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Introduction
Functional Overview
Terminology
Infrastructure
Setup
Execution
Integration with WMS

INTRODUCTION TO MANUFACTURING

Compiere Manufacturing provides functionality to support the manufacturing requirements of the small to mid-sized discrete manufacturing industry.  It was introduced to Compiere in version 3.6
It enables you to manufacture items, sub-assemblies and finished goods requiring multiple mandatory and optional manufacturing operations. You can track moves and costs related to labor, material and scrap at each step.

MANUFACTURING FUNCTIONAL OVERVIEW

Compiere Manufacturing helps companies to streamline and automate critical business functions resulting in lower manufacturing cost and improved efficiencies. It is a tightly integrated manufacturing solution providing tight production control, cost management and reporting.

MANUFACTURING TERMINOLOGY

Terminology

Bill of Materials

List of components (products) required to assemble a product. Also referred to as BOM.

Component

Line item of the Bill of Materials or Work Order. Components are used to create the Product Assembly. The terms Component and Material are used interchangeably.

Work Order

Document that tracks the components required to assemble a product and the assembly process.

Product Assembly

Identifies the product that is going to be assembled using a Work Order

Routing

Describes all the operations necessary to assemble a product. Each operation takes place in a work center and uses resources assigned to that work center.

Component Issue

Work Order Transaction that moves a component from Inventory to the Work Order. The component is intended for consumption in the assembly process.

Component Return

Work Order Transaction that moves a component from the Work Order to Inventory. These are typically components that were unused in the assembly process or failed quality assurance.

Resource Usage

Work Order Transaction that commits charges for operation resources to a Work Order. Resources include both labor and equipment.

Assembly Completion

Work Order Transaction that moves the finished product assembly from the Work Order to Inventory.

Assembly Return

Work Order Transaction that moves the finished product assembly from Inventory to the Work Order. This is typically used in case the finished product assembly requires some rework.

Work Order Move

Work Order Transaction that consumes components and creates the finished product assembly. It tracks the movement of the in-progress product assembly across routing operations.

Supply Type

Specifies the sourcing option for a component. Components with a push supply type must be issued from the Inventory to the Work Order by explicitly entering and completing a Component Issue transaction. Components with an operation pull or assembly pull supply type are issued automatically by Compiere when the operation or assembly is completed. Pull is sometimes referred to as backflush.

Cost Basis Type

Specifies how cost for materials and resources is to be allocated to determine the cost of manufacturing a product assembly. The cost may be tracked by Per Item or Per Batch.

Cost Charge Type

Specifies how resources will be charged for a work order. Resources with a cost charge type of Manual must be explicitly charged by entering and completing a Resource Usage transaction. Resources with an Automatic cost charge type will be charged automatically by Compiere when an operation is completed.

Work Order Class

One time setup to control document type and accounting setup for Work Orders and Work Order Transactions.

Delivery Locator

Identifies a locator in a warehouse where the finished product assembly will be completed into.

Staging Locator

Intermediate locator where Warehouse Management Tasks move picked components to before a Component Issue transaction finally moves them to the Work Order.

Work Center

Identifies a location inside a warehouse where manufacturing operations are carried out.

MANUFACTURING INFRASTRUCTURE

Bill of Materials functionality

Bill of Materials

Use the Bill of Materials to specify the components that are required to manufacture the product assembly, and how many of each component are required. You can define Bills of Material with any number of levels.

For more information on Bill of Materials, refer to the Bill of Materials section of the Utilities chapter.

Costing functionality

Standard Costing

You must use Standard Costing to enable product costs to be tracked using Compiere Manufacturing.
For more information on Standard Costing, refer to the Costing chapter.

Cost Rollup

The Cost Rollup process calculates the standard cost of a product assembly based on the BOM, Routing and cost definitions defined in Compiere. It can be used to get an estimate of the standard cost of manufacturing a product assembly. It can also be used to simulate the cost of manufacturing using alternate BOM and Routing for a product assembly. This process calculates and sums the following costs: material and material overhead costs of components, resource costs of resources used in operations, overhead costs of work centers where operations take place and material overhead costs of the product assembly itself. You will need to define a new Material Cost Element with Manufacturing Material Cost checked.

Standard Cost Update

Use the Standard Cost Update process to update the cost of product assemblies based on the cost calculated by the Cost Rollup process.

Manufacturing Setup

Work Order Class

Define work order classes to specify the work order related document types and accounts to be used for any work order belonging to that class.

Production Resource

Use production resources to track labor and equipment usage in work orders. You can assign production resources to work centers in the Work Center window. Once they are assigned, you can enter production resources in routings and work orders. You can enter a cost to be charged for the resource in the Product Costs window.

Work Center

Define a work center to identify a production area consisting of people and machines. A work center is associated with a specific warehouse. You can enter work center overhead costs to be charged per item or by batch.

Operation

Define operation names that can be used throughout the organization or shared across organizations. This helps you standardize operation names and descriptions.

Standard Operation

Define standard operations to completely describe one unit of work. These are standard operations that are performed repetitively across many manufacturing activities. Each operation is complete in itself and is not dependent on other operations in any way. Copy standard operations to routings and work orders to simplify data entry. Document attachments on standard operations are automatically copied to routings and work orders.

Routing

Define a routing to describe all the operations necessary to manufacture a product. Operations can be mandatory or optional and must take place in a work center. You can optionally specify the setup and run time and resources required for each operation. A routing can be defined for any BOM product. Routings are specific to a warehouse. You can mark one routing as the default per product per warehouse. This is routing is automatically defaulted in work orders. You can also mark one routing as the default per product for the Cost Rollup process.

Work Order Sort Criteria

Define sorting criteria for work order operations. This is used to sort work order operations for bulk processing in the Generate Work Operation Requirements window and the Wave Planning (Work Order Selection) window.

Order Type Group

If you plan to use WMS picking rules to source components for production in MFG, define an order type group that includes your Work Order document type. For more details on the Order Type Group window, see the Warehouse Management chapter.

Manufacturing Execution

Work Orders

Define a work order to track assembly of a product. Enter a product assembly and quantity and then select a BOM and Routing to describe the component requirements and manufacturing operations. Pick a warehouse and locator where the finished product assembly will be stored. A work order can be generated by the material planning engine as well.
Once you are satisfied with the work order, you should prepare it. This releases the work order to the shop floor and allows you to perform transactions. If you entered a scheduled from or to date and operation setup and run times, the infinite capacity scheduler will calculate work order operation and resource schedules when you prepare the work order.
Once you complete executing all work order transactions, you can complete the work order. This prevents any future transactions and calculates work order value variances. You cannot complete a work order if you have open work order transactions.

Link Work Orders and Sales Orders

You can manually create a work order and link it to an existing sales order. The sales order must be of type Standard. This functionality is for reference purposes only and will not automatically generate shipments once the work order is executed.

Work Order Types

You can create Standard, Repair, or Refurbish work orders. For Repair or Refurbish work orders, you can create a work order that accepts its product assembly as a component. This allows you to issue the same item to the work order (in addition to other components if necessary) as the item that comes out.

Work Order Operations

Define the mandatory and optional operations required to manufacture the product assembly. The operations can be copied from the default routing for the product assembly by using the Copy Work Operation Requirements. This process copies over the operations and resources required for each operation from the Routing definition and the materials required for each operation from the BOM definition. Alternatively, you can enter this information manually.
Each work order is executed in a specific warehouse. Each operation must take place in a work center in this same warehouse and utilize resources associated with the work center. Enter an operation setup time and runtime per unit manufactured to enable work order scheduling calculations.

Work Order Components

Define the list of components and quantity required in each routing operation to manufacture the product assembly. This list can be defaulted from the BOM using the Copy Work Operation Requirements or BOM Explode functions. Make updates as needed before running any work order transactions.
You can track component quantities issued and consumed in a work order. Indicate whether the components are going to be issued via explicit component issue transactions (Supply Type Pull) or automatically by Compiere (Supply Type Operation Pull or Assembly Pull). In case of pull or backflush components, enter the locator from where the component will be issued.

Work Order Resources

Define the list of resources required in each routing operation to manufacture the product assembly. This list can be defaulted from the Routing using the Copy Work Operation Requirements or it can be manually entered. Resources include both labor and equipment. Resources must be assigned to the operation's work center before they can be included here.
You can track resources charged in a work order. Indicate whether the resources are going to be charged via explicit resource usage transactions (Cost Charge Type Manual) or automatically by Compiere (Cost Charge Type Automatic)

Work Order Transactions

Use work order transactions to issue and return components and product assemblies, charge resources and to create product assemblies. The different types of work order transactions are Component Issue to Work Order, Component Return from Work Order, Resource Usage, Work Order Move, Assembly Completion to Inventory and Assembly Return from Inventory. These transactions may update Inventory and product costs depending on their type. These transactions result in accounting entries that track product movement and resource usage.

Component Issue to Work Order Transactions

Use these transactions to issue components from Inventory to a work order. You can continue to execute Work Order Move transactions to indicate assembly progress without issuing components, but you must issue all the required components before you can complete a finished product assembly into Inventory.
Components are issued to a specific operation and you can only issue components listed in the work order document. In the case of Repair and Refurbish work orders, you can also issue the product assembly to the work order. To automatically issue all work order components, run the Generate Push Component Lines function in the Work Order Transaction window or use the Generate Work Operation Requirements window. You can view components required, issued and consumed by querying a work order and viewing the component details.
Component Issue transactions are automatically generated by work order moves for components with Pull supply types. You cannot enter component issue transactions for such components.

Resource Usage Transactions

Use these transactions to charge resources to a work order. Resources may be charged at anytime so long as the work order is in progress.
Resources are charged to a specific operation. You can charge any resources so long as they are assigned to the specific operation's work center even if they were not initially included in the work order. To automatically charge all required resources as defined in the work order, run the Create Resource Transaction Lines function in the Work Order Transaction window, use the Generate Work Operation Requirements window or the Generate Resources Charges window.
Resource Usage transactions are automatically generated by work order moves for resources with Automatic cost charge type. You can enter resource usage transactions for such resources to track additional usage.

Work Order Move Transactions

Use work order moves to manufacture a product assembly step by step based on the operations in a work order. You can move a product assembly from one operation to another and also to intra-operation steps like Queue, Run and To Move. You can choose to move partial quantities to an operation and step but cannot move more than the quantity to be assembled specified in the work order. At any point in time, you can query the work order and look at the operation details to see the product assembly quantity at each operation and step. You can also choose to scrap product assemblies in these transactions.
Optionally check the Complete this Assembly checkbox to automatically move the product assembly through all the remaining mandatory operations and complete it into Inventory. Optional operations are not executed unless you explicitly move the product assembly to them.
Executing a work order move will automatically generate child transactions for Component Issue and Resource Usage for pull components and automatically charged resources. In addition, if you had chosen to complete the assembly, an Assembly Completion transaction will also be generated.

Assembly Completion to Inventory Transactions

Assembly completions are used to transfer the finished product assembly from the work order to Inventory. The delivery locator specified on the work order will be used by default, but can be overridden by the user when entering this transaction. You can complete partial quantities of the product assembly but cannot over-complete.
An assembly completion will fail if all required push components have not been issued to the work order.

Component Return from Work Order Transactions

Use component returns to return components from a work order back into Inventory. You can only return components issued to a work order but not consumed in work order moves.

Assembly Return from Inventory Transactions

Use assembly returns to return product assemblies from Inventory back to a work order. You can choose to return the assembly to any operation and redo the assembly operations.

Work Order Value

Use this window to view the value associated with the work order after completing and posting work order transactions. Once the work order is completed and posted, you can also view the variance between the estimated and actual costs.

MANUFACTURING SETUP

Document Types

First you will need to create the Work Order Document Type and Work Order Transaction Document Types. To do this, open the Document Types window from the Main Menu.


 
Create a new Document Type. Start by entering a name of the new Document Type in the Name field and enter the print text you would like to use for this Document Type in the Print Text field.

Select a GL Category of Manual or None using the drop menu for the GL Category field.

Select Work Order using the drop menu for the Document Base Type field.

Leave the Sales Transaction check box unselected.

Select the Document is Number Controlled check box if this document is Number controlled.

You may leave the Print Format field blank and the Document Sequence field blank. The Document Sequence determines the numbering of documents.

You can leave the Document Copies set to a value of 0.

Click 'Save' and add the Work Order Transaction Document Type using the steps listed above until both Document Types for Manufacturing are in place.

Verify Document Types

Once you have added the Manufacturing Document Types you must run the Verify Document Types process in Compiere. The Verify Document Types process ensures that there is a Document Type for all Document Base Types and creates the missing Period Controls for each Document Type.

To run the Verify Document Types process, open the Verify Document Types process from the Main Menu and click 'Ok' to proceed with the verification. Once the process completes Compiere will return the results of the verification..

Calendar Year and Period

Next, you will need to open the Period for the new Document Types. The Calendar Year and Period window allows you to define the Calendars that will be used for Reporting and Period Control. Each Tenant has one or more Calendars.

You can access the Calendar Year and Period window from the Main Menu.


 
Once the correct Calendar Year is open, select the correct period from the periods tab and click the 'Edit' button to view the appropriate period in Single Record view.

From this point click the Open/ Close all button and select the Open Period action from the Period Action drop menu to open the period for all document types. Then click 'OK' to proceed.

Compiere will complete the process and return the result of the Period Action update.

To open the period for specific Document Types, select the appropriate Document Type from the Period Control tab.

Work Order Account Setup

Currently only Standard Costing is supported for tracking product costs. You can choose Standard Costing in the Costing Method field of the Accounting Schema window.

You must specify values for the following accounts in the Default tab of the Accounting Schema: Work Order Material, Work Order Material Variance, Work Order Material Overhead, Work Order Material Overhead Variance, Work Order Resource, Work Order Resource Variance, Work Center Overhead, Work Order Overhead Variance, Overhead Absorption, Work Order Scrap, Resource Absorption and Material Overhead.

Once the values are in place you can create work order classes.

Work Order Class

You must create Work Order Classes to specify the work order related document types and accounts to be used for any work order belonging to that class. This one time setup is necessary before you start defining work orders.

The Work Order Document Type defined in the work order class will be automatically assigned to your work order when you pick the work order class. When you create work order transactions, they will inherit the Work Order Transaction Document Type from the work order class picked in the work order. The accounts defined in the class will be used during accounting of the work order and its transactions.

To define a Work Order Class, select the Work Order Class window from the Main Menu.

Enter a name for this Work Order Class in the Name field and optionally provide a description for this Work Order Class in the Description field.

Select a Work Order Document Type from the drop menu of the Work Order Document Type field.

Then select a Work Order Transaction Document Type from the drop menu of the Work Order Transaction Document Type field.

The Work Order Type restricts the work order classes available for selection in the work order based on its work order type.

Work order classes with no specified work order type are available for selection on any type of work order. Work order classes with a specified work order type can only be selected for that type of work order.

The Default check box is only available when a Work Order Type is selected.

Work order classes with a specified work order type and default checked will be automatically selected when defining that type of work order. You may choose to override this default value.

You can only have one default work order class for a given organization and work order type. This restriction is automatically enforced for you by Compiere.

Production Resource

You may optionally define production resources to track the cost of labor and equipment in work orders. Production resources must have a Person or Equipment Resource Group and may only be used in Manufacturing currently. Resources in the Other Resource Group are used for billing professional services and may not be used in Manufacturing. E.g. Mary Consultant.

Define Production Resources in the Production Resource window accessible from the Main Menu.

Enter the Name of the Production Resource, and a Description if you wish.

Choose a Resource Group of Person or Equipment.

If you have selected Person, optionally select a Skill. Skills are defined in the Skill window accessible from the Main Menu.

Enter a UOM by which the product will typically be charged. Choose a Product Category and Tax Category.

If you have selected Equipment Resource Group, optionally enter Make and Model of the equipment and indicate if a Permit is Required for use of this equipment.

Indicate if this production resource is to be charged automatically or manually by entering the Cost Charge Type. Currently, production resources are charged on a Per Item basis type only.

Click on the Accounting tab to enter the Accounting information for your Production Resource. Note that the Accounting tab will only be displayed if your Preferences indicate it.

The values for the accounts in this tab have defaulted from the Product Category selected in the Production Resource tab. You can leave these values as they are or you may modify them as necessary. The Accounts can be modified by clicking on the button of the desired account.

The Resource Absorption account is used to offset the resource value in resource usage transactions. For a description of the other accounts, view the Accounting section in the Products chapter.

You may view and update production resources and their accounts in the Product window as well.

Work Center

Define work centers to identify a production area consisting of people and equipment. A work center is associated with a warehouse. Each manufacturing operation is executed in a work center.

Define work centers in the Work Center window accessible from the Main Menu.

Enter the Name of the Work Center.

Select a Warehouse where the work center is located.

Optionally enter a Description and Comment.

Check Default to indicate if this is the default work center for the selected warehouse. You can only have one default work center per warehouse.

Move to the Resource tab to assign Production Resources to this work center.

Enter one or more Production Resources. A Production Resource may be assigned to more than one Work Center.

Click on the Accounting tab to enter the Accounting information for your Work Center. Note that the Accounting tab will only be displayed if your Preferences indicate it.

The values for the accounts in this tab have defaulted from the Accounting Schema defaults. You can leave these values as they are or you may modify them as necessary. The Accounts can be modified by clicking on the button of the desired account.

The Work Center Overhead account is used to capture the overhead incurred in work centers.

Operation

Define operation names that can be used throughout the organization or shared across organizations. Define operations in the Operation window accessible from the Main Menu.

Enter the Name of the Operation.

Optionally enter a Description.

Standard Operation

Define standard operations to describe common performed and simplify data entry and maintenance. Copy standard operations to routings and work orders to simplify data entry. Document attachments on standard operations are automatically copied to routings and work orders.

Define standard operations in the Standard Operation window accessible from the Main Menu.

Select an Operation as the Name of the Standard Operation.

Optionally enter a Description and Comment.

Select a Warehouse and a Work Center within that warehouse where this operation is performed.

Optionally enter a Setup Time and Runtime per Unit to indicate how long it takes to setup this operation and perform it for manufacturing one unit of the product assembly.

Select a UOM of Day or Hour for the setup and run times.

Indicate if this operation is Hazmat or marked as Permit Required.

Click on the Resource tab to enter production resources required for execution of this operation.

Enter a Sequence to indicate the order in which this production resource is required.

Select a Production Resource that was previously assigned to the work center selected in the operation.

Enter a Per Unit Quantity and UOM to indicate the quantity of the production resource required for assembly of a single unit of the product assembly.

Select a Cost Charge Type of Manual or Automatic.

You can optionally choose to attach a document to the Standard Operation by clicking on the Paper Clip icon in the toolbar. When you create a Routing or Work Order operation by using a Standard Operation, any attachments on the Standard Operation will be copied over to the Routing or Work Order operation.

Routing

Define routings to describe all the operations necessary to manufacture a product assembly. One or more routings can be defined for BOM products. Routings are specific to each warehouse and operations in a routing must take place in a work center associated with that warehouse.

Define routings in the Routing window accessible from the Main Menu.

Enter a Name for the routing.

Select a Product Assembly for which this routing is defined.

Select a Warehouse for which this routing is defined.

Optionally enter a Description and Comment.

Mark a routing as the Default if you want. You can only have one default routing for a Product Assembly - Warehouse combination.

Mark a routing as the default to be used in the Cost Rollup program. You can only have one default cost rollup routing per Product Assembly.

Click on the Operation tab to enter the operations for your routing.

Enter a Sequence to indicate the order of your operation.

Now you can enter the operation manually or copy it from a Standard Operation. If you wish to copy it from a Standard Operation, select a standard operation and fields will be automatically copied to.

To enter an operation manually, select a Work Center associated with the routing warehouse. This is the area where the operation will be performed. Resources assigned to this work center can be charged for this operation.

Select an Operation as the Name for this routing operation.

Optionally enter a Description and Comment.

Indicate if this operation is optional by checking the Optional checkbox. If this checkbox is not checked, the operation is mandatory.

Optionally enter a Setup Time and Runtime per Unit to indicate how long it takes to setup this operation and perform it for manufacturing one unit of the product assembly.

Select a UOM of Day or Hour for the setup and run times.

Indicate if this operation is Hazmat or marked as Permit Required.

Click on the Resource tab to enter production resources required for execution of this operation.

Enter a Sequence to indicate the order in which this production resource is required.

Select a Production Resource that was previously assigned to the work center selected in the operation.

Enter a Per Unit Quantity and UOM to indicate the quantity of the production resource required for assembly of a single unit of the product assembly.

Select a Cost Charge Type of Manual or Automatic.

You can optionally choose to attach a document to Routing operations by clicking on the Paper Clip icon in the toolbar in the Operation tab. When you create a Work Order by using a Routing, any attachments on Routing operations will be copied over to the Work Order operations.

Work Order Sort Criteria

Work Order Sort Criteria are used to sort work order operations for bulk processing.

Define work order sort criteria in the Work Order Sort Criteria window accessible from the Main Menu.

Enter the Name of the Work Order Sort Criteria.

Optionally enter a Description.

The Document Base Type will default to Work Order and cannot be updated. This indicates this sort criteria is for Work Orders.

Move to the Sort Criteria Line tab to provide the sorting columns and sequence.

Enter a Sequence indicating the sorting priority of this sort criteria.

Select an Info Column indicating the column data that is to be used for sorting. Some options available for sorting are Work Order No and Operation Schedule Dates.

Select Ascending or Descending in the Order By Type field to provide the sorting direction.

WORK ORDER EXECUTION

Work Order

You can create Work Orders to track assembly of products. To create a Work Order, select the Work Order window from the Main Menu.

 

Select an Organization and Warehouse you want to work with. The completed product assembly will be placed in a locator of the warehouse you select. Only components from the selected warehouse can be consumed in the manufacturing process.

Select a Work Order Type from the drop menu. Choose Standard to manufacture product assemblies. Choose Repair or Refurbish to make fixes to an existing product.

Select a Work Order Class from the drop menu. The work order classes available for selection will be restricted based on organization and work order type. For more information on Work Order Class, refer to one of the previous sections on Work Order Class.

You can also associate a work order to a sales order or sales order line. To do this select Sales Order in the Source field and then select a Sales Order and optionally a Sales Order Line.

Important: The Sales Orders must be Standard sales orders (not POS, for example) and the lines must be for stocked items that have a validated BOM defined. Only sales order lines with un-shipped items are available for selection.

When a Sales Order Line is used as the method of work order creation, the product, quantity, and business partner information are automatically defaulted. When a work order is created with a sales order line as its source, certain things (such as product) cannot be changed.

Optionally enter a Supervisor and Representative. The Supervisor value you enter her defaults onto operations in the next tab. You can then create transactions for operations you supervise.

Select a Priority. Optionally provide a Description.

Select a product to be assembled in the Product Assembly field. Note that only stocked, manufactured products with a validated Manufacturing BOM are available for selection.

Pick a Delivery Locator where the finished product assembly will be stored. The locator must be in the warehouse you selected previously.

Then enter the Quantity you want to assemble. The UOM will default to the primary UOM defined for the product assembly.

The BOM and Routing values will be automatically populated if you defined defaults. Otherwise, you'll need to enter them.

Quantity Assembled indicates the number of product assemblies that have completed the manufacturing process and have been moved into Inventory.

Quantity Available indicates the number of product assemblies that have been completely manufactured but have not yet been moved from the Work Order to Inventory. This number also includes product assemblies returned from Inventory to the Work Order.

Quantity Scrapped indicates the number of units scrapped.

Optionally enter the Scheduled Dates for the product assembly job. If you only enter the from or to date, the other date will be automatically calculated using an infinite capacity scheduler when you prepare the work order. Setup and run times on the operations are used for scheduling calculations.

The Actual Date From will be automatically populated when you Prepare the Work Order document. The Actual Date To will be automatically populated once all required product assemblies are built.

Verify the correct date is in place for the Account Date field.

At this point you may save. After saving you cannot update certain values like work order type and work order class. Now you can enter the work order operations in the Operation tab. You can do this easily by clicking the Copy Work Operation Requirements button. This will copy operations and resources from the specified Routing and components from the specified BOM. The Operation Sequence No in the BOM Component of the BOM definition is matched to the routing operation sequence to determine the material requirements for each operation.

Once all the operations, components and resources are in place, you may click the 'Prepare' button to set the status of the work order to "In Progress" effectively releasing it to the shop floor.

For more information on Work Order statuses, refer to the section that appears later in this chapter called Work Order Statuses.

Work Order Operation

Define work order operations to describe all steps in the manufacturing process. Click on the Operation tab to enter operations for a work order.

Enter a Sequence number to indicate the order of operations.

Indicate if this operation is optional by checking the Optional check box. If this check box is not checked, the operation is mandatory.

Now you can enter the operation manually or copy it from a Standard Operation. If you wish to copy it from a Standard Operation, select a standard operation and fields will be automatically copied to.

To enter an operation manually, select a Work Center associated with the routing warehouse. This is the area where the operation will be performed. Resources assigned to this work center can be charged for this operation.

Select an Operation as the Name for this routing operation.

Optionally enter a Setup Time and Runtime per Unit to indicate how long it takes to setup this operation and perform it for manufacturing one unit of the product assembly.

Select a UOM of Day or Hour for the setup and run times.

Optionally enter a Supervisor and Description. You can then create transactions for operations you supervise.

Indicate if this operation is Hazmat or marked as Permit Required.

Now you can enter the material and resource requirements for each operation.

Work Order Component

Work Order Components are a listing of the material requirements for the work order. You can only issue items from Inventory to the work order if they are listed as Work Order Components. There is an exception for Repair or Refurbish Work Orders where you may issue the product assembly to the work order.

Click on the Component tab to enter components for each operation. You can enter components for a Work Order manually, by clicking the Copy Work Operation Requirements button in the Work Order tab, or by performing BOM Explode. Use the Copy Work Operation Requirements button to easily copy all the standard, optional and alternate components of the Bill of Materials to the Work Order Component lines. Operations and resources from the Routing will also be copied by this process.

Use the BOM Explode window accessible from the Main Menu to exercise control in picking optional and alternate Bill of Materials components. Note that there are some restrictions if the BOM component is a BOM item itself. For more details on BOM Explode, refer to the Bill of Materials section of the Utilities chapter.

You can always edit the work order components list after you have run a BOM Explode or Copy Work Operation Requirements process so long as the Work Order is in the Draft status.

Enter a Line No to indicate the order in which components are consumed for a particular operation.

Select a product in the Component field. This product must be stocked in the work order's warehouse.

Optionally enter a Description.

Enter a Per Unit Quantity to indicate the quantity of the component required per product assembly for this operation. The UOM defaults to the component's primary UOM. During work order execution, you can consume more components than you initially planned for.

Quantity Issued tracks the component quantity issued from Inventory to the Work Order minus any quantity returned back to Inventory.

Quantity Used indicates the number of components consumed in creation of the product assembly. If you have consumed a component, you cannot return it back to Inventory.

Supply Type lets you control if the component will be issued automatically (backflush) or not. If the Supply Type is Push, the component needs to be explicitly issued by entering and executing a Component Issue transaction. If the Supply Type is Operation Pull or Assembly Pull, Compiere will generate the necessary Component Issue transaction during Work Order Move or Assembly Completion respectively.

Cost Basis Type defaults to Per Item indicating that the component cost will be charged for each individual unit of the component consumed.

Work Order Resource

Work Order Resources are a listing of resources required in each routing operation to manufacture the product assembly. Click on the Resource tab to enter resources for each operation. You can enter the resources manually or by using the Copy Work Operation Requirements button in the Work Order tab.

Enter a Sequence No to indicate the order in which resources are required for a particular operation.

Select a production resource in the Production Resource field. This production resource must be assigned to the operation's work center in the Work Center window. During work order execution, you can use production resources even though you did not enter them here.

Optionally enter a Description.

Enter a Per Unit Quantity to indicate the quantity of the resource required per product assembly for this operation. The UOM defaults to the production resource's primary UOM. During work order execution, you can charge fewer or more units for a production resource than indicated here.

Quantity Used indicates the number of production resources consumed in creation of the product assembly.

Scheduled Date From and To are populated by an infinite capacity scheduler that runs when you Prepare the work order provided you have provided a Scheduled From or To date in the Work Order tab and setup and run times for the operations.

The Actual Date From and To will be automatically populated as you execute operations.

Cost Charge Type lets you indicate whether the production resource is going to be charged via explicit resource usage transactions (Cost Charge Type Manual) or automatically by Compiere (Cost Charge Type Automatic).

Work Order Statuses

To change the Status of a work order, from the Work Order window, review the information in place.

Click the Prepare button to set the status of this Work Order to "In-Progress." Once a Work Order is set to "In Progress," the Work Order is released to the shop floor and the work order attributes and components may not be changed.

Here is a list of valid Work Order Statuses and their definitions.

Status

Description

Drafted

A work order starts out in Drafted status. You may change any work order attributes or components (with possible restrictions based on Source). Once the work order information is reviewed, click Prepare to set the work order to In Progress status.

In Progress

The work order is released to the shop floor for execution. The work order is frozen for data entry and no attribute or component changes are permitted. Execute Work Order Transactions to issue components, charge resources, build or scrap product assemblies and complete them into Inventory. Optionally return product assemblies back to the work order in case fixes are needed. Once the required product assemblies are built and verified, click Complete.

Completed

No more product assemblies can be built. No more Work Order Transactions are permitted. Variances between the standard cost and actual cost will be available for viewing in the Work Order Value window. You can only complete a work order if there are no open work order transactions.

Voided

No further execution of the work order is permitted. All Work Order Transactions will be automatically reversed.

Closed

The work order is entirely executed and no further actions or status changes are permitted.

Work Order Transaction

Create Work Order Transactions to issue or return components, charge resource, build product assemblies, complete them to Inventory or return them back to the Work Order for rework. To create a Work Order Transaction, simply open the Work Order Transaction window from the Main Menu. Alternately, you can create transactions in batch mode using the Generate Work Operation Requirements window or the Generate Resources Charges window. These two windows are discussed in subsequent sections.


 

First verify the Organization selection.

Select the Work Order from the drop menu of the Work Order field. Work orders available for selection are restricted by the organization and to those with In Progress status. A number of fields will default from the Work Order like Product Assembly, Locator, Business Partner, etc.

Select the Work Order Transaction Type to indicate the type of transaction you want to enter.

If you select Component Issue to Work Order as the transaction type, the Generate Push Component Lines button will be displayed. Click this button to easily create Component Transaction Lines by copying all components with Supply Type Push for all operations in the Work Order. The Locator value you enter here will be used as the default locator for any new Component Transaction Lines you enter. It indicates the locator from which the component will be issued.

If you select Component Return from Inventory as the transaction type, the Generate Push Component Lines button will be displayed. Click this button to easily create Component Transaction Lines to return all unused components for all operations in the Work Order. The Locator value you enter here will be used as the default locator for any new Component Transaction Lines you enter. It indicates the locator to which the component will be returned.

If you select Resource Usage as the transaction type, the Create Resource Transaction Lines button will be displayed. Click this button to easily create Resource Transaction Lines by copying all production resources with Cost Charge Type Manual for all operations in the Work Order.

If you select Work Order Move, you will be prompted to enter the Operation From, Step From, Operation To, Step To and the Quantity of the product assembly you want to move. You can check Complete this Assembly to move the product assembly to the final operation and complete it into Inventory. The Optional checkboxes indicate if the operation you have selected is optional or not. Only forward operation moves are permitted. The valid list of operations is retrieved from the operations defined in the Work Order. The valid step options are Queued, Run, To Move and Scrap.

If you select Assembly Completion to Inventory as the transaction type, you will be prompted to enter the Quantity of the product assembly you wish to complete. The Locator indicates where the product assembly will be completed to.

If you select Assembly Return from Inventory as the transaction type, you must enter the Operation To indicating the routing operation the product assembly will be returned to. You can continue to rework the product assembly from this operation onwards. You will be prompted to enter the Quantity of the product assembly you wish to return. The Locator indicates where the product assembly will be returned from.

Once all of the information and required line items are in place, you may click the 'Complete' button to execute the transaction. You may void a work order transaction at any time so long as it is not closed. Any product moves will be appropriately reversed.

All work order transactions need to be Completed, Voided or Reversed before the work order can be completed.

Component Transaction Line

Component Transaction Lines are a list of the components processed by this transaction. Click on the Component Transaction Line tab to enter component lines for Component Issue or Component Return transactions. You can enter the components manually or by clicking the Generate Push Components Lines button in the Work Order Transaction tab.

These lines are automatically populated by Work Order Move and Assembly Completion transactions to show components consumed or movement of products.

Enter a Line No to indicate the order in which components are consumed for a particular operation.

Select an Operation to which this component is issued to or returned from.

Select a component in the Product field. This component must be entered in the operation's component requirements in the Work Order and must have a Supply Type of Push. In case of Repair or Refurbish Work Orders, you can include the product assembly here even it if is not listed as a component requirement.

Cost Basis Type defaults to Per Item.

Enter a Quantity indicating the quantity of the component being issued or returned. The UOM defaults to the component's primary UOM.

The Locator indicates where the component will be issued from or returned to.

Optionally enter a Description.

Resource Transaction Line

Resource Transaction Lines are a list of the resource processed by this transaction. Click on the Resource Transaction Line tab to enter resource lines for Resource Usage transactions. You can enter the resources manually or by clicking the Create Resource Transactions Lines button in the Work Order Transaction tab.

Enter a Sequence to indicate the order in which resources are consumed for a particular operation.

Select an Operation in which this resource is used.

Select a production resource in the Production Resource field.

Cost Basis Type defaults to Per Item.

Enter a Quantity indicating the quantity of the resource being used. The UOM defaults to the production resource's primary UOM.

Optionally enter a Description.

Generate Work Operation Requirements

Use this window to create work order transactions in batch-mode.

Enter search criteria to return a list of work order operations. If you check Supervised Operations Only, the search will only return those operations where you are marked as a Supervisor in the Operation tab of the Work Order window.

Select one or more operations or enter a number in the Process Rows field to select the first n result rows. Choose a transaction type to be generated. Valid values are Component Issue, Component Return or Resource Usage. Click Process to generate transactions.

In case of Component Issue, only components with Supply Type Push that have not already been issued will be issued. In case of Component Return, only unused components will be returned. In case of Resource Usage, only resources with Cost Charge Type Manual will be used.

In case you don't see the results you expect, check the log file for errors and warnings. Component issues may fail because of insufficient availability in the default warehouse locators.

Generate Resource Requirements

Use this window to quickly enter resource usage across work orders.

Enter search criteria to return a list of operations the resource may be charged to. Deselect Resource in Operation to return operations where the selected resource is not originally listed as a requirement.

Select one or more operations. Update the resource quantity used if needed. Click Process to generate Resource Usage transactions.

Work Order Value

Use this read-only window to view work order value details for material in and out, material overhead in and out, resource in and out, work center overhead in and out and scrap. This information is populated every time you post a completed work order transaction.

Once you Complete and post a work order, the variance values will be updated to show any difference between standard cost and actual cost.

INTEGRATION WITH WMS

Starting with Compiere Release 3.6, Compiere Manufacturing integrates with Compiere Warehouse Management to enhance component picking and assembly putaway.

Overview

If you have both MFG and WMS installed, licensed and setup, you can issue Work Order Components with a Supply Type of Push from Inventory to Work Orders using WMS picking rules. You can use WMS putaway rules to move finished product assemblies from the Delivery Locator to the locator identified by WMS rules. When you return unused components from Work Orders, you can leverage WMS putaway rules to place components back into their correct locators.
The user flow for picking components for Work Orders is similar to picking products for Shipments. Use the Wave Planning (Work Order Selection) window to create a wave for component issues to multiple Work Order Operations. Then use the Wave Release window to release the wave. Complete picking tasks and this will automatically issue the picked components from Inventory to the Work Orders.
To use the putaway rules, move the finished product assemblies or returned components to an staging locator and run the Putaway process using this staging locator as the source.

Execution

To pick components for production using WMS picking rules, first create a wave using the Wave Planning (Work Order Selection) window or the Wave Planning (Work Order Selection) process. You can access them both from the Main Menu.

Enter search criteria to return a list of work order operations. Only work order operations in need of Push components will be returned. Select one or more operations or enter a number in the Process Rows field to select the first n result rows. Choose a Work Order Fulfillment Rule to restrict component picking based on stock availability. Click Process to create a Wave.

Follow the outbound WMS flow to release the Wave and complete Tasks to issue the components to the Work Orders. For more details on WMS, view the Warehouse Management chapter.

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