Overview

Production orders are only planning elements in material requirement planning or detailed scheduling. For the actual manufacturing to start, the production orders must be broken down into production stages.

All production stages are created for the entire production order. The production stage describes the production of lots (materials) in the production process or service provision.

Within the make-to-order scenario, production stages can be:

• Generated automatically based on order-specific BOMs.
• Generated automatically based on a BOM template and then modified manually based on specific requirements of the demand order.

Production stages are used to:

• Plan quantities, dates, and resources of the manufacturing process.
• Control the execution of the production stage.
• Specify rules for account assignment and settlement of costs incurred.

During the process, the BOM is exploded and the items are transferred to the production stage.

The stage generation options allow you to:

• Specify demand or even make reservations for the BOM items held in stock.
• Set capacity requirements for work centers.
• Set purchase requirements for items that are not in stock and for externally processed operations.

Create production stages in make-to-order scenario flowchart

Paths

How to generate production stages based on BOM data

1. Go to Manufacturing and click Production order queue management under Production scheduling and controlling.

2. The workplace shows the list of production orders with the Queued status only.

3. Set the Pending release for production filter.

4. Select an order and click .

5. In the Generate stages menu, select the Do not produce if available at warehouse check box and leave all the other check boxes cleared.

6. Сlick Generate.

7. The system will automatically:

• Generate stages based on the BOM.
• Generate stages for the production of intermediate products.
• Assign a unique number with mask МС00-1.36.1, which includes:
  • МС00-1 is a short production order number
  • 36 is a sequence number of the production order list
  • 1 is a sequence number of a stage
  • Manufacturing stage description, which is copied from the BOM. To change it, click the Main tab and enter a new value in the Description field
• Set the status to Active if there are no errors.

Paths

How to specify products to be produced

1. Go to Manufacturing and click Stage dispatching under Production scheduling and controlling.

2. In the Production stage document, click the Production tab.

3. Add a new line, choose product Items, and enter the Quantity to be manufactured.

4. Check the Assignment field:

• It must be filled with a successor stage if the current production stage is manufacturing intermediate products.
• It is left empty if the current production stage is manufacturing finished products.

5. Review the products and quantity to be manufactured during this production stage.

How to specify materials and components required for production

1. In the Production stage document, click the Supply tab.

2. Add a new line, choose a component and material Items, and enter the Quantity to be supplied.

3. In the Actions field:

• Select Do not supply if the component or material is already available in the shop floor storeroom.
• Select To supply if the component or material must be transferred from the warehouse.

4. Select lines and click Supply to fill the Action field in bulk mode.

5. Specify a supplying Warehouse.

6. Specify a Product cost element.

7. Select lines and click Fill to fill the Warehouse and Product cost element fields in bulk mode.

8. For components or materials that must be produced as part of this production order:

• In the Produced in process column, select the check box and specify a BOM.
• Generate a new supplying production stage. See How to generate production stages above.

9. Specify a shipment date:

• Select the one-day shipping check box and enter a date.
• Clear the one-day shipping check box and enter dates for each line.

How to specify internal work required for production

1. In the Production stage document, click the Supply tab.

2. Click Add and fill the Items, Variants, and Quantity columns.

3. Specify a requested Shipment date.

4. In the Actions column, select Do not supply.

5. Enter Additional requirements.

6. Click Attachments and attach necessary files.

How to specify employee activities

1. In the Production stage document, click the Labor costs tab.

2. Add a new line, choose an Activity kind, and enter the Quantity to be supplied.

3. In the Assignee field, specify a person responsible or a team.

4. Specify a Product cost element.

5. Select lines and click Fill to fill the Assignee and Product cost element fields in bulk mode.

How to define scheduling variants

Place stages on the shop floor calendar

1. In the Production stage document, click the Main tab.

2. In the Scheduling option section, select the According to work centers availability check box.

3. Specify the fixed duration of the production stage in days, hours, or minutes.

4. The system will use a working calendar of the shop floor in production scheduling.

Place stages on the work center calendar

1. In the Production stage document, click the Main tab.

2. In the Scheduling option section, select the By available work centers check box.

3. Click the Work center types tab.

4. Add a new line, choose a Work center, and enter the standard Running hours to be spent.

5. Specify the Preliminary buffer and Follow-up buffer time.

6. Specify Load of several work center types.

7. Select the Continuous check box if you need to occupy the work centers without any interruptions.

Place stage on the calendar manually

1. In the Production stage document, click the Main tab.

2. In the Scheduling option section, select the Manually check box.

3. See how to define the production schedule manually on the Schedule production orders page.

Postpone stages after events

1. In the Production stage document, click the Main tab.

2. Clear the Not earlier than check box.

3. Select this check box and specify a date if you need to place this stage in the required future date.

How to save production stages

1. Go to Manufacturing and click Production order queue management under Production scheduling and controlling.

2. Set the Revise stages filter.

3. Select an order and click to view stages with data errors.

4. Open the stage and set the status to Created.

5. Post the document.

6. The system will automatically:

• Perform standard checks on whether the required fields are filled and their values are correct.
• Indicate an error kind.
• Provide recommendations on how to fix the error.

In the table below, you can see the most common errors and actions required to fix them:

7. Make the necessary adjustments and post the document again.