Manufacturing

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Bookmarks: Both a BOM and a kitset | Non-stock or non-diminishing products | An example of a typical production job | How to reverse a production job? | Reverse manufacturing

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In a snapshot, there are three steps in the manufacturing process:

1. Create job
2. Start
3. Finish

The benefits include:

• Real-time raw material stock levels
• Simple process means efficiency
• Capacity to add complex logics

 

Watch the vide below for a simple manufacturing process

 

 

Both a BOM and a kitset

A product can be setup or configured as a BOM and a kitset.

A BOM consists of the raw material products that are required to manufacture one unit of the finished goods product. A BOM holds stock, cost and it can be sold and purchased.

A kitset consists of the products to be sold as a bundle. For example: A burger meal as a kitset that consists of a burger, chips and a drink. A kitset does not hold stock, cost and can be sold. When sold, the cost for the kitset is the sum of it's items costs. It's inventory level is the lowest available inventory from it's items.

This is a flexible way of creating a product that can be used in a production job as well as selling it with different units.

For example:

Product: ABCDE-GALLON

Manufacturing unit: GALLON

Selling unit: LITRE or multiples of LITRE

It is a BOM that consist of RM-X, RM-Y, LABOUR, OVERHEAD, CLEANTIME and so on.

It is also a kitset that consist of 3 units of ABCDE-LITRE

Create a new production job to make 100 ABCDE-GALLON

The result:

1. inventory level of ABCDE-LITRE is increased by 100 times 3 = 300 litres

2. sell one unit of ABCDE-GALLON, it comes with 3 units of ABCDE-LITRE, and the inventory level of ABCDE-LITRE is reduced by 3.

 

Non-stock or non-diminishing products

Non-diminishing products can be added to a BOM or a production job.

For example:

• Create a new product SKU "LABOUR", and set it to
  • Non-diminishing
  • The unit to HOUR (or similar)
  • The labour cost into the "Last buy price" field

 

An example of a typical production job

•     Setup a BOM for making a single bicycle
•     Create a new production job to make 100 bicycles
•     Based on the BOM, the system automatically calculates how much raw materials are required and add them into the job
•     Raw materials can be edited, removed and added
•     There are three main statuses of a production job:
  • Open
  • In progress
  • Completed
•     Once a job is completed, the system automatically;
  • Reduces the raw materials stock
  • Increases the finished goods stock by the "Production quantity"
  • The total raw materials cost will be used to calculate the finished goods' unit cost for receiving into stock.
  • If the finished goods product requires batch tracking, then a production batch number will be prompted and created.

Optional: a production stage for the production job can be recorded so that from the jobs overview page, you can see what stage each production job is at.

To import bill of materials in bulk, go to Products menu > Import data > choose "Bill of materials" from the data type dropdown, then click to download the data template. It requires just three columns, see below:

A. BOM SKU (mandatory)
B. BOM description (readonly)
C. Item SKU (mandatory)
D. Item description (readonly)
E. Quantity (mandatory)

 

How to reverse a production job?

Sometimes a completed production job might need reversing, and to do this, follow the steps below:

1. On the manufacturing production jobs list page, search or bring up the completed job that to be reversed
   
2. Click "Reverse production"
   This will create a reversal copy of the job and opens it up for final confirmation
3. Once ready, click "Finish & complete" to commit the reversal
   
    

The reversal job is an exact reverse copy of the original job. It includes the following steps:

• Negative production (output) quantity
• Negative raw material/service (input) quantities
• Reversal of batch number entries for both raw materials and finish goods product

If you wish to discuss your requirements, please email help@zeablue.com

 

Reverse manufacturing

Doing a reverse manufacturing job is the same as doing a normal manufacturing job and it has the same process. The differences are:

• Enter a negative quantity number into the production quantity field: the negative number indicates a reverse manufacturing mode. When the job is completed, the system reduces the finished goods stock and increases the raw material items stock.
• The reversal cost of the finished goods product calculates from its FIFO cost
• The unit costs of the raw material items will be calculated from their respective last purchase order cost