Manufacturing Order
An order to make one item: how much, by when, from which BOM or formula and routing, in which manufacturing unit, with its components reserved and its status from Planned to Closed.
What it is for
You pick the Manufacturing Category, Type (Standard, Rework, Disassembling, Research and Development), date, site, item, quantity and Manufacturing Unit, or a Plan whose lines bring those in, then the Bom/Formula and Routing. The BOM lines are worked out as Quantity Per Unit times the order quantity; Adjustment Quantity lets you add or take away on a line. The order takes its input and output warehouses from the manufacturing unit's lines.
Status. A new order is Planned. Release on the toolbar makes it Released, and it is refused while a line with reservation type Always Manual is not fully reserved or an active ingredient is not batch balanced. On release, the reserved stock is booked against the order and, when the site creates transfer requests for manufacturing, a transfer request moves components from their default warehouses to the input warehouse. Confirmations then bring it to Closed when the confirmed quantity reaches the order quantity. Cancel (after a confirmation question) makes it Canceled and blocked, and frees its reservations; an order with a confirmation cannot be cancelled, blocked, deleted, set back to Planned or lose a confirmed line. A Closed or Canceled order cannot be changed.
Toolbar. Reserve Inventory on a line opens the reservation of that component from its default warehouse (and the input warehouse when the unit allows it). Batch Balancing, on a Planned Process Order, picks the batches of active ingredients by potency. Packaging adds packing materials from a Packaging. View Inventory shows the stock of the item and its components per site and warehouse.
Rework names the batch to rework instead of a BOM and lets you edit Standard Quantity. Process Order shows ingredient types and batch yield; a released Standard, Rework or R and D process order gets its batch number from the item's batch group.
Nothing posts on this screen: stock and cost move on the confirmation.
Every field in plain words
Header
| Field | What it means | What to put |
|---|---|---|
| Release Manufacturing Order | Recorded on the order. | As needed |
| Manufacturing Order | The order number. | Given on Create. Required |
| Manufacturing Date | The manufacturing date; BOMs must be valid on it. | A date. Required |
| Production Order Status | Planned, Released, Closed or Canceled. | Set by the toolbar and confirmations. Required |
| Manufacturing Category | Production Order (BOM), Process Order (formula) or Assembly Order. | Pick one. Required |
| Type | Standard, Rework, Disassembling or Research and Development. | Pick one. Required |
| Production Cycle | The production cycle. | Optional |
| Item No | The item to make. | An item of Type BOM or FOR; with a Plan, one of its items. Required |
| Item Variant | Its variant. | Required for a variant item |
| Name | Its name. | Filled in |
| Unit | Its unit. | Filled in |
| Manufacturing Quantity | How much to make. | Above zero. Required |
| Confirm Quantity | Quantity confirmed so far. | Calculated |
| Block | Marks the record as blocked. | Tick to retire it |
| Notes | Free notes on the record. | Any text |
| Plan | The plan this order belongs to. | Optional |
| Manufacturing Unit | The manufacturing unit. | Pick one of the site. Required |
| Manufacturing Pool | The pool. | Optional |
| Bom/Formula | The bill of material or formula. | An approved one valid on the date; required unless the setting allows otherwise |
| Routing | The routing. | Pick one |
| Manufacture Group | The manufacture group. | Optional |
| Delivery Date | When it is due. | A date |
| Delivery Time | Time due. | A time |
| Site | The site. | Pick one. Required |
| Opportunity | A sales opportunity. | Optional |
Bill of Material
The components, from the BOM or formula.
| Field | What it means | What to put |
|---|---|---|
| Item Category | Category. | Filled in |
| Ingredient Type | Ingredient type. | Process Orders. Filled in by the system |
| Item No | The component. | From the BOM |
| Item Variant | Its variant. | When the setting allows. Filled in by the system |
| Name | Its name. | Filled in |
| Unit | Unit. | From the BOM |
| Quantity Per Unit | Per unit of output. | From the BOM |
| Standard Quantity | Quantity Per Unit times the order quantity. | Calculated; editable on Rework |
| Balancing Quantity | Quantity from batch balancing. | Calculated |
| Adjustment Quantity | Add or take away. | A quantity |
| Required Quantity | Quantity required. | Filled in by the system |
| Standard Cost | Standard cost. | From the BOM |
| Total Cost | Total cost. | Calculated |
| Line Text | A note on the line. | Any text. Filled in by the system |
Routing
The operations, from the routing. The Resource link shows their resources and hours.
| Field | What it means | What to put |
|---|---|---|
| Operation | Operation. | From the routing |
| Name | Name. | Filled in by the system |
| Operation Group | Group. | Filled in by the system |
| Sequence | Sequence. | Filled in by the system |
| Sequence Rule | Rule. | Filled in by the system |
| Total Hours | Hours. | Calculated |
| Total Cost | Total cost. | Filled in by the system |
| Resource | Link. Opens the resources. | Filled in by the system |
Packaging (toolbar)
Packing units used; their materials join the BOM lines.
| Field | What it means | What to put |
|---|---|---|
| Packaging | A packaging. | Pick one |
| Name | Name. | Filled in by the system |
| Quantity | Output packed in it. | In total not above the order quantity |
| Contain Quantity | Units it holds. | From the packaging |
| Packing Quantity | How many packs. | Above zero |
How to configure it
On Manufacture and Controlling Setting: whether a Standard order may go without BOM, whether the BOM and Routing parts are hidden, whether the Packaging part is used, whether variants are required on lines, and the transfer request journal. On the manufacturing unit: the warehouses and reservation from the input warehouse.
Scenarios
- A factory makes 1,000 units of a finished good from stock components. Standard order, BOM and routing, reserve the components, Release, then confirm.
- A drug maker's API strength differs by batch. Process Order; run Batch Balancing before Release.
- A batch failed inspection and is reworked. Type Rework, name the batch, set the quantities, release and confirm.
- A kit is taken apart into its components. Type Disassembling; the confirmation brings the components back.
What it is connected to
- Master Planning - orders raised from a plan
- Bill Of Material - components
- Routing - operations
- Manufacturing Unit - warehouses
- Manufacture Order Confirmation - confirms output
- Inventory Reservation and Item Transfer Request - reservations and transfer requests
- Plan to produce - the whole chain
If something looks wrong
- "Production Order - Production Quantity cannot be Zero or Negative" Enter a quantity.
- "Production Order - Batch Yield cannot be Zero or Negative" Enter a yield.
- "Bill of Material - Line ID: ... - Item is variant, please define" Pick the component variant.
- "Bill of Material - Line ID: ... - unit cannot be empty" Fill the unit.
- "Bom is not valid in given Plan Dates" No BOM line is valid on the manufacturing date. Check the BOM dates.
- "Production Order BOM Lines cannot be empty" Pick a BOM or add lines.
- "Routing Lines - Line ID: ... - Resource cannot be empty" The routing lacks a resource.
- "Please reserve the items" on Release. An Always Manual component is not fully reserved. Reserve it.
- "Please run Batch Balancing" Balance the active ingredients first.
- "Default Warehouse is not defined in Item In Legalentity" Give the component a default warehouse for the site.
- "Cannot Update Closed/Canceled Manufacturing Order" The order is finished or cancelled.
- "You are unable to modify the production order status from 'Released' to 'Planned' as the Confimration is already created." It has a confirmation.
- "Production Order : ... Cannot be Cancel. ..." / "... Cannot be Delete. ..." It has a confirmation.
- "Production Confirmation already created, You cannot block this Production Order" Leave it unblocked.
- "Line ID : ... - cannot be removed. It was already referred in Confirmation." Keep that line.
- "There is an problem in Production Unit Input/Output Warehouse" Add a matching line on the manufacturing unit.
- "Transfer Request Journal is not defined in setting" The site creates transfer requests but the setting has no journal.
- "Line ID - ... - Stock is not available for reservation ..." / "... Quantity is not available enough for reservation" Not enough free stock. Receive or transfer stock, then reserve again.
- "Line ID : ... - Packing Unit is Mandatory" / "... Packing Quantity cannot be zero or negative" / "Sum of Quantity can not greater then Production Order Quantity" / "Packing Unit ... Not found" Fix the Packaging lines.