Manufacture Order

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Work Orders

Icon.Manufacture Order.png The Manufacture Order module, located in the Manufacturing group, organizes work orders and allows for items to be manufactured, disassembled, and repaired. Manufacture orders can be created individually or generated from sales order demand and inventory levels. This article outlines the process, functions, tabs, and module options of the Small.Manufacture Order.png Manufacture Order module. The following table of contents and flow chart can be used to navigate the article.


Create MOReverse, Disassemble, Standard, Repair or Custom?ReverseCustomStandardDisassembleRepairSelect ReverseSelect DisassembleChoose BOMChoose WOSelect RepairSelect CustomChoose Item to RepairCreate BOMChoose BOMIssue MOStart WOPick WOFinish WOMO Flow Chart.png


PROCESS

1. Create a manufacture order

Follow the steps below to create a manufacture order and add a work order:

  1. Open the Small.Manufacture Order.png Manufacture Order module and click the New Button.png New button on the module toolbar.
  2. Add a work order by selecting a bill of materials from the BOM field.
    BOM Combo Box.png

This will create a standard work order using the items on the selected bill of materials. A work order can also be added by clicking the Add Icon Button.png Add button to the right of the BOM field. This displays a wizard with more details such as lead time. Lead time is the estimated time to complete the work order and takes into account the bill of material's estimated time (found on the Details tab of the BOM) and the default vendor's lead time (found on the Vendors tab of the part) for any parts with insufficient inventory.

2. Choose a work order type

There are several types of work orders. Standard and Reverse work orders are based off of a saved Bill of Materials. Disassemble work orders are based off of a previous work order. Repair and Custom work orders are created within the Small.Manufacture Order.png Manufacture Order module by adding custom materials. Click the Add Icon Button.png Add button to the right to choose the work order type to be added.

Add BOM Wizard.png.

Follow the steps below for each type of work order:

Standard

A standard work order processes a BOM the way it was set up. Raw Goods will be consumed and Finished Goods will be produced.

  1. Click the Add Icon Button.png Add button to the right and choose Standard.
  2. Click Next and select the BOM to manufacture.
  3. Click Next to proceed through the wizard, entering the quantity, date, and notes. Then click Finish.

Reverse

A reverse work order reverses a BOM by making the raw goods become finished goods and the finished goods become raw goods.

  1. Click the Add Icon Button.png Add button to the right and choose Reverse.
  2. Click Next and select the BOM to reverse.
  3. Click Next to proceed through the wizard, entering the quantity, date, description, and notes. Then click Finish.

Disassemble

A disassemble work order is similar to a Reverse, but disassembles a finished work order instead of a BOM.

  1. Click the Add Icon Button.png Add button to the right and choose Disassemble.
  2. Click Next and select the work order to disassemble.
  3. Click Next to proceed through the wizard, entering the quantity, date, description, and notes. Then click Finish.

Repair

A repair work order repairs a part. The part will not be consumed, but the cost may be adjusted if labor or other materials are added to the work order.

  1. Click the Add Icon Button.png Add button to the right and choose Repair.
  2. Click Next and select the Part to repair.
  3. Click Next to proceed through the wizard, entering the quantity, date, description, and notes. Then click Finish.
  4. Add the materials needed for the repair by following the Customize materials steps.

Custom

Instead of using a saved BOM, a custom work order can be created.

  1. Click the Add Icon Button.png Add button to the right and choose Custom.
  2. Click Next to proceed through the wizard, entering the date, description, and notes. Then click Finish.
  3. Add the custom materials by following the Customize materials steps.

3. Customize materials

Before issuing a manufacture order, the materials to be used on a work order can be customized on the Materials tab. This is especially applicable for Repair and Custom work orders, but the materials can be customized for any type of work order. Follow the steps below to customize the materials.

  1. Click the Materials tab and highlight the desired work order.
    MO materials subtab.png
  2. Click the Add Icon Button.png Add button to the right.
  3. Choose the item type to be added.
    Add Custom Item.png
  4. Click Next and enter the Part, quantity or any information required to complete the wizard.
  5. The buttons in the component toolbar to the right can also be used to remove, rearrange, or reconfigure items on the work order.

Once the manufacture order has been issued, the Materials tab will become read-only, but changes can continue to be made on the WO Details tab in much the same way. See Materials and WO Details tabs for more information regarding these similar tabs.

4. Issue a manufacture order

Once all of the items have been added to a manufacture order, the manufacture order must be issued. Click the Issue button in the module toolbar to issue the manufacture order. When the manufacture order is issued, the work orders are created. Once a work order has been created, Assigned Users can be added, changes can be made on the WO Details tab, and the work order can proceed through the fulfillment process.

5. Fulfill a work order

Once the manufacture order is issued, each work order can be fulfilled. A work order must be started, picked, and finished. Work orders can proceed through these steps individually by using the appropriate buttons on the component toolbar to the right. Clicking the Finish button in the component toolbar will perform the Start and Pick steps if they have not already been completed. These steps can also be performed quickly for all work orders by using the Quick Fulfill wizard located on the module toolbar.

Start a work order

Starting a work order flags the work order so that work may begin. The Started Date is stored so that the duration of the work order can be estimated. Complete the following steps to start a work order.

  1. Highlight one or more work orders and then click the Start Icon Button.png Start button located on the component toolbar to open the Start Work Order wizard.
    Start Work Order.png
  2. Make any necessary changes to the Start Quantity and the Assigned Users and click Next.
  3. View or print any desired reports and click Finish.

The Start step can also be performed when finishing a work order.

Pick a work order

Picking a work order will gather the raw goods needed to manufacture the finished good.

  • To pick a work order, highlight the work order and then click the Pick Icon Button.png Pick button located on the component toolbar. This will load the work order in the Small.Picking.png Picking module where the pick can be started and finished.

The Pick step can also be performed when finishing a work order, eliminating the need to load the Picking module.

Finish a work order

Finishing a work order will consume the raw goods and place the finished goods into inventory. If the work order was created for a sales order, the inventory needed for the sales order will become available to pick. Complete the following steps to finish a work order.

  1. Highlight one or more work orders and then click the Finish Icon Button.png Finish button located on the component toolbar to open the Finish Work Order wizard.
  2. If the work order has not been started, the Start Work Order step will be displayed. Make any necessary changed and click Next.
  3. The Picking Step allows the pick to be modified and finished. Verify the picking information and click Next.
    Pick Work Order.png
  4. The Raw Material Consumption step allows the actual consumption quantities to be adjusted. Make any necessary adjustments and click Next.
    Raw Material Consumption Step.png
  5. The Add Finished Good step specifies the inventory location of the Finished Goods as well as the finished date.
    Receive Finished Goods Step.png
    If there are multiple finished goods, the Add Finished Goods step allows the cost to be divided and provides buttons for duplicating, deleting, and applying costs.
    Receive Multiple Finished Goods Step.png
    Enter any applicable information and then click Next.
  6. View or print any desired reports and click Finish.

FUNCTIONS

Module buttons

New Button.png New creates a new manufacture order.

Issue Button.png Issue changes the status of a manufacture order to Issued.

Unissue Button.png Unissue changes the status of a manufacture order to Entered.

Save Button.png Save saves any changes made to the manufacture order.

Delete Button.png Delete deletes the manufacture order if it is in an Entered status. Issued orders can be unissued to return them to the Entered status.

Close Short Button.png Close Short will replace the Delete button when an order has a status of Partial. Work orders must either be in an Entered or Fulfilled status to close short a manufacture order. To void a work order, click the Void Work Order button located on the component toolbar.

MO to PO Button.png MO to PO generates a purchase orders with the items that are short or all of the items on the manufacture order. Options can be customized in the Small.Manufacture Order.png Manufacture Order module options.

Quick Fulfill Button.png Quick Fulfill quickly fulfills all work orders. This will proceed through the Finish Work Order wizard for each work order on the manufacture order.

Auto MO Button.png Auto MO launches the Auto MO wizard to automatically create manufacture orders.

Duplicate Button.png Duplicate creates a copy of any manufacture order. The order number will automatically be assigned and the new MO will have an Entered status.

Email Button.png Email opens a window to compose an email. If the module's default report is specified, the PDF report will be attached. Email can be configured on the Email tab tab of the Small.Settings.png Settings module.

Print Button.png Print sends the default module report to the printer.

How To Button.png How To opens this article in a web browser.

Refresh Button.png Refresh reloads whatever is currently open in the module.

Work order buttons

The work order component toolbar is located to the right of the item list and has several functions. Each function will be performed on the highlighted work order.

The Start  button starts the highlighted work order.

The Pick button picks the highlighted work order.

The Finish button finishes the highlighted work order.

The Delete button deletes the highlighted work order.

The Void button voids the highlighted work order.

Auto MO wizard

The Auto MO wizard is an easy way to generate manufacture orders for parts whose inventory levels are low. In order to use Auto MO on a specific part, Reorder Level Points should first be created for that part. The following instructions outline the process of using the Auto MO wizard:

  1. Make sure parts have the correct reorder levels established.
  2. Click the Auto MO button on the module toolbar.
  3. Set any desired filters and click Next.
    Auto MO wizard step 1.png
  4. Confirm the list of the orders to be created. An item can be skipped by un-selecting it. Quantities can also be modified as necessary. Click Finish to create a separate manufacture order for each item or select the option to combine items into one order.
    Auto MO wizard step 2.png

Create MO from SO

When a sales order, with an item that needs to be manufactured, is issued, a manufacture order will automatically be created. The sales order number is displayed on the General tab of the Small.Manufacture Order.png Manufacture Order module and can be clicked to jump directly to the sales order.

MO tied to SO.png

Assign users to a work order

Users can be assigned to a work order as soon as manufacture order is issued, and the work order created. To add users, highlight the work order, and add users on the Assigned Users tab below.

MO assign users.png

Users can also be assigned in the Finish work order wizard.

Calculate cost

Once a manufacture order has been saved, the Calculate Cost Button.png button can be clicked to load the Manufacture Order Projected Cost report. The costs of the raw goods are used to determine the cost of the finished good. For unfulfilled work orders, finished good costs are estimated using the current costs of the raw goods when the report was generated. For fulfilled work orders, the actual costs of the raw goods from the time the order was fulfilled will be displayed. NOTE: When an item is sold, the cost that is exported to the accounting system will not come from this report, but will be determined by the current cost of the selected costing method.

MO Projected Cost.png

Search

The Search Icon Button.png Search pane on the left can be used to filter by Number, BOM Number, SO Number, or Status. Records can also be found by typing in the table. Click the Advanced Search button to search the Custom Fields and the following search options.

Manufacture order advanced search.png

TABS

General tab
MO general subtab.png
The General tab provides the core information for the manufacture order. The following information is available on the General tab:
  • Number - The order number will default to the number in the Small.Manufacture Order.png Manufacture Order module options.
  • Date Scheduled - The date scheduled will default to the order creation date.
  • Location Group - The Location Group will default to the user's default Location Group.
  • Type - The Type field is a custom field for informational purposes. It does not alter the behavior of the order. Default type values include Disassemble, Maintenance, Manufacture, Repair, and Service, but the value can be customized in the Small.Custom Field.png Custom Field module by clicking on the Custom Lists and then double-clicking BOM Type.
  • Sales Order - The Sales Order section will be visible if the order was generated from a sales order.
  • Work Orders - The Work Orders section provides a list of work orders on the manufacture order. The work order buttons to the right are used to modify the currently highlighted work order. The Details and Notes tabs below the item list display information for the currently highlighted work order, and allow the quantity, date, location, class, assigned users, priority, etc. to be edited.
  • Category - The calendar category can be set on the lower Details tab. The Category label can also be customized in the module options.
Details tab
MO details subtab.png
The Details tab displays details and notes for the manufacture order.
  • Date Created - The date the order was created.
  • Date Issued - The date the order was issued.
  • Date Fulfilled - The date the order was fulfilled.
  • Created By - The user that created the order.
  • Revision - The number of times the order has been saved.
  • Last User - The last user to modify the order.
  • Last Modified - The most recent date the order was saved.
  • Notes - A field for adding notes to the order. Click the Save button to save notes.
Materials and WO Details tabs
MO materials subtab.png
MO wo details subtab.png
The Materials tab and the WO Details tab are very similar. Both tabs allow items to be added, removed, or rearranged. However there is one important difference between the two tabs:
  • The Materials tab is used BEFORE the manufacture order is issued.
  • The WO Details tab is used AFTER the manufacture order is issued.

A work order is created when the manufacture order is issued, meaning the WO Details tab will be empty until the manufacture order is issued. Before the work order is created, edits can be made on the Materials tab. As soon as the manufacture order is issued, the Materials tab will become read-only, and edits can be made on the WO Details tab.

  • The Materials tab has a Reconfigure this item Icon Button.png Reconfigure this item button that allows a configurable item to be adjusted.
  • The WO Details tab has a Create new BOM Icon Button.png Create new BOM button that will create a new BOM with the current configuration.
Memo tab
MO memo subtab.png
The Memo allows memos to be viewed and added to a manufacture order. The top pane displays a list of memos. Highlighting a memo will display the entire memo in the lower pane. The buttons to the right of the memo list can be used to Add, Edit, Delete, or Print a memo.
Custom tab
MO custom subtab.png
The Custom tab is used to enter custom fields for a manufacture order. The fields displayed on the Custom tab can be customized in the Small.Custom Field.png Custom Field module. Custom fields can be searched by clicking the Advanced Search button in the manufacture order search pane. Some reports also have Custom Field filters.


MODULE OPTIONS

Some aspects of the Small.Manufacture Order.png Manufacture Order module can be customized by opening the module, clicking the Tools menu, and then selecting Module Options.

General tab
Manufacture Order Module Options.png
  • Next Number
The characters entered in this field will be used as the next order number. Every time a new order is created, the final group of numbers will be increased by one. For example, Pier1-Order99-LA will be incremented to Pier1-Order100-LA.
  • Distribute Finished Good costs
When a Work Order has multiple finished goods, the cost of the raw goods must be distributed between the finished goods. There are two options for the default distribution; however with either option, the distribution can be manually adjusted when finishing the Work Order.
  • Evenly - The costs will be distributed evenly between each finished good based on the quantity of the finished good.
  • Weighted - The cost distribution will be weighted according to the current cost of the finished goods in inventory.
Example: A Work Order produces 3 WidgetA and 1 WidgetB. The cost of the raw goods is $100. If the costs are distributed evenly between the four finished goods, each one will receive a cost of $25 for a total of $100. For weighted cost distribution, the current cost of the finished goods in inventory is used to adjust the costs proportionally. If WidgetA currently costs three times as much as WidgetB, then the costs on the Work Order will be adjusted accordingly. WidgetB will receive a cost of $10 and each WidgetA will receive a cost of $30 for a total of $100.
  • Issue the Manufacture Order when Sales Order is issued
With this option checked, a Manufacture Order that is auto created from a Sales Order will automatically be issued when the Sales Order is issued.
  • Start the pick when starting a Work Order
If this option is on, flagging a Work Order as started will also flag the pick as started.
  • Prompt the user when fulfilling if there are no labor raw goods
If this option is on, a message will be displayed when trying to fulfill an order that doesn't have labor.
  • Category Name
The calendar category label can display customized text.
MO to PO tab
Manufacture Order Module Options MO to PO.png
  • Enable manufacture order to purchase order conversion
This option enables the MO to PO button on the module toolbar which creates purchase orders for the items on a manufacture order.
  • Round quantities up to the nearest whole number
With this option on, the quantity on the purchase order will be the manufacture order quantity rounded up to the nearest whole number.
  • Use the manufacture order's UOM on Purchase Order
With this option checked, the UOM on the purchase order will be the same UOM used on the manufacture order.
  • Combine line items of the same part number
If the manufacture order has the same part multiple times, this option will combine the quantities into one line item on the purchase order.