Manufacturing in Emeron ERP #

The Manufacturing module in Emeron ERP is designed to streamline and optimise the production process. It integrates with other modules to conduct various manufacturing operations effectively.

• Workstations: Represents the locations or equipment where production activities are carried out.
• Job Cards: Provides detailed instructions and tracking for each step in the production process.
• Bill of Materials (BoM): Defines the components and raw materials needed to produce a finished product.
• Work Orders: Manages the creation, tracking, and execution of work orders based on MoMs.
• Production Planning: Helps in scheduling and optimizing production runs to meet demand and manage resources efficiently.
• Quality Control: Ensures products meet quality standards through inspections.
• Inventory Management: Integrates with the Inventory module to manage raw materials, work-in-progress, and finished goods.
• Reporting and Analytics: Offers insights into production performance, costs, and efficiency to support informed decision-making.

The Manufacturing module in Emeron ERP helps improve productivity, reduce costs, and enhance overall production efficiency by providing a unified platform for managing all aspects of the manufacturing process.

Manufacturing Dashboard #

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Number Cards #

In Emeron ERP, Number Cards are a type of widget or visual component that displays key metrics or numerical data in a dashboard. They are typically used to show quick, high-level insights that help users keep track of important business performance indicators or operational statistics.

1. Monthly Total Work Order :- You will get the total count of Work Orders which are in Open, In Progress, and Completed state. The Work Orders created one month before the current date will be displayed in the number card.
2. Monthly Completed Work Order :- The user will get the total count of Work Orders which are in the Completed state. The Work Orders created one month before the current date will be displayed in the number card.
3. Ongoing Job Card :- The user will get the total count of Job Cards that are not in the Completed state.
4. Monthly Quality Inspection :- The user will get the total count of Quality Inspection records which are in the Submitted state. The Work Orders created one month before the current date will be displayed in the number card.

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Dashboard #

You can see some predefined graph reports in the dashboard when you open the Manufacturing module. These reports are fully customizable, you can choose what to show or hide and also configure the metrics on which the reports are shown.

Produced Quantity #

The chart will give the information about the total quantity produced (using Work Order) in the last year on a Quarterly basis. Users can also view the chart data based on Daily, Weekly, Monthly, Yearly basis.

Completed Operation #

The chart will give information about the total number of operations completed in the last year on Quarterly basis. Users can also view the chart data based on Daily, Weekly, Monthly, Yearly basis.

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Work Order Analysis #

This chart will give the information about the number of Work Orders based on Not Started, In Process, Stopped, Completed statuses. This Donut chart will provide the information based on the last year’s Work Order data. Your can also change the date range by clicking on the Filter button.

Quality Inspection Analysis #

This chart will give information about the number of Quality Inspections based on Accepted and Rejected status. The chart type is a donut and it will provide the information based on the last year’s quality inspection data. Your can change the date range by clicking on the Filter button.

Pending Work Orders #

The chart will give information about the number of Work Orders that are pending based on the aging days. The number of aging days is calculated based on the difference between the current date and planned start / actual start date days.

Last Month Downtime Analysis #

The chart will give information about the total number of minutes a machine was not working in the last month. This helps the operator to know which machine has not performed well and requires maintenance.

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Work Order Quantity Analysis #

The chart will give information about the total number of quantities that are Pending and Completed based on the Work Orders every month for the last year.

Job Card Analysis #

The chart will give information about the total number of Job Cards which are in the Pending and Completed states every month for the last year.

Bill Of Materials #

A Bill of Materials is a list of items and sub-assemblies with quantities required to manufacture an Item.

A BOM may also contain the manufacturing operations required to manufacture the Item.

A Bill of Materials (BOM) is at the heart of the Manufacturing system and the most important document that will help to create other document types like Work Orders and Job Cards. Emeron ERP supports multi-level BOM. To know more, visit.

The BOM is a list of all materials (either bought or made) and operations that go into manufacturing a finished product or sub-assembly. In Emeron ERP, each item (sub-assembly) could have its own BOM hence forming a tree of Items with multiple levels.

To make accurate Purchase Requests, you must always maintain correct BOMs.

To access the BOM list, go to: > Home > Manufacturing > Bill of Materials > Bill of Materials

> Note that once a BOM is submitted, it cannot be edited. You can only cancel the existing, duplicate it and submit another one. A BOM is also linked to multiple places in the Manufacturing module, so making changes to it can be time-consuming and tedious. Hence it is a good practice to carefully think and fill out the BOMs before submitting.

1. Prerequisites #

Before creating and using a BOM, it is advised that you create the following first:

• Item
• Operation
• Workstation
• Routing

2. How to create a Bill of Materials #

1. Go to the Bill of Materials list, click on New.
2. Select the Item to be manufactured. The Item name, UoM, company, and currency will be fetched automatically.
3. Enter the quantity of the Item that will be manufactured from this Bill of Materials.
4. Under the Items table, select the raw materials (Items) required to manufacture the Item. Then proceed to:
5. Select the quantity of Raw Material used.
6. Set an Item operation here to be fetched in Work Orders later.
7. If this Item is a sub-assembly, the default BOM for it will be fetched.
8. Select the Source Warehouse to track inventory.
9. Enter the scrap percentage that will remain after this raw material is used.
10. Under the Scrap section, select the scrap Item that will be created when manufacturing and its quantity. The scrap Item can also have a Rate if it is a by-product and not waste. Skip this section if 100% of raw materials are completely utilized. If the scrap Item is the same as the Item to be manufactured, it is set as a Process Loss Item and its quantity is subtracted from the manufactured Item quantity.
11. Save and Submit.

In the Items table, you’ll see an option ‘Include Item in Manufacturing’. Raw Materials need to have this checkbox ticked. In case there are Operations or services you need to include in the BOM that are not necessarily an Item used for manufacturing, uncheck this checkbox. For example, treating the plastic with a chemical involves some cost but it is not an Item and the cost needs to be tracked.

2.1 Bill of Materials with Operations #

To add Operations tick the ‘With Operations’ checkbox. Now, an Operations table can be seen. This option is useful for tracking the costing of various Operations performed to manufacture the Item. Operations can be added easily by setting a template with the Routing master.

1. In the “Operations” table, add the operations that need to be performed to manufacture this particular Item.
2. For each operation, you will be asked to enter a Workstation where the Operation will be performed. A default Workstation can be set from the Operation document.
3. Enter the Operating Hourly Rate, Operation Time in minutes, and the Batch Size created with the Operation. The Operating Cost will be calculated based on these values.

> Note: Workstations are defined only for product costing and Work Order Operations scheduling purposes not tracking inventory. Inventory is tracked in Warehouses set in the Items table of the BOM.

Transfer Material Against needs to be set for a BOM With Operations. Materials can be transferred against a Work Order in bulk or individual Job Cards. Changing this affects whether the ‘Material Transfer for Manufacture’ is done against the Work Order at once or multiple times against the individual Job Cards. Setting this option depends on factors like time taken to manufacture the item, value of the items manufactured, number of parts used in manufacturing, the skill of your labor involved, etc.

2.2 Additional options when creating a Bill of Materials #

• Is Active: An Item could also be manufactured using an alternate set of materials/operations. In that case, uncheck this checkbox to disable this BOM and use another one.
• Is Default: This BOM will be selected by default in Work Orders etc. when the Item selected.
• Inspection Required: This will make ‘Quality Inspection’ mandatory for raw materials and the finished goods. Select the Quality Inspection Template after ticking this checkbox.
• Allow Alternative Item: Sometimes when manufacturing a finished good, specific materials may not be available. If you tick this, you can create and select an alternative item from the Item Alternative list. For example, using plastic beads instead of plastic crystals. For more details visit this page.
• Allow Same Item Multiple Times: In some manufacturing cases, the same item needs to be added twice. For example, two metal pipes of length 0.5m each to form another shape. Here the quantity cannot be simply set to 2 and be done since the UoM will show 1m as total but we need 0.5m + 0.5m in the form of two pipes for production. Ticking this checkbox allows you to select the same item multiple times.
• Set rate of sub-assembly item based on BOM: Enabling this checkbox will set the rate of sub-assembly items based on their BOMs. If unchecked, the rate will be fetched from the Valuation Rate of the sub-assembly Item. Incase of Phantom Item, this setting is ignored and valuation rate of the phantom item will always be based on the contents of its BOM.
• Is Phantom BOM: If this is checked, it means that this BOM does not produce any item. Instead, it is only a logical grouping of raw materials. The Production Item in this BOM should be a non-stock item. If this non-stock item is added as a “raw material” in any other BOM, the BOM will be exploded automatically regardless if explosion or multi-level BOM is enabled or not.
• Rate Of Materials Based On: The Rate of raw materials used can be calculated based on different parameters.
• Valuation Rate: The Valuation Rate set in the Item master.
• Last Purchase Rate: The Rate is fetched from the last Sales Order/Invoice.
• Price List: The Rate will be fetched from the Item Price. For more details, visit this page.

3. Features #

3.1 BOM Costing #

The Costing section in a BOM gives an approximate cost of manufacturing the Item.

The costing is calculated from the Valuation Rate of the raw materials/sub-assemblies involved and the Operation costs.

In case the BOM was submitted when the costs for Items/Operations were not updated, you can update the costs using the Update Cost button. This will fetch the latest price/costs.

The BOM cost can also be set to be updated automatically via Manufacturing Settings, ‘Update BOM Cost Automatically’ option.

3.2 Materials Required (Exploded) #

This table lists down all the raw materials required to manufacture an Item. It also fetches raw materials for the sub-assemblies/phantom items along with the quantities. The non-exploded table will not list the raw materials required for producing the sub-assemblies.

For example, to manufacture a plastic shaving brush you need some raw materials and the bristles as a sub-assembly. For the handle, you manufacture your own plastic, but for the bristles, you use raw plastic crystals.

3.2.1 Do Not Explode #

If user wants to exclude the exploded items then they have to enable the checkbox “Do Not Explode” in the BOM Item table. This option is made read only and is unchecked by default if Item is a Phantom Item.

Use Case: #

• Laptop
• Motherboard (Kept in stock)
• Keyboard

A company manufacture the Laptop which required two sub-assembly items as Motherboard and Keyboard. The company does the manufacturing once they received the order from the customer. The Manufacturing Time required for the Motherboard is more than the Keyboard, therefore the company does the manufacturing of the Motherboard individually irrespective of the sales orders and kept in the stock. As the item Motherboard is already in stock it helps to reduce the overall Manufacturing Time of the main item Laptop. Now while preparing the BOM for the Laptop in the Emeron ERP, they don’t want to Explode the BOM of the item Motherboard but they want to Explode the BOM of the item Keyboard. Therefore we have added the checkbox “Do Not Explode” for the BOM Item. With this user will enable the checkbox “Do Not Explode” for the item Motherboard and not for the item Keyboard.

3.3 Project and Website #

The BOM can be linked to a Project to track progress, Project costing, etc. In case of engineer to order, every order could be a Project and the sub-assemblies would be Tasks. The completion can be tracked by linking to a Project in that case.

The BOM can also be shown in the Website for Open-source hardware products. Open-source hardware is similar to open-source where the product specifications are listed publicly.

3.4 BOM Template #

With BOM template you can create BOMs for template items (against which you create variant items). These BOMs can be used as the default BOM while making Work Orders against the template Item’s variants. You can also add the template items as raw materials in the template BOM. While making Work Order from the BOM Template, Emeron ERP gives provision to select the Item Variant against the template Item, for more details check following screenshot.

The user can also make the BOM for the variant item using the template BOM. To make the variant BOM:

• Go to the BOM Template.
• Click on Create button.
• Click on Variant BOM.
• Select the Variant Item for which you want to make the BOM.
• If the raw materials in the BOM is a template Item, then system gives provision to select the Item Variant.

3.5 After Submitting #

Once the BOM is submitted, the following document types can be created against the BOM from the Dashboard:

4. Video #

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Workstation Type #

If users have the same types of multiple Workstations (Machines) and users want to auto-assign jobs to the available workstation based on workstation type then this feature is the good option for them. A Workstation Type document will allow you to set the same operating cost to multiple operations by just setting the Workstation Type in the Operations table in BOM or Routing.

After adding Workstation Type, users has to assign the Workstation Type to the respective Workstation and set the Workstation Type to the respective Operation in the BOM.

After setting up Workstation Type when user make the Work Order with Operations system will create Job Cards against the Operation and set the available Workstation based on the Workstation Type set in the BOM.

Operation #

An Operation refers to any manufacturing operation performed on the raw materials to process it further in the manufacturing path.

The Operation master stores a single manufacturing operation, its description and the Default Workstation for the Operation.

Prerequisites #

Before creating and using an Operation, it is advised that you create a Workstation first.

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How to create an Operation #

1. Go to the Operation list, click on New.
2. Enter a name for the Operation, for example, cutting.
3. Select the Default Workstation where the Operation will be performed. This will be fetched in BOMs and Work Orders.
4. Select a Quality Inspection Template for the operation in the Job Card section. It will be fetched on the Job Card for that particular operation when Work Order is created. When a new Quality Inspection is created from the Job card, then the same Quality Inspection Template is set for the Quality Inspection.
5. Optionally, add a description to describe what the Operation involves.
6. Save.

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Once saved, the following can be created against an Operation:

Routing #

Routing is a template of BOM Operations.

A Routing stores all Operations along with the description, hourly rate, operation time, batch size, etc. Creating a Routing for your BOM Operations is useful when similar Operations are used for manufacturing different items.

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Prerequisites #

• Operation
• Workstation

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How to Create a Routing #

1. Go to the Routing list, click on New.
2. Enter a name for the Routing.
3. Enter the Operations in the BOM Operation table:
4. Select the Operation.
5. The default Workstation will be fetched.
6. Enter the Hourly Rate for running this Operation.
7. Enter the Operation Time in minutes.
8. Enter the Batch Size, i.e. the number of units processed in this Operation.
9. The Operating Cost will be calculated based on the Hourly Rate and the Operation Time.
10. Save.

Once created, a Routing can be selected in a BOM to fetch the Operations stored in the Routing.

Sequence ID in Routing #

Sequence ID enforces the users to complete the operations sequentially via Job Card. In case a user tries to complete an operation before completing any of its precedent operations as per the Sequence ID, the system throws a validation error.

Manufacturing Reports #

There are various reports in the Manufacturing module that help you track Work Order progress, production analytics, BOM reports, etc.

In all of these reports, you can set a chart to show a visual representation. To do this, click on the Set Chart button.

These reports can be accessed from:

Home > Manufacturing > Reports

Open Work Orders #

Shows the open Work Orders which have not started production yet.

Work in Progress Report #

This report shows any work orders that have started and are in progress. The status of these Work Orders is ‘In Process’.

Issued Items Against Work Order #

Items that are issued to a Work Order and are transferred to the Work in Progress Warehouse are shown here.

Completed Work Orders #

Work Orders which are completed with all the quantities in it manufactured are shown in this report.

Production Analytics #

This report shows the overall analytics of all Work Orders.

BOM Search #

In this report, you can search for specific BOMs based on the raw materials items used in them, then open it. Useful if you have a lot of BOMs.

BOM Stock Report #

On selecting a BOM in this report, the raw material quantity in Warehouses will be shown. As you can see, the items which have insufficient quantity are shown in red and ones with enough quantity to manufacture the BOM Item are shown in green.

Work Order Summary #

To access the Work Order Summary, go to:

Home > Manufacturing > Reports > Work Order Summary

This report will give information about the Work Order. Using this report user will understand the number of produced quantity against each Work Order as well the status of the Work Order.

Using this report user can check the status of the Work Orders which are linked to the Sales Order. Also using this report users can check the Work Orders based on the status like Not Started, In Process, Completed, and Stopped.

BOM Search #

To access the BOM Search report, go to:

Home > Manufacturing > Reports > BOM Search Report

In this report, you can search for specific BOMs based on the Items (raw materials) used in them. This report is useful if you have hundreds or thousands of BOMs.

Job Card Summary #

To access the Job Card Summary, go to:

Home > Manufacturing > Reports > Job Card Summary

This report will give information about the Job Card as well as their status. Using this report users can check the month’s Open and Completed Job Cards for the selected periods.

BOM Stock Report #

To access the BOM Stock Report, go to:

Home > Manufacturing > Reports > BOM Stock Report

The BOM Stock Report provides information about the raw materials required quantity and the in-stock quantity of the warehouse (which is selected in the filter). As you can see, the items which have insufficient quantity are shown in red and ones with enough quantity to manufacture the BOM Item are shown in green.

Open Work Order Report #

We can easily identify the manufacturing progress of certain items in our organizations using Open Work Orders in Emeron ERP.

In this report users are able to see:

• Items that need to be produced
• The total quantity to produce
• The quantity that has already been produced

For further details, users can proceed to click on the work order and expand it e.g. MFG-WO-2018-00009. This helps you prioritise Work Orders by their date