Manufacturing — User Guide

Manufacturing Admin

• Creates: product manufacturing setup rules, BoM, routings, work centers, and configuration standards.
• Updates: approved master data when controlled changes are required.
• Approves: BoM revisions, routing sequence changes, and critical consumption policy changes.
• Should not change freely: released production quantities or execution logs without process review.

Planner

• Creates: manufacturing orders, planned dates, and release priorities.
• Updates: schedule, owner assignment, and order readiness status.
• Approves: release-to-execution when readiness checks pass.
• Should not change freely: BoM and routing master definitions.

Production Supervisor

• Creates: work-order assignment plan by work center.
• Updates: execution progress, pause/continue actions, and blocker notes.
• Approves: completion readiness before order closure.
• Should not change freely: cost assumptions and warehouse policy setup.

Work Center Operator

• Creates: operation execution logs and practical status updates.
• Updates: start/pause/continue/done progression and time tracking entries.
• Approves: operation completion at assigned step level.
• Should not change freely: master BoM, routing order, or cross-center policy.

Inventory / Warehouse Coordinator

• Creates: component issue and finished-goods receipt handoff records.
• Updates: movement references tied to production orders.
• Approves: warehouse-side handoff completion based on policy.
• Should not change freely: manufacturing order planning parameters.

Quality / Reviewer (where used)

• Creates: review notes and exception records.
• Updates: verification status tied to completed output.
• Approves: pass/fail or acceptance checkpoints based on local process.
• Should not change freely: released quantity or consumption logs without governance.

Ownership rule:

• BoM and routing changes should be owned by Manufacturing Admin (or designated engineering owner).
• Production execution should be owned by Planner/Supervisor/Operators.
• Warehouse issue/receipt ownership should stay with Inventory/Warehouse coordinators.

1. Products and variants

• Confirm manufactured products and product variants are complete.
• Validate product type/category and sales/purchase/manufacturing flags.
• Confirm SKU/barcode conventions and readiness for production use.

1. Units of measure

• Define unit categories and reference units.
• Set conversion ratios and precision standards.
• Validate quantity consistency for BoM and order execution.

1. BoM setup

• Create bills of materials for each manufactured product.
• Add components, quantities, and unit-of-measure mapping.
• Define variant applicability where needed.
• Establish review and approval control for BoM updates.

1. Routing setup

• Build routings with ordered operations.
• Define default durations and start-next-operation behavior.
• Add notes and Work instruction where needed.
• Validate against real production flow.

1. Work centers

• Create work center name/code standards.
• Set working hours, capacity, and time efficiency assumptions.
• Define cost/hour references for review reporting.

1. Warehouse handoff design

• Confirm Components warehouse for issue.
• Confirm Finished Products warehouse for receipt.
• Validate issue and receipt handoff sequence for production closure.

1. Readiness and consumption rules

• Define Manufacturing Readiness policy (all components vs first operation availability).
• Define consumption behavior (strict vs flexible).
• Confirm fields for qty to consume, reserved, and consumed.

1. Shortage and purchase-request policy

• Define when to create purchase request from manufacturing shortages.
• Define owner for shortage escalation and follow-up.
• Set review routine for recurring shortage items.

1. Costing expectations

• Confirm cost/hour assumptions by work center.
• Align expectations for Total Material Cost and Total Labour Cost review.
• Define variance thresholds for management escalation.

1. Go-live test scenarios

• Test one full cycle: BoM + routing + manufacturing order + execution + consumption + finished-goods posting.
• Test shortage flow with create purchase request.
• Test status transitions: draft / planned / confirmed / in progress / done / canceled.
• Test planned vs actual quantity, time tracking, and variance review.

1) Create a BoM for a manufactured product

1. Select or create the manufactured product.
2. Create the BoM and add components.
3. Enter quantities and assign units of measure.
4. Review completeness and production readiness.
5. Approve/standardize the BoM for release.

2) Create routing and work centers

1. Define required work centers.
2. Create routing for the target product.
3. Add operations in execution order.
4. Assign duration assumptions and Work instruction notes.
5. Validate routing against real shop-floor sequence.

3) Create and release a manufacturing order

1. Select product and quantity to produce.
2. Link BoM and routing.
3. Set planned start/planned finished dates and owner.
4. Check material readiness and shortages.
5. Confirm and release the order.

4) Execute work order

1. Start work order at assigned work center.
2. Progress through operations in sequence.
3. Update status (pause/continue) and track production time.
4. Record blockers and waiting states.
5. Mark operation complete when finished.

5) Consume materials and receive finished goods

1. Issue components from Components warehouse.
2. Record actual consumption against planned requirement.
3. Confirm quantity produced.
4. Receive output in Finished Products warehouse.
5. Close work order and manufacturing order with handoff verification.

6) Handle shortages with purchase requests

1. Identify missing component quantities during readiness checks.
2. Create purchase request from manufacturing.
3. Track shortage impact on release and schedule.
4. Resume execution when components are available.
5. Log recurring shortage causes for planning improvement.

7) Monthly production review

1. Review work order status summary and throughput by period.
2. Compare planned vs actual output.
3. Review material usage variance and recurring exceptions.
4. Review work-center cost/time performance.
5. Review BoM changes logs and identify control gaps.
6. Assign corrective actions for next cycle.

Work order summary

• Contains: work orders by status, owner, and work center.
• Used by: Production Supervisor, Planner.
• Decision supported: daily release priority and bottleneck escalation.

Throughput by period

• Contains: quantity produced by day/week/month and trend context.
• Used by: Operations management, Planner.
• Decision supported: capacity and output reliability planning.

Planned vs actual output

• Contains: quantity to produce vs quantity produced by order/product.
• Used by: Production Supervisor, Operations manager.
• Decision supported: schedule correction and execution discipline review.

Material usage and variance

• Contains: planned component usage vs consumed quantities and key deviations.
• Used by: Manufacturing Admin, Inventory/Warehouse Coordinator.
• Decision supported: BoM accuracy updates and consumption control actions.

Cost and variance review

• Contains: Cost/Hour context, Total Material Cost, Total Labour Cost, and duration deviation indicators.
• Used by: Operations management, finance reviewers.
• Decision supported: corrective action on cost drift and productivity issues.

BoM changes logs

• Contains: change type, quantity change, date/time, and user history.
• Used by: Manufacturing Admin, reviewers/auditors.
• Decision supported: master-data governance and change-accountability control.

Components are missing at release time

• Check availability in the Components warehouse.
• Confirm reserved quantities are not locked by another order.
• Create purchase request if shortage blocks planned release.

Routing does not match real production flow

• Review operation sequence with supervisor and work center lead.
• Update routing order and durations under controlled approval.
• Revalidate with one pilot order before broad release.

Work order cannot start

• Verify manufacturing order status is confirmed/in progress per policy.
• Check material readiness rule for required components.
• Confirm work center assignment and owner permissions.

Consumption looks wrong

• Compare qty to consume vs consumed quantities by operation.
• Review unit-of-measure conversions and precision settings.
• Investigate manual overrides and enforce strict behavior where needed.

Finished goods were not posted correctly

• Verify quantity produced entry before closure.
• Confirm target Finished Products warehouse selection.
• Recheck issue/receipt handoff logs before re-posting adjustments.

Shortage-driven purchase request is missing

• Confirm shortage threshold and trigger policy configuration.
• Validate user role can create purchase request from manufacturing.
• Check request linkage in order references.

BoM changed without control

• Review BoM changes logs and identify who changed what.
• Restrict edit rights to Manufacturing Admin/designated owner.
• Enforce approval flow before applying master-data updates.

Teams confuse Manufacturing with Inventory ownership

• Clarify ownership matrix in onboarding:
• Manufacturing owns how products are built and executed.
• Inventory owns stock balances and warehouse movement control.
• Procurement owns supplier buying and purchase cycles.