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Production Order Lifecycle Guide

A step-by-step walkthrough of the manufacturing workflow from setup to completion.

Phase 1: System Setup

Before starting a production order, ensure your master data is correctly configured.

  1. Define Configurations: Navigate to Config to set up Work Centres (machines/stations), Shift Calendars, and Cost Rates.
  2. Create Items: Under Inventory, define your Raw Materials (components) and Finished Goods (the final products).
  3. Establish BOM & Routing: In BOM, create a Bill of Materials for your Finished Good, mapping the required materials and specifying the routing operations across different work centres.
  4. Set Quality Plans: In Quality, define inspection criteria and checklists for the product.

Phase 2: Order Creation & Material Issue

  1. Create Production Order: Go to Production, click "New Order", select the Finished Good, BOM, quantity, and dates. Set status to "Released".
  2. Issue Materials: Open the order, go to the Materials tab, and issue the required raw materials from the main inventory to the Shop Floor (WIP).

Phase 3: Shop Floor Execution

  1. Track WIP: As production moves between stations (e.g., Mixing to Assembly), update the WIP Ledger to track the flow of semi-finished goods.
  2. Log Operations: Record the actual time taken by operators and machines at each work centre.
  3. Record Wastage: If any materials are scrapped during the process, record them in the Wastage section to keep accurate inventory and costing.

Phase 4: Quality Control

  1. Perform Inspections: Create an Inspection Order against the Production Order or specific Lots to verify against the Quality Plan.
  2. Handle Defects: If a test fails, generate an NCR (Non-Conformance Report) to document the defect.
  3. Root Cause Action: If the defect highlights a systemic issue, create a CAPA (Corrective Action) to resolve the root cause.

Phase 5: Order Completion & Costing

  1. FG Receipt: Once production and QC are complete, record an FG Receipt to move the final products from WIP into the main inventory for sale.
  2. Close Order: Change the Production Order status to "Completed".
  3. Cost Variance Analysis: Review the Cost Variance tab to compare Standard Expected Costs vs. Actual Incurred Costs (materials, labor, overhead) to evaluate profitability and efficiency.