Work Order

Work Order

The Production Planner issues a Work Order to the factory floor as a directive to produce a specific item in a specified quantity.

The Work Order also aids in determining the stock entry (Material Requirements) for the item's Bill of Materials.

The Production Plan, which is based on Sales Orders, can generate the Work Order.

Go to: to access the Work Order list.

Home > Manufacturing > Production > Work Order

1. Prerequisites

It is suggested that you first create the following before making and using a Work Order:

Bill Of Materials
Operation
Workstation

2. How to Create a Work Order

Click New from the Work Order list.
Choose the product that will be produced.
The system will retrieve that item's default BOM. The BOM can also be modified.
Input the desired production volume. Only when this is set will items made of raw materials be fetched.
The system will retrieve all Operations from the BOM if the specified BOM mentions any Operations; these values can be altered. For more information, see section 3.2.
Put a date on the planned start (an Estimated Date at which you want the Production to begin).
Use Multi-Level BOM: This option is by default turned on. Leave this enabled if you want to plan materials for sub-assemblies of the manufactured item. This checkbox can be turned off if the sub-assemblies are planned and produced independently. Please visit this page to learn more.
Select Warehouses:
1. Source Warehouses: In the Item row, choose this Warehouse. the location of your raw material warehouse. A different source warehouse can be used for each necessary component. Source warehouse options include group warehouse as well. The raw materials will be set aside in these warehouses for use in production upon submission of the Work Order.
2. Work-in-Progress Warehouse: the storage facility to which your Items will be moved once manufacture has started. Another option for a work-in-progress warehouse is Group Warehouse.
3. Target Warehouse:the storage facility where finished goods are kept before being sent.
4. Scrap Warehouse: The Scrap Warehouse must be chosen if the BOM generates scrap material.
Required Items: The BOM will be queried to retrieve all necessary items (raw materials) and populate this table accordingly. Moreover, any item's Source Warehouse can be changed from here. Also, this table allows you to keep track of moved raw materials during production.

Note: Although choosing the Warehouses is not required to submit a Work Order, you cannot save a Work Order without doing so.

A sales order can also be used to establish a work order straight away.

2.1 Additional Options when Creating a Work Order

Sales Order: It will be fetched here if you establish a Work Order from a Sales Order. You can also connect this Work Order to an existing Sales Order that contains the product that needs to be made.
Project: To track progress in situations like engineer to order, link the work order to a project.
Allow Alternative Item: There are occasions when specific materials are not readily available for the manufacture of a final object. Using plastic beads rather than plastic crystals, as an illustration. The finished product itself could differ. By checking this box, you can choose an alternative item. Please visit this page to learn more.
Skip Material Transfer to WIP Warehouse: Typically, a stock entry is made when raw materials are moved to a warehouse for work in progress. Since the raw material is deemed to have been utilized in this instance, the stock entry is omitted. If this checkbox is selected, the following choice will be displayed.
Backflush Raw Materials From Work-in-Progress Warehouse: When this option is selected, a Stock Entry of the type "Manufacture" will be generated automatically. As a result, another stock entry was made for your target warehouse and raw materials from the source warehouse were used to make completed goods.

3. Features

3.1 Time

Here, you can enter the anticipated delivery date as well as the planned start date. When a work order is created, the current date and time are used as the default for the planned start date.

3.2 Required Items table

For the raw material items utilized here, the Source Warehouse can be altered. The default Warehouse can be set globally in Stock Settings or at the item level in the item master.

Required Quantity: Based on the Bill Of Materials, this will be automatically determined.
Transferred Quantity: Items are moved from the Source Warehouse to the Work In Progress Warehouse once the Work Order is started and the Job Cards are processed. The quantity in the WIP Warehouse is displayed in this field. The 'Skip Material Transfer to WIP Warehouse' checkbox prevents this column from being updated.
Consumed Quantity:This field will be updated after the item from the WIP warehouse has been used and the finished product has been produced.
Allow Alternative Item: By checking this box, you can choose an alternative item from the Item Alternative list if the specified Item (raw material or sub-assembly) is not readily available.
Skip Material Transfer: This checkbox needs to be enabled if you don't want to send a specific raw material to the warehouse for work in progress.

You can still choose an item after unchecking this option for it in the BOM and Work Order, but no Stock Entries will be produced against it.

The following two fields in the Needed Items table will also display the availability in the corresponding Warehouses once the Work Order has been saved:

Available Qty at Source Warehouse
Available Qty at WIP Warehouse

3.2 Operations table

Materials can be moved in accordance with a Job Card or a Work Order. Normally, this is taken from the Bill of Materials, but you can also edit it there.

The BOM will be queried for the following data:

The workstations where the operations will be carried out are listed in the operations table.
The Operations that will be carried out on the Items are listed in the Items table.

Moreover, these values are mutable.

The following fields will be displayed following the saving of the work order:

Completed Qty: how many Items were involved in this operation.
Status: If the operation is ongoing, finished, or pending. When the Job Cards are changed, this status is also updated.
Operation Time: Although it can be altered, this is taken from the BOM.
Planned Operating Cost: Based on factors like Operational Time, Hourly Rate, Manufactured Amount, etc., this is computed.

As job cards are updated, the Real Operation Time, Actual Operating Expense, Actual Start Time, and Actual Finish Time are updated as well.

3.3 Operation Cost

They are displayed in this section:

Planned Operating Cost: This was obtained in accordance with the BOM's specified Procedures.
Actual Operating Cost: Based on the Operations carried out on the Items, this is retrieved from the Job Cards.
Additional Operating Cost: You can include here any more costs you might have incurred making the item.
Total Operating Cost: This is determined by adding the additional operating cost to the actual operating cost.

These figures are computed in accordance with the job cards.

3.4 More Information

Here, the manufactured item's description and stock UOM are displayed.

This section will be updated when a Work Order is generated from a Material Request.

3.5 Transferring Materials for Manufacturing

Once your work order has been submitted, you must transfer the raw materials in order to start the manufacturing process.
By doing this, a stock entry will be made with all the items needed to finish this work order and add them to the WIP warehouse. Depending on whether you checked the box for "Use Multi-Level BOM," this will either add the sub-assembly Items in their current state or explode them to reveal the raw materials.
Start by clicking. Job Cards for the relevant Operations will be created once you click Start.
Specify the volume of materials that will be moved during this run.
A Stock Entry for "Material Transfer for Manufacturing" will be displayed for you. Send it in.
Based on the Stock Entry, Material Transferred for Manufacture will be updated in the Work Order.

3.6 Material Transfer through Stock Entry

These are use scenarios for this choice:

If a material transfer is made in bulk or when it is not necessary for it to be tracked against a specific Work Order.
If two different Users are in charge of the Material Transfer and Production Entry.

If so, you can select the "Skip Material Transfer" checkbox, allowing you to create the Stock Entry of type "Manufacture" without any further steps by selecting the "Finish" button.

3.7 Creating Job Cards

With Job Cards, the Work Order's progress can be monitored.
Drafts of Job Cards are created based on when a Work Order is Submitted.
Click the + sign next to Job Card on the Work Order dashboard to add more Job Cards to a Work Order.

To know more about Job Cards, visit this page.

3.8 Updating Finished Goods

You must update the Completed Items after finishing the Work Order.
Via the creation of a stock entry, all the components and subassemblies will be taken out of the WIP warehouse and added to the finished goods warehouse.
Choose "Finish" from the menu.
State the volume of materials being moved.

Tip: You can also partially complete a Work Order by updating the Finished Goods stock creating a Stock Entry.

3.9 Capacity Planning in Work Order

When a Work Order is submitted, the system schedules all activities for the Work Order based on the Scheduled Start Date and the accessibility of the Workstations (if Work Order has Operations specified).
Time Log drafts are also produced in accordance with the planned operations.

The system will reserve a time slot for each of the work order operations sequentially following the scheduled start date based on the workstations' availability when the work order is submitted. The availability of the workstation is based on its timings, the list of holidays, and whether or not another Work Order Operation is scheduled for that time period.

In the Manufacturing Options, you can specify the number of days the system should try scheduling the tasks. By default, this is set to 30 Days. The system will prompt you to interrupt the operation if it takes longer than the allotted time. The system will produce and save Time Logs after scheduling is complete. Then, you can edit them and submit them.

4.0 Stopping a Work Order

When a work order is stopped, its status is changed to Stopped, signifying that all production activities related to that work order have come to an end. However, before canceling the work order, the user must confirm if the raw materials that were sent to the warehouse for work in progress have been returned or not. The system will throw an error and prevent the user from stopping the work order in the event that the user attempted to terminate the work order without returning the raw materials.

A Work Order may be stopped by clicking the "Stop" button.

Moreover, the paused Work Order may be reopened.

4.1 Return Non Consumed Materials to the Stores from WIP Warehouse

When the work order is finished, you wish to return any extra materials you transferred to the Work In Progress warehouse to the Store warehouse. Then, select Return Components from the Work Order menu. The return stock record is then created by the system with the type Material Transfer for Manufacturing.

Also, you can use the Work Order Consumed Materials report to compare the returned components to the work order.