Manufacturing orders and work orders

SecureIO Manufacturing allows users to manufacture products using manufacturing orders (MOs) and work orders.

At its most basic level, manufacturing can be performed in one step. When using one-step manufacturing, SecureIO creates an MO and generates transfers to move components out of inventory and finished products into stock.

Tip

The number of steps used in manufacturing is set at the warehouse level, allowing for each warehouse to use a different number of steps. To change the number of steps used for a specific warehouse, navigate to Inventory app ‣ Configuration ‣ Warehouses, then select a warehouse from the Warehouses page.

On the Warehouse Configuration tab, find the Manufacture radio input field and select one of the three options:

• Manufacture (1 step).

• Pick components then manufacture (2 steps).

• Pick components, manufacture, then store products (3 steps).

Create a manufacturing order

To manufacture a product in SecureIO Manufacturing, begin by navigating to Manufacturing app ‣ Operations ‣ Manufacturing Orders, then click New to create a new MO.

On the new MO, select the product to be produced from the Product drop-down menu. The Bill of Material field auto-populates with the associated bill of materials (BoM).

Specify the Quantity of the product to be produced.

If a product has more than one BoM configured for it, the specific BoM can be selected in the Bill of Material field, and the Product field auto-populates with the associated product.

After a BoM is selected, the Components and Work Orders tabs auto-populate with the components and operations specified on the BoM. If additional components or operations are required for the MO, add them to the Components and Work Orders tabs by clicking Add a line.

Finally, click Confirm to confirm the MO.

Process manufacturing order

An MO is processed by completing all of the work orders listed under its Work Orders tab. This can be done on the MO itself or from the Shop Floor module.

Basic workflow

Work orders can be completed from the Work Orders tab or a work order form.

Work Orders tab

To complete work orders from the MO itself, navigate to Manufacturing app ‣ Operations ‣ Manufacturing Orders, then select an MO.

On the MO form, open the Work Orders tab. When work begins on the first work order that needs to be completed, click the • (Start) button for that work order. SecureIO Manufacturing then starts a timer that tracks how long the work order takes to complete.

When the work order is completed, click the • (Done) button for that work order. Repeat the same process for each work order listed in the Work Orders tab.

After all work orders are complete, complete the MO.

Work order form

To process work orders from their forms, open the Work Orders page by navigating to Manufacturing app ‣ Operations ‣ Work Orders. A list of work orders displays. Choose a work order from the list. The work order form opens.

In the top corner of the form, the status of the work order is displayed. When changing the status from To Do to In Progress, a new Time Tracking entry is created. The Planned Date updates to the current date and time, with the end time based on the Expected Duration.

Work on a work order can be split into different Time Tracking entries. To end an entry and pause work, change the status of the work order to To Do. Then, to add a new entry and begin work, change the status of the work order back to In Progress.

If Instructions are included, click an instruction. The Open: Check window opens. Click the • (Expand) icon in the top corner of the pop-up window. A quality check order form opens. Follow the Instructions, then click Pass to mark the instruction as completed.

After all instructions are completed, complete the work order by changing its status to Done.

After all work orders for the MO are complete, complete the MO.

Complete the MO

Back in the MO form, after completing all work orders, click Produce at the top of the screen to mark the MO as Done and register the manufactured products into inventory.

Partially complete the MO

To produce a partial quantity of the manufacturing order, enter the number in the Quantity field at the top of the manufacturing order, then click Produce. If the quantity of consumed materials does not match the quantity of products produced, a Consumption Warning pop-up window appears. Click Confirm to keep the existing quantity of consumed materials, or click Update Quantities & Validate to match the consumed quantities to the partial MO quantity of products produced.

Click Close Production in the You produced less than the initial demand pop-up window, and a second Consumption Warning pop-up window appears. Click Confirm to keep the existing quantity of consumed materials, or click Update Quantities & Validate to match the consumed quantities to the full MO quantity of products produced.

The MO is marked as Done and the manufactured products are registered into inventory.

Shop Floor workflow

To complete the work orders for an MO using the Shop Floor module, begin by navigating to Manufacturing app ‣ Operations ‣ Manufacturing Orders, and then select an MO.

Manufacturing orders can be opened in the Shop Floor module from two different locations:

• From the MO form

• From the main SecureIO dashboard

MO form

On the MO, click the • Shop Floor smart button. The MO opens in the Shop Floor module.

When accessed directly from an MO, the Shop Floor page defaults to the Overview for the MO to be carried out. The page shows a card for the MO that displays the MO number, the product, the number of units to be produced, and the next work order required for the MO.

Click the work order in the Overview to open it in its work center, then process it in Shop Floor.

Shop Floor module

Open Shop Floor from the main SecureIO dashboard.

Click the MO or work order from the Overview or work center view, then process the work order in the Shop Floor module.

Complete work orders in Shop Floor

Process the work order by completing each step listed on its card. Click a step and follow the instructions in the pop-up window. Repeat this process until all steps are addressed.

After completing all steps for a work order, a button appears in the footer of the work order card. If any other work orders must be completed before the MO can be closed, the button is labeled Mark as Done. If there are no additional work orders to complete, the button is labeled Close Production.

Clicking Mark as Done causes the work order card to disappear. After it disappears, the work order’s status is marked as Done on the MO, and the next work order appears in the Shop Floor module, on the work center page, where it is configured to be carried out. Any additional work orders can be processed using the instructions detailed in this section.

Clicking Close Production causes the work order card to disappear. The MO is marked as Done, and the units of the product that were produced are entered into inventory.

Adding or editing work order components

Components can be edited from the work order form.

Open a work order form by navigating to Manufacturing app ‣ Operations ‣ Work Orders and selecting a work order from the list.

In the work order form, open the Components tab.

Mark components as Consumed by selecting the checkbox for them on the product line.

Add components by clicking the Add component link and adding them from the Products form. After all additional components are added, return to the work order form by clicking Back to Order.

Work order properties

Add properties to a work order to customize it.

Open a work order form by navigating to Manufacturing app ‣ Operations ‣ Work Orders and selecting a work order from the list.

In the work order form, click the ⚙ (Actions) icon, then select ⚙ Edit Properties. Add a property to the work order form. To add additional properties, click the • Add Property link.

When all properties are added, click the ⚙ (Actions) icon, then select ⚙ Save Properties. The properties are added to the form.

Example

In the work order form for a Table, a Wood Type property is added to track the type of wood used for a product.

Lot/serial number tracking

Lot numbers and serial numbers are used to identify and track products in SecureIO. Serial numbers are used to assign unique numbers to individual products, while lot numbers are used to assign a single number to multiple units of a specific product.

When manufacturing products are tracked using lots or serial numbers, SecureIO requires the lot or serial number to be assigned to each product before manufacturing can be completed. This ensures that each product is properly tracked from the moment it enters inventory.

Configure products for tracking

By default, SecureIO tracks the quantity of each product on hand, but does not track individual units of a product. Lot or serial number tracking must be enabled for each product individually.

To track a product using lots or serial numbers, begin by navigating to Inventory app ‣ Configuration ‣ Settings, then scroll down to the Traceability section and select the Lots & Serial Numbers checkbox. Finally, click Save to save the change.

Next, click on Inventory app ‣ Products ‣ Products and select a product to track. In the General Information tab, update the Tracking field.

The default Tracking setting is By Quantity, which only tracks the quantity on hand. Select By Lots to track the product using lot numbers, or By Unique Serial Number to track the product using serial numbers. To specify that a product should not be tracked, select None in the Tracking field.

Doing so enables the Lot/Serial Number field on an MO or the Register Production instruction on a work order operation.

Configure an MO for products with lot or serial numbers

To manufacture a product tracked by lots or serial numbers, navigate to Manufacturing app ‣ Operations ‣ Manufacturing Orders. Click New to create a new MO.

In the Product field, select a product tracked using lots or serial numbers and enter the desired Quantity. Click Confirm to confirm the MO.

After the MO is confirmed, the Lot/Serial Number field appears above the tabs of the MO form. By default, this field is empty.

Lot number manufacturing

To populate the Lot/Serial Number field with a lot number, click the Generate Lot button next to the field. Doing so automatically generates a lot using the next available number and enters it in the field.

Alternatively, click on the Lot/Serial Number field and select an existing lot number, or manually enter a new lot number and click Create “#” in the drop-down menu.

Either of these methods assigns a lot number to the products in the MO before production is finished. It is also possible to complete production and close the MO by clicking Produce without assigning a lot number. Doing so automatically generates and assigns a lot using the next available number.

Serial number manufacturing

Clicking the Produce button closes the MO and automatically generates and assigns serial numbers for the quantity of the products being produced.

For single-unit MOs, enter a number manually in the Lot/Serial Number field and click Create “#”, or click the Generate Serial button next to the field to automatically populate the field with the next available serial number.

For MOs that manufacture multiple units, click the Generate Serial button next to the Lot/Serial Number field. The Assign Serial Numbers pop-up window opens.

In this window, the next available serial number is automatically entered into the First SN field. Keep this number or enter a number manually into the field.

The Number of SN field is automatically populated with the number of units produced by the MO. Keep this number or enter a number manually into the field, then click the Generate button to generate serial numbers for the units in the MO. Click Apply to apply the serial numbers to the products in the MO.

On the MO, click Produce to mark the products as produced and mark the MO as Done.