In some cases manufacturing is very simple, it is just to reduce materials from inventory as product is made, perhaps directly at dispatch time. Manu Online has two important tools to make the administration of this very light touch: dedicated work orders with open work orders automatically and backflush.
Set up the item for dedicated work orders
Dedicated work orders are the key to make to order. The word "dedicated" means that the work order is dedicated to a certain sales order line. The option "open work orders automatically" means that there is no need to go to the production section and click the New button because the work order will be opened automatically when the sales order is activated.
Open the item card for the product:
- Check that Plan for is set to Manufacturing
- Go to the Manufacturing tab and the Properties sub tab
- Set Dedicated work order and Open work order automatically
- Make sure that under the Structure tab there is the list of items that go to make up this product (bill of materials).
Set up the item for backflush
Backflush is the process of reducing consumed items automatically when certain actions happen on the work order.
In this example we will use the backflush for materials when the work order is created. There are also options for using materials at work step completion. You need to decide do you want materials marked as removed from inventory and the beginning or the end of your process, or some where along the way in multistep work orders.
Go to the Backflush sub tab on the item and set this check box for this.
Note that backflush will logically only work for items that are not lot or serial number tracked.
By backflushing the materials at work order open they are removed from inventory so would prevent other work orders using that quantity. The process would normally only be used if there is a short time between entering the order and dispatching it to the customer, or if you wish to "hard" allocate materials to work orders.
Enter and activate the sales order
Create a new sales order for the product. Note that on the line details tab it will be marked to dedicated work order. There will be a message with the number of work orders opened - one for each line with dedicated work order.
Materials have now been reduced from inventory and are in the work order.
Note that backflush will only occur for items that sufficient quantities in stock at the location of the work order (assuming negative stock is not allowed at that location).
The work order is created and can be seen the Production menu. The work order number will include the sales order number dash line number, which makes it easy to search for.
Complete the work order
Move all products to stock and complete the work order.
Click the two buttons to do this on the first tab of the work order.
There is no need to press the Withdraw initial materials because Backflush has been used. But this would be an alternative way to achieve the same.
Note that there are also various options for closing work orders from the work cell screen or with barcode etc.
Dispatch the order to the customer.
Dispatch the order in the normal way to the customer.