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8. Manufacturing Products
1) Manufactured Products
2) Manufacturing Requirements
3) Production Orders
4) W.I.P.
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8.1 Manufactured Products
Any Account product that is not marked as 'PO Required' is deemed to be manufactured.
Manufactured products require a Bill of Materials and Labour that is created under Setup|Accounts via the B.O.M.s tab on the detail window.
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8.2 Manufacturing Requirements
Select the menu option Sources|Production Orders|Manufacturing Requirements and click Yes to the prompt 'Do you wish to re-create the Required Manufacture Products list?', then enter 90 to the prompt 'Number of days of sales to extract'.
Data is now extracted and the Manufacturing Requirements window opens.
Products are included in the extracted data when the on-hand quantity, less outstanding customer quote/delivery note quantities, has fallen below the buffer stock level.
Columns with a pink header can be altered.
By placing a tick on a row in the PO Reqd column and clicking Create Production Orders, will create a Production Order for the product using the 'Std Batch Qty' and 'Start Date' values.
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8.3 Production Orders
Select the menu option Sources|Production Orders|Enter to open the Production Orders List window.
Click the 'Add New Record' icon in the toolbar to insert a production order record, then press F3 to open the detail window.
Set a Status of 'Planned' and a Start date before selecting the Product to be manufactured.
On selecting the product, the End Date is computed from the Start Date plus the 'Days to Produce' held in the product record.
The default Bill of Materials and Labour operations are imported into the Production Order.
Whilst the Status is 'Planned' the Bill of Materials and Labour operations can be changed.
Set the Plan Qty to be manufactured.
When production commences, change the status to 'Open'.
Materials and Labour can now be issued to the Production Order. This can be done directly for Materials by entering a quantity and draw location in the respective 'Issue Qty' and 'Location' columns.
Labour hours can be entered in the 'Curr Hrs' column for the appropriate Operation and Work Centre.
When a material or Operation/Work Centre is used that has not been planned, use Add Line to add a new blank line that can be completed with the necessary details.
On completing material issues and labour operations, click  to update the Ledger and Production Order.
Alternatively, materials can be issued to a Production Order via Sources|Products|Product Movements and Labour via Sources|Time Logs|Enter.
When a Production Order is complete and the manufactured product is ready for placing into stock, change the Status to 'Closed'. Enter the 'Actual Qty' produced, any 'Scrap' quantity and 'Put in Location' values, before clicking to update the Ledger and Production Order. When this is done the orders Journal Number is changed to the ledger journal number used for the posting.
The ledger entries can be seen via menu option Ledger|Posted Journal Edit. The journal can be edited; the only restriction being that the line item must not be marked as 'Cleared'.
Production Orders can be viewed using the menu option Sources|Production Orders|View.
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8.4 W.I.P.
The default W.I.P A/c is set under Setup|Companies on the Accounts tab.
When materials or labour are issued to a Production Order the WIP A/c is debited. See journals 200038 and 200039 below.
When a Production Order is closed the WIP A/c is credited. See journal 200040 below.
Therefore any value in the WIP A/c is the value of Open Production Orders.
If the menu option Ledger|Account Item Clearing is used, account postings for individual Production Orders can be marked as 'Cleared' in order to help manage and reconcile the account with open Production Orders
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