User Manual

Manufacturing Order Details

The Manufacturing Order has two views, the administrative view, for detailed overview and management, and reporting views, for reporting work in real-time.

Accessible from Production planning -> Manufacturing Orders, the administrative view of the Manufacturing Order allows to

  • see all order details and costing information,
  • see, edit, and book the required materials,
  • see and edit the operations and their details,
  • add product serial numbers,
  • assign workers to operations,
  • edit reported start-stop information,
  • open attached files and see images,
  • one-click finish of the order according to the plan,
  • return order to production,
  • add notes.

Jump to a topic:

  1. Where can I report production operations?
  2. How to book, add or release materials?
  3. How to edit an operation, e.g. to assign workers?
  4. How to change the manufacturing order quantity?
  5. How is an operation's duration calculated?
  6. How are manufacturing overhead, labor, and materials costs calculated?
  7. How to return a finished manufacturing order to production?
  8. How to print the work sheet (job traveler, job sheet)?
  9. What are the Manufacturing Order statuses, how are the statuses updated?
  10. What is a multi-level manufacturing order?
  11. How to add important notes or a flag to an order?
  12. How to record serial numbers?
  13. How to keep track of subcontracted operations?
  14. How to approve or release a Manufacturing Order for production?

Reporting production operations

The workers can report start-end times of work operations, quantities produced, part consumption, and lot and serial numbers. For live reporting of production, open one of the reporting views:

  1. Click the Go to production button inside the Manufacturing Order details.
  2. Or, go to software section My production plan, which is the worker's interface, and open the operation.
  3. Or, log in to Internet-kiosk, which is the simplified reporting interface for touchscreens.

In MRPeasy, it is possible to report an operation started and even finished before a previous operation is finished. The software does not lock down the reporting or freeze when a previous person forgot to report their actions.

For example, in a production line, when an operation was finished, the next operation can start, even when the previous worker forgets or did not have time to yet report it in software. If the software would lock up, one of two very serious consequences can happen:

  1. workers would go on working, and omit reporting at all, since software is locked;
  2. production would stop until the reason for lock-up is found and corrected, which could potentially result in serious delays.

Finalizing the manufacturing order

As a production manager, you could be reporting for the workers, or you might need to finalize the order because a worker didn't press Finish production. For reporting the manufacturing order finished:

  1. Open the Manufacturing Order in Edit mode.
  2. Click the Finish production as planned button at the bottom of the Manufacturing Order details page.

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 will be marked reported according to their estimated times.
  • Finished products will be available in stock.

Editing the Manufacturing Order

Adding parts, booking and releasing materials

Under Materials section inside the MO details, it is possible to allocate new parts or return allocated parts to stock.

For booking materials:

  1. Open the Manufacturing Order in Edit mode. 
  2. Book the parts:
    a. Automatically: click Book all parts to book available items from stock (default by FIFO; or by FEFO, for perishable goods).
    b. Manually: click Add a bookingAdd a booking button on the material's line, choose the materials from available stock lots, or create a Purchase Order.

For adding a new part, click the Add a booking Add a booking button in the top right corner of the Materials table.

For returning booked materials to stock one-by-one:

  1. Open the Manufacturing Order in Edit mode. 
  2. Click Return to stock Return to stock button on the material's line.
  3. Enter the quantity to return.
  4. To remove the demand for the material, if it's not required at all, repeat the previous action on the "Not booked" line.

For returning booked materials to stock all at once:

  1. Click the Release all booked parts button.
    Booked materials will be returned to stock. Consumed materials will not be returned to stock.

NB! Materials can be added or removed by updating the Bill of Materials and pushing the update to the existing Manufacturing Order (before the order is marked started).

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.

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.

For editing an operation:

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

For rescheduling an operation, there are two options:

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

NB! Operations can be added or removed by updating the Routing and pushing the update to the existing Manufacturing Order (before the order is marked started).

NB! Default workers or departments can be set in each workstation's details or in the Routing (the workstation's setting overrules the routing).

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 before the production has started, or after it has finished.

During production, the workers can report the produced quantity, which will update the MO quantity, if different. The reported quantity of the last operation will update the total quantity of the MO.

If the quantity is changed before the MO is started at Production planning -> Manufacturing Orders -> MO details page:

  • Required materials and operations are recalculated.
  • Parts are automatically booked, if available.
  • Operations are rescheduled.
  • The quantity of the Target lot is updated.

If the quantity is changed after the MO is finished at Production planning -> Manufacturing Orders -> MO details page:

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 Return to production button at the bottom of the Manufacturing Order details page.

Printing the manufacturing order, job traveler

Manufacturing orders can be printed in three versions:

  1. PDF wide, a document for the management, includes cost information.
  2. PDF medium, a job sheet for the worker.
  3. PDF narrow, a less detailed job sheet for the worker.

For printing a very detailed job sheet, click on the Go to production, then print the PDF of that page.

Statuses of a Manufacturing Order

Manufacturing order statuses are assigned automatically by MRPeasy:

  • The order is in status New if it requires approval (only used if Order Approval functionality is enabled).
  • The order status is Scheduled when it has not started.
  • The status is changed to In progress when a worker clicks on the Start Start button of the first operation.
  • The status is changed to Paused when a worker clicks on the Pause Pause button of an operation, or when a worker finishes the last operation and clicks on Finish Finish.
  • The status is changed to Done when a worker clicks on the Finish production button, or the production manager clicks on the Finish production as planned button.

Multi-level Manufacturing Order

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).
  • 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.

Notes and warnings

It is possible to enter Notes regarding this manufacturing order at the bottom of the MO details page. Important notes (incl. warnings from MRPeasy) have an Important flag Important notice in Production planning -> Manufacturing Orders table, and are shown with a thick blue border inside the MO details in the Notes section.

Reporting serial numbers in production

It is possible to report both product serial numbers and part serial numbers.

Reporting serial numbers in production:

  1. Open the Manufacturing Order in Edit mode.
  2. Scroll down to the Serial numbers section.
  3. Click Add serial number to product.
    (In the reporting screen, this button will become available after reporting the work operation started.)
  4. Serial numbers can be entered: 
    - individually, by keyboard input or barcode scanning.
    With keyboard input, the serial numbers are auto-incremented, based on the last known serial number of the product;
    - all at once, by copying them from a Notepad or an Excel file and pasting them into the first serial number field. The software will place each number in its own field.
  5. For entering part serial numbers, for every product serial number:
    1. Choose the part.
    2. Choose the serial number. (Only serial numbers from booked stock lots are available.)

If serial numbers are already saved for the product, then it is possible to add, remove, or edit part serial numbers by clicking on the View/Edit Edit button of the serial number in the MO details.

In order to use serial numbers:

  • The serial numbers functionality must be turned on at Settings -> System settings -> Professional functions -> Serial numbers: Yes.
  • Serial numbers must be enabled in the item details, at Stock -> Items.

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 cost 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.

NB! There are different strategies 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.