Works Orders are normally created automatically through Production Planning but can also be created automatically from within Sales Order Software or be created manually. Works Orders are normally based on Bill of Materials (BOMs) with both the output and input products being editable.
Usually Works Orders would be created from Sales Orders for customer bespoke items or created through Production Planning for items ordered by multiple customers or used as subassembly parts to create bespoke items.
The timing of when the Works Order is created is definable within planning and / or at product level. This flexible set up allows the production process to be optimised whilst still meeting customer demand and controlling stock levels.
Create Works Orders from Planning
The Planning process can be carried out on a selection of finished or subassembly products / Bills of Materials, using Production Planning processes.
Create Works Orders from Sales Orders
Works orders can be automatically or manually created from sales orders to produce bespoke products or services ordered by a customer. During Sales Order entry, checks can be performed to multiple levels to check if there is sufficient stock of the finished product and, if not, whether there is sufficient stock of the parts or subassembly items to produce the product.
Specify when to generate a Works Order
Flexible set up of products within the De Facto® Stock Control module allows the system to handle Sales Orders for each product very specifically, with the timing of when to generate a Works Order being set in the product. This is particularly useful at the Sales Order stage when choices include:
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Auto create Works Orders for new Sales Order Processes (SOP) - Each time the product is ordered the system can automatically create a Works Order. This is usually where the product is already in stock and the stock is being replenished.
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Auto create back to back Works Orders for new SOP - Each time the product is ordered the system can automatically create a back to back Works Order. This is particularly useful where the product is made to order or customised.
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Pick assembled if available - The system will use the stock already available but otherwise will pick the required components.
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Check or back order missing components - As with the main product the system will check whether the subassembly products are in stock and can be flagged to determine when they should be bought or made.
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Shipment of part complete items - An option exists to allow the shipment of products or assemblies with missing components. The missing items can be added to the Sales Order as back ordered items for later shipment. This is controlled in the BOM where the minimum completion level is specified. This facility is often used with items such as manuals or minor accessories.
Process Works Orders
The normal Works Order processing procedure comprises the following steps which are processed directly in De Facto or using hand-held or fixed terminals in the production area or warehouse:
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1. Pick production inputs - this will allow automatic or manual selection of stock for the Works Order and will then lock that stock.
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2. Input confirmation - this confirms the input material usage and moves it to work in progress.
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3. Output confirmation - where inputs are matched to outputs, the output products created and any scrap or remaining material can be managed.
The individual processes can be combined or carried out on a batch basis. Completion of Works Orders is prompted or automatic.
Additional features of Works Orders include:
Kitting
Allows Works Orders to be automatically processed during the Sales Order picking process. There is a further option to pick pre-assembled products if they are available with any balance being assembled if required.
Fly Kitting
Allows products requiring assembly to be specified during Sales Order processing for automatic assembly as part of the Sales Order picking process. The system produces an indented component picking table within the picking list for the Sales Order.
Labour Booking
Labour operations can be added as inputs into the BOM with labour being booked against them during Works Order processing. The entry and posting of a labour booking creates a record of labour used, this can be allocated as part of the normal output confirmation process. Set up options for employee and activity type facilitate this process.
Outside Processing
Allows works orders to be used to 'free issue' materials to external suppliers who then provide additional services, and any components to be used, to complete the Works Orders. This facility is fully integrated with the Purchase Order Processing module to handle purchase order creation, goods receipt and accounting processes.
Pro-rata Outstanding Labour
An option in Works Order parameters enables labour to be booked over and above the input detail quantity if extra time needs to be spent. When using 'quick processing' the option allocates the extra cost to the input and allows the Works Order to be completed. If there are multiple output items the additional cost is allocated pro-rata.
Additional Costs
Additional costs can be added to a Works Order as an input or output 'on cost'. For example a fixed cost for finishing charges could be created and added to certain Works Order outputs which will then increase the cost of the output product as it goes in to stock. 'On costs' can be accrued against a specific supplier, with invoices received being specifically posted against this accrual. Alternatively you could make a general accrual for costs.
All documentation required for works orders can be generated to any design, in many forms such as email, print or instruction files. The options used can be set globally and / or defined by type, using the powerful document profile options.
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