BOMs and Routings can be entered in item's details.
1. Go to the Stock section.
2. Find the item.
3. Open its details and scroll down to Bills of Materials and Routings
4. Click on the "+" button to add new.
Important! If an article is defined as a procured item (option "This is a procured item" is checked), then these sections are hidden and Purchase Terms table is displayed instead.
You can have as many levels as you wish for a BOM.
It works simply: if you have a subassembly (which has a BOM and routing) and you want to use that in a product, then add the subassembly to the product’s BOM. Now you have a multi-level BOM.
Thus, each sub-level assembly has to have a stock article.
If you are making a manufacturing order for the top level, and any of the lower level assemblies are not in stock, then the manufacturing operations for the sub-level components will be nested under the same manufacturing order.
Using the "Play" and "Stop" buttons, which register the start and end of the operation. This data can be compared with what was planned. It is also possible to enter comments during production.
Workers will see the reporting screen which can be accessed from
- section "My production plan";
- from the MO when you click on "Go to production" button; or
- from the internet kiosk.
Options 1 and 2 will take you to the same screen. On that screen you can report:
- Consumed materials in the Materials table:
- individually (shopping cart icon on material line), and
- in bulk by indicating the number of products finished (big shopping cart icon on the top right of materials table).
- Start/Stop times and finished quantity in the Operations table.
- MO is finished, the "Finish production" button will finalize the MO.
- Parts with serial numbers used in specific products with serial numbers (if the functionality is enabled)
See also the question "Can I edit quantities of raw materials in an existing Manufacturing Order?"
See more in User Manual
- It is possible to edit the bookings in a Manufacturing Order (MO) by editing the booked quantities with buttons "Add a booking" and "Return to stock" in the materials section of the MO. This easily allows you to reduce materials or add extra materials if needed.
- When you are finishing a MO, then if not all materials are marked as consumed, the software will ask you whether you would like to release or consume the unused.
- If you are reporting consumed materials with the function "Consume parts for ready products", then the software will consume all parts according to its BOM. If there are extra materials needed (e.g. you overproduce), the software will try to automatically make extra bookings if these have not been made manually earlier.
- Please take note, if you change a BOM, this will not influence any MO that was created previously.
See more in User Manual
- Through a Customer Order (CO).
If you book goods for a CO (button “Check stock and book goods”), there are two checkboxes you can tick: (1) generate manufacturing orders and (2) generate purchase orders for missing materials.
Here the available materials are booked to the MOs and POs are raised for the missing materials.
See User Manual
- Creating a MO directly in Production Planning -> Manufacturing Orders.
If MO is created then Available raw materials are booked for the MO automatically and if some are missing, these need to be procured. POs can be directly created from the MO.
If the raw materials have a min. quantity indicated (even 0), then the missing requirements will also show up in Stock -> Critical on-hand.
See User Manual
- Through the Forecasting.
If MO is created then Available raw materials are booked for the MO automatically, and if some are missing, these need to be procured.
The material requirements shown on Forecasting page do not take into account any stock quantities, this lists full requirements. If the MO is created and the raw materials have a min. quantity indicated (even 0), then the missing requirements will also show up in Stock -> Critical on-hand.
See User Manual
- Through Critical on-hand report.
If you have set minimum stock levels for products (even 0), then this report will show you which products you need to make and how many. At the end of each item’s line, there is a button to start a Manufacturing Order for this item and quantity. (The following the same as in course (2)).
See User Manual
If you make-to-order then course (1) could be the easiest; if you make-to-stock then courses (2), (3) and (4) might give the best results.
See also the answer to the question "How to raise purchasing or manufacturing requirements from a Customer Order?"
You would need to use the Critical on-hand report in which sums up all requirements.
Creating Purchase Orders (POs) from Critical on-hand list:
- For each item, it is possible to set its critical low quantity at stock under its details in Stock -> Items. After falling below, the available quantity will turn red, notifying of the need to purchase it.
- Even if you do not keep stock for some items we recommend having the Min. stock quantity for each item at least defined as 0. Then, if there is a need to order it, the item will show up in the list.
- If the Min. stock quantity has been assigned to all items, the Critical on-hand report will show all material requirements for Purchasing. This includes materials that are required in manufacturing orders, but there is not enough in stock.
- To see the list of items whose quantity is below their set critical quantity, go to Stock -> Critical on-hand. This can also be accessed from the Dashboard from Min. stock indicator.
- To create POs you need to click on the shopping cart icon on the end of the materials line. MRPeasy will also look for other materials on that list that can be purchased from the same vendor and add them on the same PO.
See more in User Manual
Please also see answer How do I know what materials I need to purchase?
To manage subcontracted services or outsourced operations, you need to enable the functionality in Settings - Professional functions.
This function allows you to issue Purchase Orders for the subcontractors, free issue parts, and create shipments.
There are two ways to handle subcontracting when you free issue parts
- Using Purchase Orders (POs).
The process is very similar to purchasing materials. Just create a PO, book materials for it, and ship.
The item needs a BOM.
The item can be set either as a manufactured or a procured item.
Purchase Terms function also works for populating the vendor and price on the PO.
See more in User Manual
- Using Manufacturing Orders (MOs).
The process is very similar to manufacturing items.
The item needs to be set as a manufactured item (i.e. not a procured item). It needs a BOM and a Routing.
In the routing, you can choose the vendor from the workstation group box. Then, in the MO you will see a new section “Subcontracts”, where you can issue a PO.
See more in User Manual here and here
- If the half-product is set as a procured item, then you will see the half-product in the materials list for the production. The materials for the half-product need to be booked in the purchase order created for the half-product.
- If the half-product is set as a "manufactured item", then you will see the subcontracted job scheduled in the production calendar and the parts booked directly under the manufacturing order.
You can directly issue a Purchase Order from the "Subcontracts" section of the manufacturing order.
There are currently two options for re-scheduling a manufacturing order:
1. By changing any date in the manufacturing order, in the Operations section.
This does not affect other dates. All other dates should be changed manually.
2. By going to Production planning -> Production schedule and choosing the "Manufacturing orders" view type (It is selected by default). Any manufacturing order that has not been started yet can be dragged by mouse to a new date. This will reschedule it completely and all dates will be updated accordingly. You can see a demonstration of this functionality in our video:
https://youtu.be/S_WfENGcyjY?t=145 (it starts at 2:05).
Changing dates in purchase orders do not reschedule the associated manufacturing orders. The manufacturing order's part status will simply update accordingly (if parts are expected on time, or late).
The overlapping must be defined in the routing when entering work operations. If an operation starts before the previous one has ended, a checkbox "Overlap" must be checked. When checked, it is asked to enter the quantity. This field specifies the number of products that must be ready in the previous operation when the next operation begins. Specifying this as zero would mean complete overlapping, parallel execution.
For production orders in the chart "Sequence", it is possible to specify the number of the operations that precede the operation (with or without overlapping).
MRPeasy allows to click on "start" button even if all materials are not reported arrived, or the previous procedure is not reported completed. This avoids situations when one worker forgets to report and all the next workers are locked out.
If resources are not physically available, then logically, there is no reason to click "start".
If resources are physically available, even if someone forgot to report it, then the operation should still start and be reported correctly.
These situations should never stop the factory from operating.
This information is available at Production Planning -> Manufacturing orders: please click the button 'Choose columns' in the upper right corner of the table and scroll the list to the bottom. The following columns will be useful:
- Planned time, h
- Actual time, h
- Duration difference, h
- Duration difference %.
This is a question of methodology.
For example, in a real-life scenario, on a production line, when an operation was finished, the next operation can and should be immediately performed - even if the previous worker forgets or did not have time to yet report it in software.
If the software would lock up, one of two serious consequences can happen:
- workers would go on working and omit to report at all since the software is locked. It would be very difficult to backtrack all actions which should have been reported, but were not;
- production would stop until the reason for lock-up is found and corrected. This could potentially result in serious delays and financial loss.
Situations like these, if solved with a software procedure instead of an organizational procedure (e.g. implementing Six Sigma, ISO, or other management methodologies; or simple due diligence by following stock lot numbers, etc.), can result in other unforeseen but very serious consequences.
When your product is fully or partly engineered according to customer's specifications, or if the product's manufacturing technology is standardized, but the product is configured to customer's specifications, then these manufacturing modes are called Engineer-to-Order or Configure-to-Order.
When no two products are the same, then each new product is a totally new item for the software and must be separately defined, in most cases.
For saving time in these situations, MRPeasy has various functionality in place:
- You can very quickly duplicate and modify a similar product, which has been made before, or which is entered on purpose as the technological foundation.
- The function "BOM with Parameters / Matrix BOM" helps to pre-define all possible product variations if the configurations are parametric, and parameter values are discrete (i.e. can be fully pre-defined).
- You can upload new engineered products via CSV or via an API connection.
- You can use "Make-to-Order Manufacturing Orders" for simple bespoke products, where you can manually type in required parts during Manufacturing Order creation, without the need for a BOM or a Routing.
All the previous options are demonstrated in the demo video about "Make to Order Manufacturing": https://www.mrpeasy.com/demo-videos/make-to-order-manufacturing/
Since these manufacturing modes create many single-use-only items, it is recommended to regularly archive the old items, after they are no longer in use.