Manufacturing

Bills of Materials

Go to Manufacturing > Master Data > Bills of Materials.

BOM Form - All Fields

Components Tab

Add raw materials and sub-assemblies:

• Product - The raw material or sub-component.
• Quantity - Amount per BOM quantity.
• Unit of Measure - Can differ from product UoM (e.g. kg vs g).
• Scrap (%) - Expected waste %. Quickenerp reserves extra material.
• Operations - Which operation consumes this component.
• Apply on Variants - For multi-variant products.

By-Products Tab

If the production process yields secondary products (e.g. sawdust, scrap metal), add them here. The by-product quantity is deducted from total production cost.

Multi-Level BOMs (Sub-Assemblies)

If a component has its own BOM, Quickenerp recursively explodes it. Create a BOM for the sub-assembly, then add the sub-assembly as a component. When the MO is created, the system shows all raw materials at the lowest level.

Kit (Phantom) BOM

For products sold as a set but not physically assembled. The components are delivered individually. Use BOM Type = "Kit". No MO is created - the kit is delivered directly from stock of its components.

BOM Versioning

Create multiple BOMs for the same product. Set one as active. Use BOM version comparison to review changes. When you archive an old BOM, new MOs use the active BOM.

Production Planning

Replenishment-Based MO Creation

Products with route "Manufacture" and a reordering rule trigger MO creation:

1. Go to Inventory > Master Data > Reordering Rules.
2. Set route = Manufacture.
3. When stock drops below minimum, the replenishment engine creates an MO.

Planned Orders

Go to Manufacturing > Planning > Planned Orders. These are tentative MOs not yet confirmed. Review and confirm them in batch. Useful for medium-term capacity planning.

MRP (Material Requirements Planning)

For advanced planning:

1. Go to Manufacturing > Planning > MRP.
2. Click Run MRP.
3. Quickenerp analyzes:

• Current stock levels.
• Open sales orders.
• Forecasted demand.
• Reordering rules.
• BOM structure (explodes multi-level BOMs).

Production Scheduling

The Gantt view in Manufacturing Orders shows scheduled MOs across work centers. Drag and drop to reschedule. Filter by work center, date, product.

Manufacturing Reporting

Manufacturing Analysis

Go to Manufacturing > Reporting > Manufacturing Analysis. Pivot table with:

• Dimensions: Product, BOM, Work Center, Operation, Vendor (for subcontracting), Date.
• Measures: Quantity Produced, Planned Quantity, Duration (hours), Cost, Scrap Quantity.
• Filters: Order Status, Date Range, Product Category.

Cost Analysis

Open a completed MO → Cost Analysis button. See:

• Raw Material Cost - Sum of all consumed components - cost price.
• Operation Cost - Time spent at each work center - hourly cost.
• Total Cost - Material + Operations.
• Unit Cost - Total Cost / Quantity Produced.

Work Center Performance

Go to Reporting > Work Center Performance. See for each work center:

• Planned hours vs actual hours.
• OEE percentage.
• Load rate (scheduled hours / available hours).
• Number of MOs processed.

Best Practices

• Review work center load weekly to avoid bottlenecks.
• Track scrap percentage per product to identify quality issues.
• Compare actual vs planned costs to improve BOM accuracy.
• Use OEE to identify underperforming work centers.