. | Starts at 1; above zero |
| Quantity Per Unit | Total Quantity divided by the BOM Quantity (unless Fixed), divided by Utilized Quantity. | Calculated |
| Scrap Quantity | Scrap as a quantity. | Or enter Scrap % |
| Scrap % | Scrap as a percentage of Quantity. | Or enter Scrap Quantity |
| Total Quantity | Quantity plus scrap. | Calculated |
| Standard Cost | Standard cost of the component. | An amount |
| Total Cost | Standard Cost times Quantity Per Unit. | Calculated |
| Rounding | Round the quantity on the order. | As needed |
| Operation | The routing operation that uses it. | Required when the BOM has a routing |
| Vendor | A vendor for the component. | Optional |
| Flushing Indicator | B issues it automatically on confirmation; M leaves it to be issued by hand. | Required for BOM and FOR usages |
| Line Text | A note on the line. | Any text |
Co-Products & By-Products
Other items that come out of the process.
| Field | What it means | What to put |
|---|---|---|
| Item No | A co-product or by-product. | Pick an item of type co-product or by-product |
| Item Variant | Its variant. | Required for a variant item |
| Name | Its name. | Filled in |
| Unit | Its unit. | Pick one |
| Quantity | How much comes out. | A quantity |
| Line Text | A note on the line. | Any text |
How to configure it
There is nothing to configure beyond the fields above. Which fields are shown, required or hidden can be changed per company by the consultant in the screen configuration.
Scenarios
- A pharmaceutical plant makes tablets whose active ingredient strength varies by batch. Mark the API Active; balance batches on the order before release.
- A dairy gets cream as a by-product of skimmed milk. Add cream on Co-Products & By-Products.
What it is connected to
- Bill Of Material - the same rules
- Manufacturing Order - Process Order
- Usage - type FOR
If something looks wrong
- "Batch Yield cannot be zero" Enter a yield, normally 100.
- "LineID - ... - Please select Active Ingredient" / "... Factor cannot be zero or negative" Fill the compensating line.
- "Controlling - Default Vendor cannot be empty for a subcontracting BOM Usage" Pick the subcontractor.
- "The dates cannot be changed because a manufacturing order has already been created ..." Keep the dates around the existing orders' dates, or cancel those orders.
- "... - Line ID: ... - Item cannot be empty" / "... Unit cannot be empty" Fill the line.
- "... - Line ID: ... - Item is variant, please define" Pick the variant of the component.
- "... - Line ID: ... - Quantity cannot be zero or negative" / "... Utilized Quantity cannot be zero or negative" Enter positive quantities.
- "... - Line ID: ... - Project Category cannot be empty" The BOM has a project. Fill Project Category on each line.
- "... - Line ID: ... - Operation cannot be empty" The BOM has a routing. Name the operation on each line.
- "... - Line ID: ... - Flushing Indicator cannot be empty" Pick B or M.
- "Co-Products & By-Products - Line ID: ... - Item Variant Cannot be Empty" Pick the variant.
- "... - Base Quantity cannot be zero or less then zero" Enter a Quantity above zero.
- "... Lines Data cannot be Empty" Add component lines.
- A question asks whether to save it as an alternate BOM. Another BOM of the same item, variant and project overlaps these dates. Confirm to save it as an alternate, or change the dates.