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OneHash Manufacturing

Streamlines production with integrated work orders, BOMs, capacity planning, inventory, and subcontracting for efficient manufacturing management.
By Frappe Content licensed CC-BY-SA 3.0
• 35 articles

Capacity Planning

Capacity Planning Capacity planning is the process in which an organization decides whether or not to accept the new orders based on the resources and existing work orders. Capacity planning has been enabled by default in your account, to know more go to: ++Home > Manufacturing > Settings > Manufacturing Settings++ | 1. Prerequisites Before creating and using a Work Order, it is advised that you create the following first: - Bill of Materials - Operations - Workstation - Work Order | 2. How Capacity Planning Works in OneHash The user has to define the number of days in the "Capacity Planning For" field under manufacturing settings to plan the upcoming work orders. For example, if you have kept the Capacity Planning For 30 days and to make 1 finished good it requires 5 days then on the current date user can only accept the 6 work orders (30/5 = 6). You can take the next Work Order when your Workstation gets free. 2.1 Create Work Order With Operations User needs to create the Work Orders with Operations so that the system will track the Job Card timings against the Work Order. Once the user submits the Work Order, system will generate the Job Card with the available Workstation's time details. If 'Allow Overtime' is disabled in Manufacturing Settings then the system schedules the job as per the timings defined in the Workstation. If "Allow Production on Holidays" is disabled then the system schedules job only on working days. 2.2 Workstation's Production Capacity In the Workstation, the user can set the 'Production Capacity'. This is the number of Operations the system will allow you work on in this Workstation. For example, if a certain Workstation can handle 10 operations at the same time, enter the 'Production Capacity' as 10. 2.3 Job Card With Timing The system will auto-create the Job Card with timing against each operation based upon the time required to complete that operation and Workstation's availability. The user has to set the planned start date and based on the operation time, system calculates the planned end date. 2.4 Work Order Planned Start Date and End Date Based on the planned start date and end date, users can calculate the capacity of their work stations. Also, they can track the status of the work order using the Calendar. To view calendar, go to: ++Work Order List > Calendar > Default++ 2.5 Capacity Planning Error If the Production Capacity days is less than time required to complete the operation then system throws a capacity planning error. In this case, user has to increase the number under "Production Capacity" days in the Manufacturing Settings or reduce the number of finished goods as per the capacity of the Workstations

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

How to use the BOM Update Tool?

BOM Update Tool From the BOM Update Tool, you can replace a sub-assembly BOM and update costs of all parent BOMs. Using this utility, you can replace an existing BOM of a sub-assembly item which is linked to a parent BOM. The system will update the new BOM in all the parent BOMs where it was used. You need to create a new BOM first. To use the BOM Update Tool, go to: ++Home > Manufacturing > Tools > BOM Update Tool++ | 1. How to use the BOM Update Tool Let's consider a scenario to understand this better. Suppose a company manufactures computers, Bill of Materials for the computer will look like this: 1. Monitor 2. Key Board 3. Mouse 4. CPU Out of all the items above, CPU is assembled separately. Hence separate BOM will be created for the CPU. Following are the items from the BOM of CPU. 1. 250 GB Hard Disk 2. MotherBoard 3. Processor 4. SMTP 5. DVD player If more items need to be added, or existing items to be edited in the CPU BOM, then create new BOM for it. 1. 950 GB Hard Disk 2. MotherBoard 3. Processor 4. SMTP 5. DVD player Select Current BOM and New BOM of the sub-assembly Item: To update the new BOM in all the parent BOMs, where CPU is selected as sub-assembly, you can use the Replace button. On clicking Replace button, old BOM of CPU will be replaced with the new BOM in the BOM of finished Item (Computer). Will BOM Replace Tool work for replacing the exploded Items in the parent BOM? No, exploded Items which do not have any BOMs of their own cannot be replaced in the parent BOM. For example, consider if the Item Monitor does not have a sub-assembly and it cannot be updated using this tool. For updating exploded Items you should Cancel and Amend current BOM, or create a new BOM for the finished item. Update BOM Cost Using the button Update latest price in all BOMs, you can update the cost of all Bill of Materials, based on the latest purchase price/price list rate/valuation rate of raw materials. This is useful if your updated BOM has materials with different Rates. On clicking this button, the system will create a background process to update all the BOM's cost. It is processed via background jobs because this process can take a few minutes (depending on the number of BOMs) to update all the BOMs. This functionality can also be executed automatically daily. For that, you need to enable "Update BOM Cost Automatically" from Manufacturing Settings.

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

Item Alternative

Item Alternative An Item Alternative is an Item similar to the original one and can be used instead of the original Item in manufacturing. If the raw material defined in the BOM is not available during the production process then their respective available alternative Item can be used to complete the production process. First you need to enable the "Allow Alternative Item" in the Item. To access the Item alternative list, go to: ++Home > Stock > Items and Pricing > Item Alternative++ This can also be done by clicking the plus sign next to 'Item Alternative' from the Item master dashboard. You can enable Two-Way replacement between an Item and their alternative item if both can be used as an alternative to each other. | 1. Prerequisites Before creating and using an Item Alternative, it is advised that you create the following first: - Item | 2. Item Alternative for Work Order To allow to using alternative Items in the manufacturing process, the user can configure to 'Allow Alternative Item' in the BOM/Work Order 2.1 Provision to allow the alternative item in the BOM You can enable 'Allow Alternative Item' in a BOM then select the alternative item in the Stock Entry. This can also be done with a Work Order. 2.2 Provision to Allow Alternative Item in the Work Order User can also enable/disable allow alternative item for individual Work Orders. Ticking on the 'Allow Alternative Item' checkbox will show a button named 'Alternate Item'. You can click on this to set the Item Alternative in the Work Order. This is how you use Item Alternative in a Work Order: This is how you use Item Alternative with a Stock Entry: If the 'Allow Alternative Item' checkbox in the Item table is disabled, you cannot set an Alternate Item for this Item. 2.3 Item Alternative for subcontract In subcontract, the user has to transfer raw materials to the subcontracted supplier to get finished good from them. If the raw material is not available in the stock, with this feature, the user can transfer the alternate item of the subcontracted raw material to the supplier. This is done in the Stock Entry. After this, when you create a Purchase Receipt from the Work Order, the alternate item will be shown.

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

How to Set up Subcontracting?

Subcontracting In subcontracting, you employ an external party to carry out tasks for your organization, especially manufacturing. Subcontracting is a type of job contract that seeks to outsource certain types of work to other companies. It allows work on more than one phase of the project to be done at once, often leading to quicker completion. Subcontracting is practiced by various industries. For example, manufacturers who make a number of products from complex components subcontract certain components and package them at their facilities. If your business involves outsourcing certain processes to a third party Supplier where you supply the raw materials and the third party does the labor/production, you can track this by using the subcontracting feature of OneHash. | How to Set up Subcontracting 1. Create separate Items for the unprocessed and the processed product. For example, if you supply unpainted X to your Supplier and the Supplier returns you X, you can create two Items: “X-unpainted” and “X”. 2. Create a Warehouse for your Supplier so that you can keep track of Items supplied. (you may supply a month's worth of Items in one go). 3. For the processed Item, in the Item master, enable “Is Sub Contracted Item”. Creating a BOM Make a Bill of Materials for the processed Item, with the unprocessed Items as sub-items. Let's consider a simple example, where you manufacture a pen. The processed pen will be named under Bill of Materials(BOM), whereas, the nib, plastic, ink, etc. will be categorized as sub-items. This BOM will be without Operations if all of the production work is done by the third party. Creating a Purchase Order Make a Purchase Order for the processed Item, the one for which you've created a BOM. When you “Save”, in the “Raw Materials Supplied”, all your un-processed Items will be updated based on your Bill of Materials. You can also select the Warehouse in which the raw materials would be reserved for subcontracting under Reserve Warehouse. 1. The costs involved with the subcontracting process should be recorded in the Rate field of the Items table in the Purchase Order shown as follows: 1. In the previous image, we are providing the subcontractor with 2 boxes of each of the 3 materials to manufacture 240 pens. The cost involved with one pen is 27 and the total cost for all pens is hence 6,480 2. You need to set 'Supply Raw Materials' as Yes since this Purchase Order is for subcontracting. 3. From a Purchase Order, select the raw materials to transfer to subcontractor: 1. Once the Purchase Order is submitted, you can view the reserved quantity of the item from the item dashboard as well. Creating Stock Entry to Transfer Raw Materials Now that the raw materials are reserved, make a Stock Entry to deliver the raw material Items to your Supplier. In the Purchase Order, click on Transfer > Material to Supplier. Set the Source and Target Warehouses. The Stock Entry will be of type 'Send to Subcontractor' where you transfer from one Warehouse to another. Tick 'From BOM' and select the BOM, enter the quantity, and click on the Get Items button. Creating a Purchase Receipt to receive the finished items Receive the Items from your Supplier using a Purchase Receipt. You need to enter the Supplier Warehouse from where the raw materials will be taken and finished goods will be received in the Accepted Warehouse. Consider this like a backflush for subcontracting. Click on Create > Purchase Receipt from the Purchase Order. Set the Accepted and Supplier Warehouses. Make sure to check the “Consumed Quantity” in the “Raw Materials” table so that the correct stock is maintained at the Supplier’s end. You need to select the Supplier's Warehouse where you'll receive the finished goods. Supplier Sourced Raw Material While creating a BOM for subcontracting, there might be few raw materials like nuts and bolts which the Suppliers will have to procure themselves. While creating a Stock Entry for "Transfer" from Purchase Order, these items can be excluded one by one, but it is impossible to do so if you have more than 100 items. If some raw material is sourced by the Supplier directly, then such raw materials have to be included in the BOM. - It will have zero value in BOM. . - In Purchase Order, this raw material will not appear in Supplied Items since it is not supplied. - Also, while creating a "Transfer", such items will be excluded from the Stock Entry. || Notes - Make sure that the “Rate” of processed Item is the processing rate (excluding the raw material rate). - OneHash will automatically add the raw material rate for your valuation purpose when you receive the finished Item in your stock. - OneHash will automatically default the 'Reserve Warehouse' in the Purchase Order from the BOM. If not found in the BOM, it would default it from the default Warehouse set in the Item. You can set the default Reserve Warehouse for all the Items in the Purchase Order from the 'Reserve Warehouse' field in the Raw Materials Supplied section.

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

How to create a Job Card?

Job Card A Job Card stores actual production information about a particular Operation performed on a particular Workstation. A Job Card is created from the Work Order and given to each of the Workstations in the manufacturing floor to start the production of an item with a certain quantity in each of the operations defined in the Work Order. Job Card allows each Operation's workstation to issue a “Material Request” and “Stock Transfer to Manufacture” for raw material required against a “Job Card”. Job Card completion will change the production status in Work Order, we can track the completion of production progress for each of the Operations defined in the Work Order. To access the Job Card list, go to: ++Home > Manufacturing > Production > Job Card++ | 1. Prerequisites Before creating and using a Job Card, it is advised that you create the following first: - Bill of Materials - Operation - Workstation / Machine - Work Order | 2. How to Create a Job Card Job Card for Operations is automatically created when a Work Order is submitted. This is what a Job Card looks like: To use a Job Card follow these steps: 1. Click on the Start Job button, then on Complete Job when you're done. 2. Alternatively, you can also fill the From Time and To Time in the Time Logs table. 3. Select the Employee to whom the Job Card was assigned. 4. Enter the Completed Quantity. This is the number of Items on which the Operation was performed for the selected time interval. 5. Add more rows in the Time Logs table and record time using the Start/Completed buttons. 6. Click on Submit. In a Work Order, the Operations and Workstations are fetched from the BOM of an Item. For ease of use, you should ensure that the Routing is configured in the BOM. Each Job Card created will have Workstation & Operations assigned. The raw material required from each Source Warehouse will be calculated based on quantity required for production. On submitting a Work Order, Job Cards will be auto-created based on the values in the Operations table. 2.1 Select Work Order with Item to Manufacture You can select 'Transfer Material Against' as 'Job Card' on the Bill of Materials to transfer raw materials for Production against Job Cards. In the Work Order, you can select the option: 2.2 Using a Job Card Employee assignment and timing detail will also be defined in Job Card. The time taken to do a job can be recorded. If multiple employees are working on the same Operation, add new job cards by clicking on the 'Create Job' Card button. 2.3 Material Request against Job Card A Material Request will be raised from the Job Card as a basis/order to prepare raw material required for the manufacturing process. The Material Request raised will have its reference to the original Job Card number. Track the Manufacturing Progress in The Work Order by The Completion of Each Operations defined in Work Order. Job Card completion allows you to track the manufacturing progress inside the Work Order by looking at the completion of each Operation related to the Work Order. | 3. Features 3.1 Tracking Quality Inspection || Introduced in Version 13 For production orders, the quality of in-process (semi-finished) goods also needs to be tracked. It is defined by the process (operation) performed on it which is in turn defined in the Job Card. In-process tests are different than incoming and outgoing material tests. Monitoring quality during manufacturing helps to make sure that the finished product produced is of the desired quality. You can create a Quality Inspection for the Production Item against the Job Card. For more details, refer the Quality Inspection page.

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

How to create a Production Plan?

Production Plan A Production Plan helps in production and material planning for the Items planned for manufacturing. These production items can be committed via Sales Order (to Customers) or Material Requests (internally). Production Plan helps the user to plan production against multiple Sales Orders or the Material Requests. Also, it helps in Material Procurement planning for the raw material item, based on the quantity of finished products to be manufactured. To access the Production Plan list, go to: ++Home > Manufacturing > Production > Production Plan++ | 1. Prerequisites Before creating and using a Production Plan, it is advised that you create the following first: - Item - Material Request - Sales Order - Bill of Materials - Routing | 2. How to Create a Production Plan As mentioned earlier, a Production Plan can be used for planning the manufacture of Items against Sales Orders or Material Requests. The common steps are: 1. Go to the Production Plan list, click on New. 2. Select whether to get items from a Sales Order or a Material Request. A Production Plan can also be created manually where you can select the Items to manufacture. Production Against Sales Orders 1. Select option as Sales Order from the 'Get Items From' drop-down list. The system will show the filters, using that you can pull the Sales Orders for the production. You don't need to use all these filters if you have only a few Sales Orders in a particular time frame. 1. Click on Get Sales Orders to fetch sales orders based on the above filters. 1. Click on 'Get Items for Work Order' to fetch the items from the above Sales Orders. Items only for which a BOM is present will be fetched. 1. On expanding a row in the Items to Manufacture table, you'll see an option to 'Include Exploded Items'. Ticking this includes raw materials of the sub-assembly items in the production process. Production Against Material Requests 1. Select option as Material Request from the Get Items From drop-down list. The system will show the filters, using that we can pull the Material Requests for the production. 2. Click on 'Get Material Request' to fetch material requests based on the above filters. 1. Click on Get Items for Work Order to fetch the items from the above material requests. Planning for Material Requests Clicking on the 'Get Raw Materials for Production' button will fetch the required raw material Items in the Material Request Plan table. For example, to manufacture 200 plastic canes, you need 100 raw plastic Nos but have only 20 in your Warehouse, then clicking this button will add a row with 80 in the Required Quantity column. Use the following checkboxes to perform certain actions: - Include Non Stock Items: To include non-stock items in the material request planning. i.e. Items for which 'Maintain Stock' checkbox is unticked. Refer the Item page for more details. - Include Subcontracted Items: To add subcontracted Item's raw materials if include exploded items is disabled. - Ignore Existing Projected Quantity: If enabled then the system will create the Material Request even if the user has already ordered or requested the respective items. For example if you need 100 quantity of raw material A and even if you already have 150, enabling this checkbox will add a request for 100 quantity of that raw material. - For Warehouse: User can set the Warehouse for which they want to create the material request. When creating Stock Entries during the production process, the system will look for raw material stock in this Warehouse. - Download Materials Required:- When this checkbox is ticked, the User will get the Excel sheet with the raw materials that are needed to complete this Production Plan. User can select the Warehouse to check the available quantity in the respective Warehouse. If the User has kept the 'For Warehouse' field as blank then the system will give the Excel sheet with raw materials and Warehouse-wise available quantity of the respective raw materials. Excel sheet will look similar to: After Submitting Once the Production Plan is submitted, the User gets an option to make Work Orders for the production items and Material Requests for the raw materials. Closing a Production Plan There could be occurrences where a Production Plan is partially complete and is going to be discontinued. This could happen due to reasons such as: - One of the items was independently produced outside the Production Plan. - A change in plans occurred and pending items will not be produced. In cases like these, Users can set the Production Plan status to Closed, so that no new Work Orders or Material Requests are created against it. Making work order for the sub-assembly items In the above screenshot, the User creates the Nokia Headphone first and then creates the Nokia Charger and then creates final finished goods. Here, the User wants to make the work order for the Nokia Headphone and Nokia Charger, to do this, the user has to enable the field "Make Work Order for Sub Assembly Items" in the Production Plan against the item Nokia Lumia. On clicking make Work Order, the system will generate the Work Order for the sub-assembly items and the finished good items:

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

Work Order: Introduction, Creation and Features

Work Order A Work Order is a document given to the manufacturing shop floor by the Production Planner as a signal to manufacture a certain quantity of a certain Item. The Work Order also helps generate the material requirements (Stock Entry) for the Item to be produced from its Bill of Materials. The Work Order can be generated from the Production Plan based on Sales Orders. To access the Work Order list, go to: ++Home > Manufacturing > Production > Work Order++ | 1. Prerequisites Before creating and using a Work Order, it is advised that you create the following first: - Bill of Materials - Operations - Workstation | 2. How to Create a Work Order 1. Go to the Work Order list, click on New. 2. Select the Item to be manufactured. 3. The default BOM for that item will be fetched by the system. You can also change the BOM. 4. Enter the quantity to manufacture. Raw material Items will be fetched only when this is set. 5. If the selected BOM has Operations mentioned in it, the system will fetch all Operations from BOM, these values can be changed. 6. Set the Planned Start Date (an Estimated Date at which you want the Production to begin). 7. Use Multi-Level BOM: This is enabled by default. If you want to plan materials for sub-assemblies of the Item you're manufacturing leave this enabled. If you plan and manufacture the sub-assemblies separately, you can disable this checkbox. Read more here. 8. Select Warehouses: 9. Source Warehouses: Select this Warehouse in the Item row. The warehouse where you store your raw materials. Each required item can have separate source warehouse. Group warehouse also can be selected as source warehouse. On submission of Work Order, the raw materials will be reserved in these warehouses for production usage. 10. Work-in-Progress Warehouse: The warehouse where your Items will be transferred when you begin production. Group Warehouse can also be selected as a Work in Progress warehouse. 11. Target Warehouse: The warehouse where you store finished Items before they are shipped. 12. Scrap Warehouse: If the BOM results in Scrap material, the Scrap Warehouse needs to be selected. 13. Required Items: All the required items (raw materials) will be fetched from BOM and populated in this table. Here you can also change the Source Warehouse for any item. And during the production, you can track transferred raw materials from this table. ||| Note: You can save a Work Order without selecting the Warehouses, but Warehouses are mandatory for submitting a Work Order. A Work Order can also be directly created from a Sales Order Additional Options when Creating a Work Order - Sales Order: If you create a Work Order from a Sales Order, it will be fetched here. You can also link an existing Sales Order which has the Item to be manufactured to this Work Order. - Project: Link the Work Order to a Project to track progress in cases like engineer to order. - Allow Alternative Item: Sometimes when manufacturing a finished good, specific materials may not be available. For example, using plastic beads instead of plastic crystals. The finished good itself could be different. Ticking this checkbox will allow you the select an Alternative Item. To know more, visit this page. - Skip Material Transfer to WIP Warehouse: Usually, a Stock Entry is created when the raw materials are transferred to a Work In Progress Warehouse. In this case, the raw material is considered to be consumed hence the Stock Entry is skipped. The next option will be shown if you tick this checkbox. - Backflush Raw Materials From Work-in-Progress Warehouse: Ticking this checkbox will automatically create a Stock Entry with type 'Manufacture'. This means that the raw materials were consumed from the Source Warehouse, used to manufacture finished goods and another Stock Entry was created for your Target Warehouse. | 3. Features 3.1 Time The Planned Start Date and Expected Delivery Date can be set here. The default for Planned Start Date is the current date and time at the time of creating the Work Order. 3.2 Required Items table The Source Warehouse can be changed for the raw material items used here. The default Warehouse can be set at the Item level in the Item master or globally in Stock Settings. - Required Quantity: This will be calculated automatically based on the Bill of Materials. - Transferred Quantity: Once the Work Order starts and Job Cards are run, items are transferred from the Source Warehouse to Work In Progress Warehouse. This field shows the quantity in the WIP Warehouse. Note that if you tick on 'Skip Material Transfer to WIP Warehouse', this column will not be updated. - Consumed Quantity: When the Item from the WIP Warehouse is consumed and the finished product is manufactured, this field will be updated. - Allow Alternative Item: If a particular Item (raw material or sub-assembly) is not available, ticking this checkbox will allow you to select an alternative item defined in the Item Alternative list. - Include Item in Manufacturing: Raw Materials need to have this checkbox ticked. This checkbox appears in the Item master, the BOM, and the Work Order. In case there are Operations or services you need to include in the BOM that are not necessarily an Item used for manufacturing, untick this checkbox. For example, treating the plastic with a chemical involves some cost but it is not an Item and the cost needs to be tracked. On unticking this checkbox for an Item, you can still select it in the BOM and Work Order, but no Stock Entries will be created against it. Once the Work Order is saved the following two fields will also show the availability in the respective Warehouses in the Required Items table: - Available Qty at Source Warehouse - Available Qty at WIP Warehouse 3.3 Operations table Materials can be transferred against a Work Order or a Job Card. This is usually fetched from the Bill of Materials, but you can change it in the Work Order also. The following will be fetched from the BOM: - In the Operations table: The Workstations where the Operations will be performed - In the Items table: The Operations which will be performed on the Items These values can also be changed. Once the Work Order is saved the following fields will be shown: - Completed Qty: The number of Items on which this Operation was performed. - Status: Whether the Operation is Pending, Work In Progress, or Completed. The status here is updated when the Job Cards are updated. - Operation Time: This is fetched from the BOM, but can be changed. - Planned Operating Cost: This is calculated based on the Operating Time, Hourly Rate, Quantity being manufactured, etc. The Actual Operation Time, Actual Operating Cost, Actual Start Time, and Actual End Time are updated when Job Cards are updated. 3.4 Operation Cost In this section, the following are shown: - Planned Operating Cost: This is fetched as per the BOM and the Operations defined in it. - Actual Operating Cost: This is fetched from the Job Cards based on the Operations run on the Items. - Additional Operating Cost: Any additional expenses you may have incurred when manufacturing the Item can be added here. - Total Operating Cost: This is calculated as Actual Operating Cost + Additional Operating Cost. These values are calculated as per the Job Cards. 3.5 More Information Here the Item Description and Stock UOM is shown for the Item being manufactured. When a Work Order is created from a Material Request, it'll be shown here. 3.6 Transferring Materials for Manufacturing - Once you have submitted your Work Order, you need to Transfer the Raw Materials to initiate the Manufacturing Process. - This will create a Stock Entry with all the Items required to complete this Work Order to be added to the WIP Warehouse. This will add the sub-assembly Items as is or explode it to show the raw materials depending on whether you ticked 'Use Multi-Level BOM' or not. - Click on 'Start'. Once you click on Start, Job Cards will be created for the Operation involved. - Mention the quantity of materials to be transferred in this run. - You'll be taken to a Stock Entry for 'Material Transfer for Manufacture'. Submit it. - Material Transferred for Manufacturing will be updated in the Work Order based on the Stock Entry. 3.7 Material Transfer through Stock Entry Use cases for this option are: - If a material transfer is done in bulk and/or is not required to be tracked against a particular Work Order. - If the responsibility for Material Transfer and Production Entry lies with two separate Users. If this is the case, you can tick the 'Skip Material Transfer' checkbox, which will allow you to make the Stock Entry of type 'Manufacture' directly by clicking on the ‘Finish’ button. 3.8 Creating Job Cards - Progress in the Work Order can be tracked using Job Cards - Drafts of Job Cards are created based when a Work Order is Submitted. - To create more Job Cards against a Work Order click on the plus sign next to Job Card on the Work Order dashboard. 3.9 Updating Finished Goods - Once you are done with the Work Order you need to update the Finished Goods. - This will create a Stock Entry that will deduct all the items and sub-assemblies from the WIP Warehouse and add them to the Finished Goods Warehouse. - Click on 'Finish'. - Mention the quantity of materials to be transferred. || Tip: You can also partially complete a Work Order by updating the Finished Goods stock creating a Stock Entry. 3.10 Stopping a Work Order When you stop a Work Order its status is changed to Stopped indicating that all production process against that Work Order has stopped. To stop a Work Order, click on the 'Stop' button. You can also re-start a stopped Work Order. 3.11 Capacity Planning in Work Order - When a Work Order is submitted, based on the Planned Start Date and the availability of the Workstations, system schedules all operations for the Work Order (if Work Order has Operations specified). - Drafts of Time Logs are also created based on the scheduled operations. On Submitting the Work Order, the system will reserve a slot for each of the Work Order Operations serially after the planned start date based on the Workstation availability. The Workstation availability depends on the Workstation timings, holiday list and if some other Work Order Operation is scheduled in that slot. You can mention the number of days for the system to try scheduling the operations in the Manufacturing Settings. This is set to 30 Days by default. If the operation requires time exceeding the available slot, the system will ask you to break the operations. Once the scheduling is done the system will create Time Logs and save them. You can Modify them and submit them later.

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

How to create a Workstation?

Workstation A Workstation stores information regarding the place where the workstation operations are carried out.  ****  Data regarding the operation cost, rent, electricity can be stored here.    ||| Note: An Operation can take place at multiple Workstations.    An Operation takes place at a Workstation. The Operation is the work performed and the Workstation is the place/machine where it is performed. For example, melting is an Operation that can be done at 10 different Workstations.    To access the Workstation list, go to:    ++Home > Manufacturing > Bill of Materials > Workstation++    | 1. How to create a Workstation    1. Go to the Workstation list, click on New.    2. Enter a name for the Workstation.    3. Under Operating Costs, enter the following as applicable:  * Electricity Cost  * Rent Cost  * Consumable Cost  * Wages    4. Save.    Optionally, you can enter a description for the Workstation.        The hours when the Workstation will be Operational can be added. On adding a Holiday list, the days listed as holidays won't be counted as working for the Workstation.        After saving the Workstation, the following actions can be performed against it:        | 2. Features    2.1 Production Capacity    Production Capacity is the total number of jobs can be executed at the same time in the respective workstation.        2.2 Working Hours    Under Working Hours table, you can add start and end times for a Workstation. For example, a Workstation may be active from 9 am to 1 pm, then 2 pm to 5 pm. You can also specify the working hours based on shifts. While scheduling a Work Order, the system will check for the availability of the Workstation based on the working hours specified.    2.3 Holiday List    A Holiday List can be added to exclude counting these days for the Workstation.    ||| Note : You can enable overtime for a Workstation in Manufacturing Settings.    | 4. Related Topics  1. Bill Of Materials  2. Operation  3. Routing  4. Work Order  5. Job Card

By Frappe Content licensed CC-BY-SA 3.0
• Last updated on Jun 18, 2025

Manufacturing Settings

Manufacturing Settings Search for Manufacturing Settings in the awesome bar Capacity Planning Capacity planning is the process in which an organization decides whether or not to accept the new orders based on the resources and existing work orders. Over Production Allowance Percentage While making Work Orders against a Sales Order, the system will only allow production item quantity to be lesser than or equal to the quantity in the Sales Order. In case you wish to allow Work Orders to be raised with greater quantity, you can mention the Over Production Allowance Percentage here. Example: In certain cases, a Workstation has to manufacture 100 units for cost effectiveness but the Work Order could be for 50 units. In this case, the Over Production Allowance Percentage would be 100. Backflush Raw Materials Based On The Stock Entry of type 'Manufacture' is known as backflush. Raw materials being consumed to manufacture finished goods is known as backflushing. When creating Manufacture Entry, raw-material items are backflushed based on BOM of production item. If you want raw-material items to be backflushed based on Material Transfer entry made against that Work Order instead, then you can set it under this field. Default Work In Progress Warehouse This Warehouse will be auto-updated in the 'Work In Progress' Warehouse field of Work Orders. Default Finished Goods Warehouse This Warehouse will be auto-updated in the 'Target Warehouse' field of Work Order. Allow Multiple Material Consumption If ticked, multiple materials can be used for a single Work Order. This is useful if one or more time consuming products are being manufactured. For example a single product takes a month to manufacture and the raw materials are consumed daily. In a regular scenario, this won't be feasible with stock entries. Enabling this option will allow you to create stock entries for material consumption without having to create an entry to backflush. End result is that you can see the stock being consumed in the Warehouses and can update the final manufacture entry at a later stage. Update BOM Cost Automatically If ticked, the BOM cost will be automatically updated based on Valuation Rate / Price List Rate / last purchase rate of raw materials. Allow Excess Material Transfer If enabled, the Material Transfer button will be visible and will allow you to transfer raw materials even if after the raw material requirement is fulfilled against a Job Card. This is particularly useful in cases where the transferred raw materials are damaged and additional raw materials need to be transferred to produce the same amount of finished goods as intended. Make Serial No/Batch from Work Order If checked, system will automatically create the serial numbers / batches for finished goods on submission of Work Order.

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Basic manufacturing setup: Introduction

Introduction OneHash comes with batteries included for all requirements of a manufacturing business like Bill of Materials tracking, Production Order planning and execution, procurement and a lot more. | 1. Master Data The Manufacturing module in OneHash helps you to maintain Warehouses(location), Workstations, Operations, Finished Goods, and Raw Materials. For manufacturing Operations and their respective Workstations are important, which can be configured based on the Finished Goods in the Bill of Materials. Warehouses are useful to store the Raw Materials and the Finished Goods. In OneHash, users can create separate Warehouse to keep Raw Materials, and Finished Goods. More details are as below: - Warehouse - Workstation / Machine - Operation - Raw Material / Finished Good - Routing | 2. Transaction Data The Manufacturing module in OneHash helps you to maintain a multilevel Bill of Materials (BOMs) for your Items. It helps in product costing, production planning, creating work orders for your manufacturing shop floors, creating job cards, and planning inventory by getting your material requirements via BOMs (also called Material Requirements Planning or MRP). More details are as below: - Bill Of Materials - Work Order - Job Card - Production Plan | 3. Types of Production Planning Broadly there are three types of Production Planning Systems: - Make-to-Stock: In these systems, production is planned based on a forecast and the Items are then sold to distributors or customers. All fast-moving consumer goods that are sold in retail shops like soaps, packaged water, etc. and electronics like phones are Made-to-Stock. - Make-to-Order: In these systems, items are manufactured only after the customer places an order of a certain number according to the customer's requirement. For example, a wedding cake. - Engineer-to-Order: In this case, each sale is a separate project and has to be designed and engineered to the requirements of the customer. Common examples of this are any custom business-like furniture, machine tools, specialty devices, metal fabrication, etc. Most small and medium-sized manufacturing businesses are based on a make-to- order or engineer-to-order system and so is OneHash. For engineer-to-order systems, the Manufacturing module should be used along with the Project module. | 4. Manufacturing impact on Inventory Work order status is dependent upon the stock transactions made against it. In OneHash, you can transfer the raw materials required to make finished goods from Store to Work In Progress Warehouse. From Work-In-Progress warehouse the raw materials can be consumed using the Stock Entry. You get the option to either bulk consume the raw materials and add the finished good or consumed the materials first and then add the finished good.

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How to create a Quality Action?

Quality Action A Quality Action is taken on a Quality Review to correct unsatisfactory results or prevent them from happening. Quality Action is a standard feature to allow implementation of corrective and preventive actions. This will meet compliance with industry regulations including GMP, ISO 9001 and 14001, TSCA, REACH, etc. Quality Action workflows provide a controlled environment and reduce the risk of repeat issues by ensuring that defined solutions and processes are met. Quality Actions can be initialized for a Quality Goal or for a Customer Feedback which may not meet the expected quality standards. Depending on that a Corrective or Preventive Action can be started. To access Quality Action, go to: ++Home > Quality > Review and Action > Quality Action++ | 1. Prerequisites Before creating and using a Quality Action it is advised to create the following first: - Quality Review Or - Quality Feedback | 2. How to create a Quality Action 1. Go to the Quality Action list, click on New. 2. Select whether it's a Corrective or Preventive action. This indicates whether the action is being scheduled for Corrective or for Preventive Purpose. 3. Select the Document Type whether a Quality Review or a Quality Feedback. 4. Select the actual Quality Review or Feedback under Document Name. 5. Enter a Resolution proposed for the problem in the Resolution field. 6. Save. The Status field indicates whether the Quality Action is Open and ongoing or Closed.

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How to create a Quality Review?

Quality Review A Quality Review is the review of a Quality Goal. A Quality Review is an inspection with a specific structure, defined roles, and procedure designed to ensure a product's completeness and adherence to quality standards. The Quality Review is used to check if all Objectives of a Quality Goal have been achieved. To access the Quality Review list, go to: ++Home > Quality > Review and Action > Quality Review++ | 1. Prerequisites Before creating and using a Quality Review it is advised to create the following first: - Quality Goal | 2. How to Create a Quality Review 1. Go to the Quality Review list, click on New. 2. Select a Quality Goal which is to be Reviewed. 3. In the Review section of the Reviews table, leave a review about a Quality Objective. 4. Save. ||| Note: If the Quality Procedure is linked to the Quality Goal, the Quality Procedure will be fetched in the Quality Review. You can also add some notes in the 'Additional Information' section. | 3. Features 3.1 Periodic Auto Creation If you have set the frequency of review in your Quality Goal, then the Quality Review will automatically be created and its status will be set to "Open". The quality manager can then check open reviews and complete the inspection. | 4. Next Steps After you have completed a Quality Review, you can create a Quality Action against it if you want to record any corrective or preventive actions.

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Quality Procedure (Standard Operating Procedure)

Quality Procedure (Standard Operating Procedure) A Quality Procedure is a Standard Operating Procedure (SOP) used as a reference to carry out routine actions A standard operating procedure (SOP) is a set of step-by-step instructions compiled by an organization to help the employees execute routine operations. SOPs aim to achieve efficiency, quality output and uniformity of performance while reducing miscommunication and failure to comply with industry regulations. A Quality Procedure can be of two types: 1. A Procedure consisting of simple steps that you must follow to achieve the Goal 1. A procedure having sub-Procedures which may also have its own steps To access the Quality Procedure list, go to: ++Home > Quality > Goal and Procedure > Quality Procedure++ | 1. How to create a Quality Procedure 1. Go to the Quality Procedure list, click on New. 2. Enter a name for the Quality Procedure. 3. In the Processes table, enter Process Descriptions. 4. Child Procedure: If the Quality Procedure being created a is a parent procedure that contains sub-procedures, link the sub-procedure here. On doing this, the current procedure becomes a parent and the 'Is Group' checkbox is enabled. 5. Save. A Quality Procedure can also be saved without entering the Process descriptions if the title is self explanatory. The 'Parent Procedure' is linked to the child procedure. For example 'Demo preparation' needs to be done before a demo and hence 'Product Demo' is the parent here: | 2. Features 2.1 Using Quality Procedure in Quality Goal Once a Quality Procedure is created, it can be used in a Quality Goal: 2.2 Linking Quality Procedures Process can either be just a instruction or a different Quality Procedure. You can link a Quality Procedure as a sub-procedure to another one: 2.3 Hierarchical View You can you also view Quality Procedures in a tree view for easy organization and navigation

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Learn more about Quality Inspection

Quality Inspection In OneHash, you can mark your incoming or outgoing products for Quality Inspection. To enable this feature go to: ++Home > Stock > Tools > Quality Inspection++ | 1. Prerequisites Before creating and using a Quality Inspection, it is advised that you do the following first: - Create an Item. - Enable Quality Inspection Criteria in the Item master. On enabling either checkboxes, submission of a stock delivery/receipt document will be allowed only after a Quality Inspection is done against it: - (Optional) Create a Quality Inspection Template. You can add inspection parameters and acceptance criteria in the template, which can be easily fetched into any Quality Inspection. After saving the template, you can set this template in the Item Master (as shown above). | 2. How to create a new Quality Inspection 1. From a Purchase Receipt/Delivery note in the Draft stage, go the Item table's Quality Inspection field and click on Create a New Quality Inspection. You can also create a Quality Inspection for Job Card in order to monitor the quality of in-process items. In this case, you can create a Quality Inspection for the Production Item in Job Card. 2. Select the inspection type whether Incoming (Purchase), Outgoing (Sales), or In Process (Manufacturing). 3. Select the Reference document type whether Purchase Receipt, Purchase Invoice, Delivery Note, Sales Invoice, or, Stock Entry. 4. Select the Item and set the sample size which will be inspected. Note that only Items for which Inspection Criteria is enabled in the Item master will be fetched. 5. The Quality Inspection Template set in the Item master will be fetched. 6. You can change who it's inspected by and also add who it's verified by. 7. Any additional Remarks about the Inspection can be added. 8. Save and Submit. | 3. Features A single Quality Inspection consists of many Quality Checks (Parameters) within it. Each of these checks could be Numeric, Non-numeric or Formula Based. 3.1 Numeric Quality Checks Numeric Quality Checks include all checks that require number-based readings and acceptance criteria. E.g. checking if a reading is in a certain range. By default the checks are numeric. There are two fields: Minimum Value and Maximum Value, to define a range that each reading must be in. These fields can be set in the Quality Inspection Template once and be simply fetched into the Quality Inspection. If any of the readings entered are not within this range, the status on the row will be set to 'Rejected' automatically on Save. 3.2 Non-numeric (Value-Based) Quality Checks Non-numeric Quality Checks include checks that require alphabetical values or those that do not require any mathematical calculations. E.g. checking if the color is white in a color quality check, Yes/No values for certain parameters, etc. For Non-numeric checks, enable the 'Non-numeric' checkbox. You will notice the field Acceptance Criteria Value and the section Value-Based Inspection are visible. Enter the field Reading Value. The Acceptance Criteria Value can be set in the Quality Inspection Template once and then be fetched into the Quality Inspection. If the Reading Value does not match the Acceptance Criteria Value, the status on the row will be set to 'Rejected' automatically on Save. 3.3 Formula-Based Quality Checks Formula-Based Quality Checks are useful for more complex scenarios where just specifying a range or an acceptance value is not enough. E.g. checking if the grade of a material is A/B/C, checking if the mean of some readings is within a certain range, etc. Formula-Based Quality Checks are applicable to Numeric and Non-numeric Quality Checks. Enable the 'Formula Based Criteria' checkbox to perform a Formula-Based Quality Check. You will then notice a field called Acceptance Criteria Formula where you can specify a formula that determines whether a certain check is Accepted or Rejected. This formula can be set in the Quality Inspection Template once and then be fetched into the Quality Inspection. This formula depends on the many Reading fields in the Readings table. For Numeric readings, reading_1, reading_2 and so on are accepted in the formula. For Non-numeric readings, only reading_value is accepted in the formula. Here are some examples of formulas: Update the readings and Save. The Status field in the Readings table rows is set automatically based on the formula for acceptance. 3.3 Manual Inspection So far, all the Quality Checks have automatic acceptance/rejection on Save. In the real world, there could be cases where a check is rejected but yet will be accepted because there is some tolerance. Such cases will require the user to determine the row-level status. To avoid any system interference in such checks, enable the 'Manual Inspection' checkbox. You can now set the status manually and it will be untouched on Save. Here Reading 1 is outside the defined range, this check would be rejected. But, since it is not very far from 0.153 we accept it manually. The status for the entire Quality Inspection can then be decided by the user. | 4. Related Topics 1. Purchase Receipt 2. Delivery Note 3. Stock Entry 4. Sales Invoice 5. Purchase Invoice 6. Job Card

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What you should know about creating a Bill of Materials?

Bill Of Materials A Bill of Materials is a list of items and sub-assemblies with quantities required to manufacture an Item. A BOM may also contain the manufacturing operations required to manufacture the Item. A Bill of Materials (BOM) is at the heart of the Manufacturing system and the most important document that will help to create other document types like Work Orders and Job Cards. OneHash supports multi-level BOM. To know more, visit this page. The BOM is a list of all materials (either bought or made) and operations that go into manufacturing a finished product or sub-assembly. In OneHash, each item (sub-assembly) could have its own BOM hence forming a tree of Items with multiple levels. To make accurate Purchase Requests, you must always maintain correct BOMs. To access the BOM list, go to: ++Home > Manufacturing > Bill of Materials > Bill of Materials++ ||| Note that once a BOM is submitted, it cannot be edited. You can only cancel the existing, duplicate it and submit another one. A BOM is also linked to multiple places in the Manufacturing module, so making changes to it can be time-consuming and tedious. Hence it is a good practice to carefully think and fill out the BOMs before submitting. | PREREQUISITES Before creating and using a BOM, it is advised that you create the following first: 1. Item 2. Operation 3. Workstation / Machine 4. Routing | HOW TO CREATE A BILL OF MATERIALS 1. Go to the Bill of Materials list, click on New. 2. Select the Item to be manufactured. The Item name, UoM, company, and currency will be fetched automatically. 3. Enter the quantity of the Item that will be manufactured from this Bill of Materials. 4. Under the Items table, select the raw materials (Items) required to manufacture the Item. Then proceed to: - Select the quantity of Raw Material used. - Set an Item operation here to be fetched in Work Orders later. - If this Item is a sub-assembly, the default BOM for it will be fetched. - Select the Source Warehouse to track inventory. - Enter the scrap percentage that will remain after this raw material is used. 1. Under the Scrap section, select the scrap Item that will be created when manufacturing and its quantity. The scrap Item can also have a Rate if it is a by-product and not waste. Skip this section if 100% of raw materials are completely utilized. If the scrap Item is the same as the Item to be manufactured, it is set as a Process Loss Item and its quantity is subtracted from the manufactured Item quantity. 1. Save and Submit In the Items table, you'll see an option 'Include Item in Manufacturing'. Raw Materials need to have this checkbox ticked. In case there are Operations or services you need to include in the BOM that are not necessarily an Item used for manufacturing, untick this checkbox. For example, treating the plastic with a chemical involves some cost but it is not an Item and the cost needs to be tracked. Bill of Materials with Operations To add Operation tick the 'With Operations' checkbox. Now, an Operations table can be seen. This option is useful for tracking the costing of various Operations performed to manufacture the Item. Operations can be added easily by setting a template with the Routing master. 1. In the “Operations” table, add the operations that need to be performed to manufacture this particular Item. 2. For each operation, you will be asked to enter a Workstation where the Operation will be performed. A default Workstation can be set from the Operation document. 3. Enter the Operating Hourly Rate, Operation Time in minutes, and the Batch Size created with the Operation. The Operating Cost will be calculated based on these values. ||| Note: Workstations are defined only for product costing and Work Order Operations scheduling purposes not tracking inventory. Inventory is tracked in Warehouses set in the Items table of the BOM. Transfer Material Against needs to be set for a BOM With Operations. Materials can be transferred against a Work Order in bulk or individual Job Cards. Changing this affects whether the 'Material Transfer for Manufacture' is done against the Work Order at once or multiple times against the individual Job Cards. Setting this option depends on factors like time taken to manufacture the item, value of the items manufactured, number of parts used in manufacturing, the skill of your labor involved, etc. Additional options when creating a Bill of Materials - Is Active: An Item could also be manufactured using an alternate set of materials/operations. In that case, untick this checkbox to disable this BOM and use another one. - Is Default: This BOM will be selected by default in Work Orders etc. when the Item selected. - Inspection Required: This will make 'Quality Inspection' mandatory for raw materials and the finished goods. Select the Quality Inspection Template after ticking this checkbox. - Allow Alternative Item: Sometimes when manufacturing a finished good, specific materials may not be available. If you tick this, you can create and select an alternative item from the Item Alternative list. For example, using plastic beads instead of plastic crystals. For more details visit this page. - Allow Same Item Multiple Times: In some manufacturing cases, the same item needs to be added twice. For example, two metal pipes of length 0.5m each to form another shape. Here the quantity cannot be simply set to 2 and be done since the UoM will show 1m as total but we need 0.5m + 0.5m in the form of two pipes for production. Ticking this checkbox allows you to select the same item multiple times. - Set rate of sub-assembly item based on BOM: Enabling this checkbox will set the rate of sub-assembly items based on their BOMs. If unticked, the rate will be fetched from the Valuation Rate of the sub-assembly Item. - Rate Of Materials Based On: The Rate of raw materials used can be calculated based on different parameters. -> Valuation Rate: The Valuation Rate set in the Item master. -> Last Purchase Rate: The Rate is fetched from the last Sales Order/ Invoice . -> Price List: The Rate will be fetched from the Item Price. | FEATURES 1. BOM Costing The Costing section in a BOM gives an approximate cost of manufacturing the Item. The costing is calculated from the Valuation Rate of the raw materials/sub-assemblies involved and the Operation costs. In case the BOM was submitted when the costs for Items/Operations were not updated, you can update the costs using the Update Cost button. This will fetch the latest price/costs. The BOM cost can also be set to be updated automatically via Manufacturing Settings, 'Update BOM Cost Automatically' option. 2. Materials Required (Exploded) This table lists down all the raw materials required to manufacture an Item. It also fetches raw materials for the sub-assemblies along with the quantities. The non-exploded table will not list the raw materials required for producing the sub-assemblies. For example, to manufacture a plastic shaving brush you need some raw materials and the bristles as a sub-assembly. For the handle, you manufacture your own plastic, but for the bristles, you use raw plastic crystals. 3. Project and Website The BOM can be linked to a Project to track progress, Project costing, etc. In case of engineer to order, every order could be a Project and the sub-assemblies would be Tasks. The completion can be tracked by linking to a Project in that case. The BOM can also be shown in the Website for Open-source hardware products. Open-source hardware is similar to open-source where the product specifications are listed publicly. 4. BOM Template With BOM template you can create BOMs for template items (against which you create variant items). These BOMs can be used as the default BOM while making Work Orders against the template Item's variants. You can also add the template items as raw materials in the template BOM. While making Work Order from the BOM Template, OneHash gives provision to select the Item Variant against the template Item, for more details check following screenshot. The user can also make the BOM for the variant item using the template BOM. To make the variant BOM: 1. Go to the BOM Template. 2. Click on Create button. 3. Click on Variant BOM. 4. Select the Variant Item for which you want to make the BOM. 5. If the raw materials in the BOM is a template Item, then system gives provision to select the Item Variant. 5. After Submitting Once the BOM is submitted, the following document types can be created against the BOM from the Dashboard: | 4. Related Topics 1. Scrap Management 2. Material Consumption 3. Nested BOM Structure

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Manufacturing Reports

Manufacturing Reports There are various reports in the Manufacturing module that help you track Work Order progress, production analytics, BOM reports, etc. In all of these reports, you can set a chart to show a visual representation. To do this, click on the Set Chart button. These reports can be accessed from: ++Home > Manufacturing > Reports++ Open Work Orders Shows the open Work Orders which have not started production yet. Work in Progress Report This report shows any work orders that have started and are in progress. The status of these Work Orders is 'In Process'. Issued Items Against Work Order To access the Issued Items Against Work Order, go to: ++Home > Manufacturing > Reports > Issued Items Against Work Order++ Items that are issued against a Work Order and are transferred to the Work in Progress Warehouse are shown in this report. Completed Work Orders Work Orders which are completed with all the quantities in it manufactured are shown in this report. Work Order Summary To access the Work Order Summary, go to: ++Home > Manufacturing > Reports > Work Order Summary++ This report will give information about the Work Order. Using this report user will understand the number of produced quantity against each Work Order as well the status of the Work Order. Using this report user can check the status of the Work Orders which are linked to the Sales Order. Also using this report users can check the Work Orders based on the status like Not Started, In Process, Completed, and Stopped. Job Card Summary To access the Job Card Summary, go to: ++Home > Manufacturing > Reports > Job Card Summary++ This report will give information about the Job Card as well as their status. Using this report users can check the month's Open and Completed Job Cards for the selected periods. Quality Inspection Summary To access the Quality Inspection Summary, go to: ++Home > Manufacturing > Reports > Quality Inspection Summary++ This report will give information about the Quality Inspections as well as the status of the Quality Inspections like Accepted or Rejected. Production Analytics To access the Production Analytics, go to: ++Home > Manufacturing > Reports > Production Analytics++ This report shows the overall analytics of all Work Orders. BOM Search To access the BOM Search report, go to: ++Home > Manufacturing > Reports > BOM Search Report++ In this report, you can search for specific BOMs based on the Items (raw materials) used in them. This report is useful if you have hundreds or thousands of BOMs. BOM Stock Report To access the BOM Stock Report, go to: ++Home > Manufacturing > Reports > BOM Stock Report++ The BOM Stock Report provides information about the raw materials required quantity and the in-stock quantity of the warehouse (which is selected in the filter). As you can see, the items which have insufficient quantity are shown in red and ones with enough quantity to manufacture the BOM Item are shown in green. BOM Operations Time To access the BOM Operations Time, go to: ++Home > Manufacturing > Reports > BOM Operations Time++ This report will give the information about the Bill of Material's total expected time in minutes as well the count of the current BOM used as a subassembly item for different Finished Goods. Downtime Analysis To access the Downtime Analysis report, go to: ++Home > Manufacturing > Reports > Downtime Analysis++ This report will give information about the captured Machines Downtime in hours. Using Downtime analysis report, operators will know which machine was not performing well and needs maintenance.

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Production Planning Report

Production Planning Report To access the Production Planning Report, go to: ++Home > Manufacturing > Reports > Production Planning Report++ This report will help users plan the finished good as well as the raw materials against the Sales Order / Work Order / Material Request (with the request type as Manufactured) data. Mostly, in the case of make to order, this report helps you plan the production of the finished goods as well the raw materials. Using this report user will get the information about the available finished goods as well as available raw materials that are required in the production process. The unavailable finished good or raw materials will be highlighted in the red color. In this report system will allocate the available stock to the order based on the sorting. The Order By filter will be use to sort the orders based upon the Delivery Date, Order Amount. For example, Bob works in the Furniture Manufacturing company. Their organization follows the make to order production planning. On Monday, Bob received the Sales Orders for tables and chairs from different customers. So Bob has checked the production planning report to check the availability of the raw materials and he found that either table or chair can be manufactured with the available raw materials. Bob used the 'based on' filter to know which Finished Good order's delivery date is earlier. He has found that he has to deliver the Table earlier so he has started working on it and his colleague has created the purchase order for raw materials which will be used to make chair. Using the Production Planning Report, this report auto allocate the raw materials to the order once it's available in the respective warehouse.

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Demand Driven Forecasting

Demand Driven Forecasting To access the Forecating Report, go to: ++Home > Manufacturing > Reports > Forecasting++ Using exponential smoothing method and past Sales Order / Delivery Note / Quotation data, the forecasting will be calculated. The exponential smoothing method formula is as below: Using exponential smoothing method, system predicts the forecasting for each period and same forecast data will be used to forecast the upcoming period data. How does the exponential smoothing method works For the above example, we have used one-year sales order data every month. The first-month forecast will be calculated based on the average of all total orders. From the second month onward, the difference between the last month's Total Order and Forecast Value will be multiplied with the Smoothing Constant Value (in between 0 to 1). The default value of the Smoothing Constant is 0.3 which gives efficient forecasting data. The last month's Total Order and Forecast Value difference called forecasting error and this error will be added in the same month of forecast value to calculate the forecast of the next month. How do the filters work 1. Company:- user can do forecasting for the specific company by applying the company filter 2. From Date and To Date :- for this period system will do the forecasting, the default from date is the current date and to date will be the one year ahead date from the current date. 3. Based On Document :- by default system uses sales order past data to forecast. User can select the other document like delivery note / quotation to forecast the data. 4. Based On :- based on quantity / amount system shows the forecast data. 5. Based On Data ( in years ) :- for forecasting requires past data, this filter helps system to check past data for number of years. 6. Periodicity :- forecasting data can be viewed in Monthly / Quarterly / Half-Yearly / Yearly basis, the old forecast data can not be displayed for Monthly period for better view. 7. Smoothing Constant - the Smoothing Constant will be used to forecast the data, the value should be between 0 and 1.

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Managing Multi-Level BOM (Bill of Materials)

Managing Multi-level BOM Consider a scenario where your manufacturing process involves producing sub-assembly items before the final product. In this case, how should you manage the BOM? First of all, you need to have BOMs for the sub-assemblies, then these BOMs should be linked to the BOM of the final finished product. In the following screenshot, you can see that the BOM for Brush Bristles (subassembly) is linked to the BOM of the Shaving Brush (final product). This is seen in the Materials table in the Bill of Materials master. The 'Materials' table will only show the sub-assemblies while the 'Materials Required (Exploded)' table will show all the raw materials required to manufacture the final product. BOM materials table where sub-assembly is shown: In the exploded view only the raw materials are shown: To use multi-level BOM in a Work Order, enable the 'Use Multi-Level BOM' checkbox. This is enabled by default. If you want to plan materials for sub-assemblies of the Item you're manufacturing leave this enabled. If you plan and manufacture the sub-assemblies separately disable this checkbox. Let's consider another example to understand this better where a computer is being assembled. The hard disk and DVD drive are also being manufactured and are the sub-assemblies. The multi-level or nested BOM will look like this: ** * Personal Computer (FG Item)** *** Mother Board** *** SMTP** *** Accessories and wires** *** Hard Disk (sub-assembly)** - Item A - Item B - Item C *** DVD Drive (sub-assembly)** - Item X - Item Y - Item Z Caution Exercise caution when updating the BOM of a sub-assembly. The part which includes the sub assembly with an updated BOM will need to be updated to reference the updated BOM for that part. The practical outcome of this is that changing a screw on a low level assembly will lead to a ripple of updated Bills of Material up through the BOM structure. Using the example of the personal computer above. Personal Computer (PC-001 with BOM-PC-001) uses Hard Disk (HDD-001 with BOM-HDD-001). BOM-HDD-001 includes the three items shown (Item A, B and C). If we need to exchange Item C for a new item (Item D) then we must update create BOM-HDD-002 (with Items A, B and D). The Hard Disk (HDD-001) is then updated to reference the new BOM-HDD-002. But, BOM-PC-001 is still referencing HDD-001 with BOM-HDD-001. The change from Item C to Item D will not be updated in the Exploded BOM for PC-001. BOM-PC-002 must be created referencing HDD-001 with BOM-HDD-002 to make this update.

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• Last updated on Jun 18, 2025

Manufacturing Dashboard

Manufacturing Dashboard To access the Manufacturing Dashboard, go to: ++Home > Customization > Dashboard > Manufacturing++ Number Cards 1. Monthly Total Work Order:- You will get the total count of Work Orders which are in Open, In Progress, and Completed state. The Work Orders created one month before the current date will be displayed in the number card. 2. Monthly Completed Work Order :- The user will get the total count of Work Orders which are in the Completed state. The Work Orders created one month before the current date will be displayed in the number card. 3. Ongoing Job Card :- The user will get the total count of Job Cards that are not in the Completed state. 4. Monthly Quality Inspection :- The user will get the total count of Quality Inspection records which are in the Submitted state. The Work Orders created one month before the current date will be displayed in the number card. Dashboard You can see some predefined graph reports in the dashboard when you open the Manufacturing module. These reports are fully customizable, you can choose what to show or hide and also configure the metrics on which the reports are shown. Produced Quantity The chart will give the information about the total quantity produced (using Work Order) in the last year on a Quarterly basis. Users can also view the chart data based on Daily, Weekly, Monthly, Yearly basis. Completed Operation The chart will give information about the total number of operations completed in the last year on Quarterly basis. Users can also view the chart data based on Daily, Weekly, Monthly, Yearly basis. Work Order Analysis This chart will give the information about the number of Work Orders based on Not Started, In Process, Stopped, Completed statuses. This Donut chart will provide the information based on the last year's Work Order data. Your can also change the date range by clicking on the Filter button. Quality Inspection Analysis This chart will give information about the number of Quality Inspections based on Accepted and Rejected status. The chart type is a donut and it will provide the information based on the last year's quality inspection data. Your can change the date range by clicking on the Filter button. Pending Work Orders The chart will give information about the number of Work Orders that are pending based on the aging days. The number of aging days is calculated based on the difference between the current date and planned start / actual start date days. Last Month Downtime Analysis The chart will give information about the total number of minutes a machine was not working in the last month. This helps the operator to know which machine has not performed well and requires maintenance. Work Order Quantity Analysis The chart will give information about the total number of quantities that are Pending and Completed based on the Work Orders every month for the last year. Job Card Analysis The chart will give information about the total number of Job Cards which are in the Pending and Completed states every month for the last year.

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• Last updated on Jun 18, 2025