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Jiwa Manufacturing - Bill of Materials

This is the first in a series of articles that looks at the Manufacturing module in Jiwa 7.

 

Overview

A Bill of Material also referred to as a Bill or BOM is a template or formula used to make a finished product or component that goes into the manufacture of another product.

In this article we look at the Bill of Materials form and how to create simple Bills.

Advanced functions and features are covered in separate articles this includes;

  • Production Areas and Lines,
  • Work centres, and
  • Sub-assemblies

Before we begin let's have a look at some of the manufacturing terms used in Jiwa.

Production areas

Dedicated area in a warehouse/factory where an item is manufactured.

For example if you manufacture doors and windows your warehouse/factory may have separate areas where each is manufactured, like

  • Door and Door Frame Production Area
  • Window and Window Frame Production Area

Production line

Production lines contained within a production area.  If we use the door and window example the Door and Frame Production area may have the following production lines;

  • Sliding Doors, and
  • Hinged Doors

Work Centre

Processes or task associated with a production line.  If we use the Door example the Sliding Doors production line may have the following work centres,

  • Door Assembly,
  • Cutting, and
  • Painting

Stage

Stages represent the steps in your manufacturing process and can be as simple or as complex as required.  Each stage can have it's own components (inputs) that go into the manufacture of one or more outputs.

Taking our door manufacturing process the bill of material may have the following stages;

  • Assembly - Frame
  • Paint
  • Assembly - Glass
  • Assembly - Final

At least one stage needs to be setup in a Bill of Material

Sub Assembly

A bill of material to create a component that is used in the manufacture of another component or a finished product.

Inputs

Components that go into the manufacture of another product

Outputs

The item that is produced at the end of the manufacturing process this can be a finished product or another component that is used to manufacture another product

 

 

 

From the menu select Manufacturing | Bill of Materials Maintenance

 

From the menu ribbon select New

 

Header Information

The General section of the form is a summary of our Bill.

Give your Bill a number and description.

 

Bill No. This is a unique identifier for you Bill of Materials.  Typically it is set to the output item.
Description Bill of Materials description
Production Area / Line

This field is optional and only required if production areas and lines are being utilised.

Production areas are created to provide more control over the manufacturing process, what gets manufactured and where by linking them to warehouses.  This feature is optional and typically implemented were more control over the manufacturing process and work scheduling is required.

Production areas, lines and works order scheduling is covered in more detail in another article.

Max Prod. Capability This is the maximum number of output items that can be produced at the time you are working with the Bill of Material based on the quantities of input items that are available.  This field is recalculated with the movement in your input items.
Enabled

When enabled the Bill of Material is active and is available for use on a works order.

When this check box is unticked, the the Bill of Material is not active and can not be used on a works order.

 

Details Tab

The details tab is divided into 3 key areas

  • Stages
  • Inputs
  • Outputs

 

Stages

Jiwa requires at least 1 stage to be set-up in a Bill.

Enter in a stage description in the Name field, for simple Bill's this could simply be Stage 1

 

Name

Stage name

Your Bill of Material must have at least 1 stage

Work Centre

Select the Work Centre that is applicable to this stage.

This field is not mandatory and can be left blank when creating simple Bill's.  Work centres are covered in more detail in separate articles.

Required Capacity

This field is only enabled when a Work Centre is selected and represents the time required to complete the stage for a single unit.

This field is greyed out when a work centre is not selected

Total Input Cost

This is the total cost of the stage based on the stage inputs

 

Components

Add the input components that are required in the stage item by clicking on the lookup icon next to the Part No. field

Check the quantity type and set the quantity to be used.

If the item has a sub-assembly select the applicable sub-assembly.

 

Part No.

Input item part number

Description

Part number description

Sub-assembly

Select the applicable sub-assembly if the component is also a manufactured item.

Hint:  You will notice that the Explode Policy field is activated if there is a sub-assembly associated with the input item.

Explode Policy

The Explode Policy controls when the works order is created for the sub-assembly.

  • Always - A new work order is automatically created when the status for the stage or the work order moves onwards from Not Started and the sub-assembly field quantity is completed.
  • Never - A new work order is not created automatically.
  • When Shortfall - A new work order is automatically created only when there is a short fall in input item
Quantity Type

Select how the input item is to be consumed when a works order is created;

  • Ratio - Adjusts the quantity of the input item based on the quantity being manufactured
  • Fixed - Quantity to be used of the input item is fixed regardless of the quantity being manufactured
Quantity

Quantity required of the input item in order to produce the output quantity.

Last Cost

Last cost from Inventory maintenance

Unit Measure

Unit from Inventory maintenance

Total Line Cost Last Cost x Quantity

 

Instructions

This tab allows you to add instructions for each production stage which can then be added to a customised works order report.

 

Outputs

Add the output item or items that will be built in the stage by clicking on the lookup icon next to the Part No. field

Check you quantity type and set the quantity to be built.

If there is more than 1 input item to be built set the cost percentage.

 

Part No.

Input item part number

Description

Part number description

Quantity Type

This is only applicable if there is more than 1 output item.  This option determines how the costs are split between the output items.

  • Ratio
  • Fixed
Quantity

Output quantity

Last Cost

Last cost from Inventory maintenance

Cost

Sum of the component costs across all stages

Cost Percentage

This field is only applicable if there is more than 1 output item on the Bill and controls how the total input costs are apportioned across the output items.

Unit Measure

Unit from Inventory maintenance

Primary

 

 

Select Save from the menu ribbon to add your new Bill of Material.

Continue to add other stages if required.

 

Other Tabs

Notes

This tab allows you to enter notes about the Bill such as updates to the bill or changes that have been made to the bill.

Documents

This tab allows you to attach documents to the Bill such as drawings

Custom Fields

This tab contains additional information that needs to be captured on a Bill via custom fields

Component Tree

This tab displays all the components contained in the Bill by stage including sub-assemblies

Bill Parents

This tab displays the items that the current Bill is a sub-assembly of

To Do

This tab allows you to add tasks specific to the Bill

 

 

Reporting

To print out the Bill Maintenance report from the menu ribbon select Print | Bill Maintenance

 

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