Manufacturing Order Details

Accessible from Production planning -> Manufacturing Orders, the administrative view of the Manufacturing Order allows to see all manufacturing order details and edit them.

Jump to a topic:

  1. Edit the details of the MO.
  2. Report progress of production operations.
  3. Print, MO PDF, label, job traveler, materials requisition sheet.
  4. Manufacturing Order statuses.
  5. Approve or release a manufacturing order for production.
  6. How is the operation's duration calculated?
  7. How are manufacturing overhead, labor, and materials costs calculated?
  8. What is a multi-level MO?
  9. Troubleshooting.

Editing the Manufacturing Order

Jump to:

  1. Change manufacturing order quantity.
  2. Book, add, or remove materials.
  3. Edit operations, assign workers/departments.
  4. How to set default workers or departments?
  5. Reschedule MO.
  6. Remove MO from the schedule.
  7. Add notes, add a red flag to the MO.

Changing the Manufacturing Order quantity

The total quantity of the MO can be changed by the production manager at Production planning -> Manufacturing Orders -> MO details page.

If the quantity is changed before the MO is started:

  • Required materials and operations are completely recalculated according to the BOM and routing.
  • Parts are automatically booked, if available.
  • Operations are rescheduled.
    • If MO quantity is decreased (duration of operations decreases), the operations are scheduled starting from the "Start" time of the first operation. I.e. generally, the start time of the MO should remain in place.
    • If MO quantity is increased (duration of operations increases):
      • If the "Due date" is undefined, the operations are scheduled by finding the first available time in the schedule starting from the current time. I.e. it is likely that the MO start time will become earlier.
      • If the "Due date" is defined, and Backward scheduling (Enterprise feature) is available, the operations are scheduled to finish as late as possible before the due date. I.e. it is likely that the MO start time will change, while the finish time will stay in place.
  • The quantity of the target lot is updated.

If the quantity is changed after the MO is started:

Adding, booking, and removing materials

Under the Materials section at Production planning -> Manufacturing Orders -> MO details page, it is possible to book new parts or return booked parts to stock as a production manager. The workers can report consumed materials in My production plan.

Managing materials with bulk actions:
  • Click "Book all parts" to book available items from stock (by FIFO; or by FEFO, for perishable goods).
  • Click "Release all booked parts" to unbook all booked materials. Consumed materials will not be affected.
  • Mass (re)book materials of all planned MOs at once to book materials.
  • Materials can be added to or removed from MO by updating the Bill of Materials and pushing the update to the existing planned MO (before the order is started).
Managing materials manually, line-by-line:
  • To increase booking of material, click "Add a booking" on the material's line.
  • To add a new material, click "Add a booking" in the top right corner of the Materials table.
  • To decrease booking and undo consumption of material, click "Return to stock" on the stock lot's line of the material.
  • To remove a material, click "Return to stock" on the "Not booked" line of the material. If the material is fully booked, first unbook it.

Editing operations, assigning workers or departments

The Operations section of a manufacturing order contains a list of the manufacturing operations, where it is possible to assign workers or departments and edit each operation.

When a new MO is created, the workers are assigned according to default settings.

For changing the worker on an operation:

  1. Open the Manufacturing Order.
  2. Find the operation in the Operations section.
  3. Change the Worker, using the drop-down menu.
  4. If you wish to assign another additional worker to the same operation, then edit the operation and click "Add worker".

While editing the operation, it is possible to

  • change, remove, and add workstations or workers,
  • edit the planned operation duration,
  • insert, edit, remove reported work times and quantity,
  • edit manufacturing overhead and labor costs.

For editing an operation:

  1. Open the Manufacturing Order in Edit mode.
  2. Scroll down to the Operations section.
  3. Click "View/Edit" to see and edit the operation details.

For rescheduling a single operation, there are two options:

  1. Use Drag-and-Drop Rescheduling in section Production planning -> Production schedule.
  2. Edit the operation duration manually inside the MO details.

If the routing is updated:

  • Operations can be added to or removed from MO by updating the Routing and pushing the update to the existing MO (before the order is started).

Notes and warnings

It is possible to enter Notes regarding a manufacturing order at the bottom of the MO details page, which is accessible:

  • for the manager, from the Production planning section.
  • for the worker, from the My production plan section.

Important notes (incl. warnings from MRPeasy):

  • Are shown with an Important flag Important notice in Production planning -> Manufacturing Orders and My production plan -> List view tables. 
  • Are shown with a thick blue border inside the MO details in the Notes section.

Reporting the progress of a Manufacturing Order

Jump to:

  1. Report progress of operations and usage of materials.
  2. Change manufacturing order quantity.
  3. Edit reported times, quantities, and materials.
  4. Operation time tracker.
  5. Finalize MO, or finish production as planned.
  6. Return finished MO to production.
  7. Create serial numbers for manufactured items.
  8. Report serial numbers of used components.
  9. Report scrap, wastage.
  10. Subcontracting.
  11. Sub-assembly overproduction in a multi-level MO.

Accessing the production reporting views

Workers, who are assigned to operations or part of the assigned department, can see their operations and report progress in the reporting views, where it is possible to:

  • report start and finish times of work operations,
  • quantities produced,
  • part consumption,
  • lot numbers,
  • serial numbers.

There are several ways to access the reporting views:

  1. Go to the software section My production plan, which is the worker's interface, where operations and material consumption can be reported.
  2. Log in to Internet-kiosk, which is a simplified reporting interface for the worker, where operations can be reported. This is most suitable for small touchscreens.
  3. Click the "Go to production" button inside the Manufacturing Order details page to access My production plan, if you are a manager.

Editing the reported times, quantities, and materials

For reporting the manufacturing order, if workers have not reported, made mistakes in reporting, or have not finalized it:

Time tracker working principles

The production workers report when they start, pause, and finish operations, according to which the manufacturing time is tracked.

If an operation is not paused at the end of a workday:

  • If it is paused or finished by the worker after hours, the full time from start to finish is considered.
    - Working hours are 9 am to 5 pm. The operation started at 10 am one day and finished at 6 pm the same day. The working time is 8 hours.
  • It will be paused automatically by the system during the night (between 1 am and 3 am). In this case, the finish time is set to the work day's end.
    Working hours are 9 am to 5 pm. The operation is started at 10 am one day and paused by the system at 1 am the next day. The working time is 7 hours.
    - Note that an operation will not be paused automatically if there is no pause between two working days.
  • If the operation starts during one workday and ends in another day's working hours, the non-working hours are ignored in the total time calculation.
    Working hours are 9 am to 5 pm. The operation started at 10 am one day and finished at 10 am the next day. The working time is 8 hours.

Finalizing the manufacturing order

To finish the MO, if a worker in My production plan did not click "Finish production":

  1. Open the MO
  2. Click "Go to production".
  3. Click "Finish production".
Finish production as planned

In the MO details page, it is possible to finish the MO with one click.

If you click Finish production as planned:

  • The Manufacturing Order is marked finished (status Done) even if operations have not been reported, or some materials have not been booked.
  • All booked materials will be automatically consumed. If some required materials were not booked, the software adds a flag Important notice and a Note to the order.
  • All unreported operations:
    - with planned times in the past, will be marked as reported according to their estimated times.
    - with planned times in the future, will be scheduled backward from button press time. For all such operations, the finish time will be the button press time, and the duration will match the planned duration.
  • Finished products will be available in stock.
Returning a finished manufacturing order to production

If the manufacturing order was marked finished by error, for returning the order to production:

  1. Open the Manufacturing Order in Edit mode.
  2. Click the "Return to production" button at the bottom of the Manufacturing Order details page.

The button "Return to production" is visible only to users with the "Lock handler" right. To change user rights go to Settings -> Human resources.

Overproduction of sub-assemblies in a multi-level MO

All sub-assemblies produced within a multi-level MO are considered as consumed in the finished product.

For making sub-assemblies to stock in excess, the following approaches can be used:

  • To prevent the situation, you could make the MO for the sub-assembly in advance. In such a case, it will not be nested into the MO of the upper-level product, and excess quantities will go to stock.
  • In case the MO is in progress already, use one of the following approaches:
    a) For the overproduced quantity, make a separate MO (and e.g. click the "Finish production as planned" button to put these to stock immediately).
    b) For the overproduced quantity, find another existing MO, where these are also produced, and report these units as produced.
    c) Use the Co-product BOM functionality to take excess subassemblies to stock.

Reporting scrap, wastage

How scrap should be reported and treated is an organizational decision of your company. Please find general guidelines below:

  1. Report scrapped products.
  2. Report scrapped parts, wastage.
Reporting scrapped products

If finished products are scrapped, and will not be taken to stock.

  • When reporting the number of made products, report only the number of good products.
  • If you plan to finish the MO with the same quantity, you may need to add extra materials.
  • If you need to finish the MO short:
    - the MO quantity can be changed anytime in the administrative view of the MO. 
    - in My production plan, if the worker reports under-production the MO quantity can be updated automatically.
  • The cost of the scrapped will be accounted for in the cost of good products.

If finished products are scrapped and will be taken to stock for further processing, there are two options:

A) Use the "Quality Control" functionality to reject scrapped products after MO finish:

B) Use the "Co-product BOM" functionality to place rejected products in stock immediately:

  • Create a separate item in stock for the scrapped finished products. Add this item to the BOM of the finished product in the "Additional products" section.
  • When reporting the number of made products:
    - report only the number of good products.
    - additionally, as the additional product quantity which is asked, report the number of scrapped products. These will be placed in stock immediately.
  • The cost of the scrapped product can be controlled with the cost allocation percentage in the BOM of the finished product. 
Reporting scrapped parts, wastage

If scrapped parts will not be taken to stock:

  • Consume the scrapped part in the MO.
  • If necessary, add extra materials from stock to replace the scrapped part.
  • The cost of scrapped parts will be reflected in the cost of the finished products.

If the scrapped part should be returned to stock and written off:

If the scrapped part will be taken to stock for further processing, use the "Co-product BOM" functionality to place it in stock immediately:

  • Create a separate item in stock for the scrapped part. Add this item to the BOM of the finished product in the "Additional products" section.
  • When reporting the number of made products, also report the number of scrapped parts. These will be placed in stock immediately.
  • The cost of the scrapped part can be controlled with the cost allocation percentage in the BOM of the finished product.

Subcontracting

The section "Subcontracts" in the Manufacturing Order details contains a list of subcontracted operations (e.g. powder coating).

If a Routing has subcontracted services, then in the Manufacturing Order, in the Subcontracts section, for each operation:

  1. It is possible to create a PO and see the link to the PO.
  2. When creating the PO, the software calculates the dates and costs using Setup time, Cycle time, Fixed cost, and Variable cost values from the routing. These can be changed or updated inside the PO.
  3. The operation is marked started when the PO is in shipped status (field "Shipped on" is filled).
  4. The operation is marked finished when the PO is received.

To create one purchase order with subcontracted operations from several manufacturing orders, please go to Procurement -> Requirements.

Attention! There are different strategies on how to use the Subcontracting module:

  1. Strategy 1: When a product or a sub-assembly is fully made by the subcontractor (a subcontracted manufacturer).
  2. Strategy 2: When an operation during production is outsourced to a subcontractor.

To use this functionality, the subcontracting functionality must be turned on at Settings -> System settings -> Professional functions -> Subcontracting: Yes.

 

Multi-level Manufacturing Order

Jump to:

  1. Explanation of a multi-level MO.
  2. Overproduction of sub-assembly.
  3. Sorting of assemblies and operations.
  4. Displayed cost of nested assemblies.

What is a multi-level MO

When sub-assemblies are not available in stock, MRPeasy automatically nests the production of these under the same Manufacturing Order.

If the manufacturing order is multi-level:

  • The materials and operations are grouped by assemblies (i.e. by BOMs and Routings).
  • If a sub-assembly does not have a routing, it is considered as a collection of parts (it is a phantom assembly / a phantom BOM).
  • Component names are displayed in green if parts for it are ready (sub-assemblies from the same MO are finished). Otherwise, the component name is displayed in red.

Important notes:

  • If the MO product is a kit (a bundle, an auto-assembly product), a multi-level MO is never created.
  • If Packing functionality is used, and the MO contains packaging material, then if the packaging material is not in stock, and the packaging has a BOM, a multi-level MO will not be created for manufacturing the packaging item.

Sorting of sub-assemblies and operations

The order in which the assemblies and their parts are displayed depends on the order into which they are sorted as a preparation before the production operations are scheduled.

All assemblies, which must be produced, are sorted as follows:

  1. First, according to the level in the BOM. The lower level assemblies are first.
    • This means that the scheduling process will start with these first.
    • Direct parts of the product are level 1, components of these are level 2, etc. a higher number is a lower level.
    • If the part's sequence number in BOM is 28.1.3.13, its level is 4.
  2. Second, according to the sequence number of the part in the BOM at that level. The lowest numbers are first.
    • If the part's full sequence number in BOM is 20.1.1.10, its sequence number at this level is 10.
    • Part 30.1.1.1 is before part 20.1.1.10.

For example, if the BOM is as follows:

Sequence nr in BOM Part Level in BOM Sequence nr at this level of BOM
1 A 1
2 B 1 1
2.1 B1 2
2.2 B2 2 2
2.2.1 B21 3 1
3 C 1 3
3.1 C1 2
3.2 C2 2

The displayed order of assemblies and operations will be the following in the MO:

# Sequence nr in BOM Part Level in BOM Sequence nr at this level of BOM
1 2.2.1 B21 3 1
2 2.1 B1 2 1
3 3.1 C1 2 1
4 2.2 B2 2 2
5 3.2 C2 2 2
6 Not applicable The product of MO Not applicable

Displayed cost of nested assemblies

It is important to note the following:

  • All costs of components, labor, and subassemblies are added directly to the costs of the MO (to the cost of the upper-level product).
  • The cost of an item that is produced in the same MO:
    • Is not included on the used part's total line (the upper line), where it is consumed.
    • Below that line, in the line which refers to its source ("Manufacturing Order ..."), it is displayed as the sum of procured items it's directly made of (excludes any of its subassemblies' costs).
  • The quantity of a subassembly that is produced in the same MO:
    • Is displayed next to the assembly title, under which all its parts are listed.
    • Is not included on the used part's total line (the upper line), where it is consumed. Below this line, which tells its source ("Manufacturing Order ...") the quantity is marked as consumed.

Example:

Manufacturing Order MO-0001
Total materials cost of MO: $150 + $100 + $0 + $150 + $100 + $25 = $525 This is the sum of all parts' total lines. This equals the cost of all lines with Lot numbers, i.e. this is the cost of all used materials from stock.
           
Subassembly A 25 pcs       The quantity of the assembly is displayed next to the heading of the assembly.
Stock item Quantity Total cost Unit cost Lot Subassembly A is made of procured parts.
Part A1 100 pcs $150 $1.50   This is a procured item.
  50 pcs $50 $0.5 L0001  
  50 pcs $100 $1 L0002  
Part A2 100 pcs $100 $100   This is a procured item.
  100 pcs $100 $100 L0003  
           
Subassembly B 1 pcs       Subassembly B is made of Subassembly A and another procured part.
Stock item Quantity Total cost Unit cost Lot  
Subassembly A 0 pcs $0 $0   The cost and quantity of Subassembly A produced in this MO is not included in the total line here.
  25 pcs $250 $10 Manufacturing Order MO-0001 This cost is the cost of procured items in the parts list of Subassembly A.
Part B1 1 pcs $150 $150   This is a procured item.
  1 pcs $150 $150 L0004  
           
The product of MO 1 pcs       The product of the MO is made of Subassembly B and another procured part.
Stock item Quantity Total cost Unit cost   The cost and quantity of Subassembly B produced in this MO is not included in the total line of Subassembly B here.
But the cost and quantity of the second piece of Subassembly B, which is taken from stock (produced in a different MO), is included here.
Subassembly B 1 pcs $100 $100  
  1 pcs $150 $150 Manufacturing Order MO-0001 This cost is the cost of procured items in the parts list of Subassembly B.
  1pcs $100 $100 L0005 This is manufactured in another MO
Part C1 1 pcs $25 $25   This is a procured item
  1 pcs $25 $25 L0006  

 

Printing documents

Jump to:

  1. Print Manufacturing Order PDF.
  2. Print materials requisition sheet PDF.
  3. Print MO label.
Printing the manufacturing order, job traveler

Manufacturing orders can be printed in four versions:

  1. PDF wide on the MO details page.
  2. PDF medium on the MO details page.
  3. PDF narrow on the MO details page.
  4. PDF from My production plan:
    1. Click on the Go to production, or go to My production plan and open the MO.
    2. Print the PDF.

Notes:

Manufacturing Order label, barcode

It is possible to print labels to identify physical items from different manufacturing orders. The labels can be printed by clicking Print label in the upper right corner of the Manufacturing order details page.

The size, information, and layout of the label can be edited with the Label editor.

The standard label contains the unique manufacturing order barcode if the Barcode System functionality is enabled.

Read also: What happens when a barcode is scanned?

Troubleshooting

Error message: "This manufacturing order cannot be canceled because items from its target lot have been consumed.".

Explanation: This means that products that were made from this MO are used somewhere already (e.g. shipped, written off, consumed in another MO...).

Resolution: The consumption of the products must be undone before the MO can be deleted.

  1. Open the Manufacturing Order.
  2. Click on the Target lot number.
  3. Open the Reports of the lot.
  4. Select the report "Bookings".
  5. Find and edit the lines where some items are consumed.
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