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Jiwa Manufacturing - Creating Work Order from Bill of Material

This is the second key article in a series that looks at the Manufacturing module in Jiwa 7.

Before proceeding please ensure that you have reviewed our article Jiwa Manufacturing - Bill of Materials

 

Overview

A Work Order also referred to as a production order or manufacturing requisition is used to produce a finished product or a component that is used in another manufactured item.

In this article we look at how to create a Work Order based on a Bill of Material.

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

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

 

 

From the menu select Manufacturing | Work Order

 

From the menu ribbon select New Work Order

  

Header Information

The General section of the form provides details relating to the overall Work Order.

Select the Bill of Material to be used by clicking on the lookup icon next to the Bill No. field to bring up the Bill of Material Search form and select the required Bill.

 

Enter in the quantity of items to be produced in the Production Qty field

 

Set your planned production dates and work order status

 

 

 

Work order Number This field will be automatically updated with the next available work order number on the first save
Date Created This field will default to the user login date but can be changed manually if required
Bill No. The Bill of Material number that is linked to the work order
Description The Bill of Material description from Bill maintenance
Reference Additional reference field
Production Area / Line

This field is automatically updated from Bill maintenance but can be manually overridden.

This field is not mandatory and if production areas are not being used can be left blank

Production Qty

The quantity to be produced (manufactured) is entered in this field

Planned Prod. Date

Planned production date.

This date is only a reference and is not used by Jiwa

Required By

Date that the output items are required by.

This date is only a reference and is not used by Jiwa

Max. Prod. Capability

This is the maximum number of output items that can be produced at the time the Work Order is created based on the quantities of input items that are available.

This field is recalculated with the movement in your input items.

Actual Prod. Date

The actual date that the Work Order has gone into production.

This date is only a reference and is not used by Jiwa

Completed Date

The actual production completion date.

This date is only a reference and is not used by Jiwa

Status

Work order status

  • Forecast - Can be included in forecast based purchases
  • Not Started - Work order has been created but not started
  • Started - Input stock is allocated to the Work Order.  Journal is created moving stock to WIP
  • On Hold - Work order is placed on hold
  • Closed - Work order has been completed
Parent Work Order

This field is automatically populated with the parent work order if the current work order is a sub-assembly

 

 

Details Tab

The Work Order Details tab has a similar layout to the Bill of Material Details tab with 3 key areas;

  • Stages
  • Inputs
  • Outputs

This tab is automatically populated from the Bill of Material that is loaded into the Work Order however this information may be changed at the Work Order level if required.

 

Stages

Confirm your stage start date

  

Name

Stage name

Your Bill of Material must have at least 1 stage

Status

The status field is not editable when the Work Order status is set to Not Started

When the Work Order Status is changed to Started the stage status field is updated to In Progress and the field is enabled.  If required the stage can then be set back to Not Started.

  • Not Started - Work order has been created but not started
  • In Progress - Input stock is allocated to the Work Order.  Journal is created moving stock to WIP
  • Completed - Stage has been completed
Start Date

Stage start date.  This field will default to the user login date

Work Centre

This field is not mandatory and can be left blank if this feature is not being used.  Work centres are covered in more detail in separate articles.  The field will automatically be populated from the Bill of Material if Work Centres are being used.

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

Adjust your inputs as required by adding lines, removing lines, adjusting quantities, changing the explode policy.

 

Part No.

Input item part number

Description

Part number description

Sub-assembly

The related sub-assembly if the input item is one that is manufactured.  The sub-assembly can be changed if required on the work order by clicking on the lookup icon next to the field to view all available sub-assemblies.

Explode Policy

The Explode Policy controls when the works order is created for the sub-assembly, this can be changed if required on the Work Order.

  • Always - A new work order is automatically created when the status of 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

Controls how input items are consumed in a Work Order

  • 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
Unit Quantity

Quantity used per unit

Total Quantity

Unit Quantity x Production Qty

SOH On Shelf

Total stock on hand in the active warehouse

SOH Available

Total stock available in the active warehouse

Quantity Taken

Actual quantity used in the production process.

This field is automatically updated with the Total Quantity when the Work Order status is changed to Started but can be changed if required

Quantity SubAssembly

Actual sub-assembly quantity used in the production process

This field is automatically updated with the Total Quantity when the Work Order status is changed to Started but can be changed if required

Quantity on Backorder

Quantity on back order

Quantity Wastage

Quantity wasted during the production process

Last Cost

Last cost from Inventory maintenance

 

Instructions

Add or update your stage instructions

 

Outputs

Confirm your output item details.

 

Part No.

Input item part number

Description

Part number description

Quantity Type

Controls how output items are created in a Work Order

  • Ratio
  • Fixed
Unit Quantity

Output quantity from Bill of Materials

Total Quantity Expected

Unit Quantity x Production Qty

Quantity WIP

Finished quantity sitting in Work in Process

This field is automatically updated with finished goods completed when the status of all stages on the Work Order have been updated to In Progress

Quantity Output

Actual quantity produced

Quantity Written Off

Quantity written off from the quantity produced

Last Cost

Last cost from Inventory maintenance, this is a read only field

Cost

Sum of the component costs across all stages, this is a read only field

Cost Percentage

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

Primary

 

 

Select Save from the menu ribbon to create your new Work Order.

 

Other Tabs

Notes

This tab allows you to enter notes that relate to the Work Order

Documents

This tab allows you to attach documents to the the Work Order

Custom Fields

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

Component Allocations

This tab is only applicable if there is more than 1 output item on the Work Order.  Inputs can be allocated to specific outputs in this tab.

To Do

This tab allows you to add tasks specific to the Work Order

 

Reporting

To print out the Work Order report from the menu ribbon select Print | Work Order

 

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