BOMs and routings
hayaterp.com ↗Set up Hayat Manufacturing — work centres with capacity, shifts and hourly rates; operations; bills of materials with components, scrap %, phantoms and sub-assemblies, by-products and co-products with a cost share; the routing of operations with setup and run times; the denim, hosiery, towel and bedding templates; a BOM drafted by AI; versions; standard cost roll-up; the multi-level explosion and where-used.
Before the first production order you describe where work is done (work centres), what is done (operations) and, per product, what it is made of and how (the BOM and its routing). Everything on this page needs mfg.plan; everyone with mfg.view can look.
A small denim unit could look like this:
| Work centre | Kind | Capacity | Operation |
|---|---|---|---|
| CUT-1 Cutting table | Section | 16 h / day | Cutting |
| STITCH-L1 Stitching line 1 | Line | 16 h / day | Stitching |
| WASH Washing plant | Machine | 20 h / day | Washing |
| FIN Finishing & packing | Section | 8 h / day | Finishing, Packing |
Work centres and operations
Work centres (menu Work centres, + Work centre) are your machines, lines and sections:
| Field | Fill |
|---|---|
| Code, Name | Short and unique in the company, e.g. STITCH-L1 |
| Kind | Machine, Line or Section |
| Capacity hours / day | Used for planned end dates and the capacity load |
| Shifts | Up to six names, e.g. Morning, Night — offered when progress is logged |
| Cost per hour | Machine cost charged for every minute logged |
| Labour rate per hour and default labour count | Labour cost = minutes × rate × workers |
| Overhead % | Added on top of labour and machine cost |
| Branch, Active | Inactive centres stay on old BOMs but are not offered |
Operations (menu Operations, + Operation) are the jobs: code, name, kind (Cutting, Stitching, Dyeing, Knitting, Weaving, Spinning, Washing, Printing, Embroidery, Finishing, Packing, Assembly, Inspection or Other) and a default work centre that new routing lines pick up.
Make a BOM
Open Bills of materials → + BOM.
- Choose the item you make and the output quantity one batch gives (e.g. 1 pair, 100 pairs, 12 towels).
- Add the components: item, quantity per batch, unit, scrap % (extra to allow for waste), phantom if it is a sub-assembly you never stock, and the step — the routing line that uses it (for back-flush).
- Optional: add by-products / co-products — e.g. yarn waste — with the quantity per batch and their cost share % of the batch.
- Add the routing: a line per operation with its sequence number, operation, work centre (the operation's default), setup minutes per batch, run minutes per unit and labour count.
- Click Create BOM. Its standard cost is worked out at once; any warning (for example a component with no cost yet) shows at the top.
Sub-assemblies. A component that has its own active BOM is a sub-assembly: its cost comes from its own BOM, and MRP plans it as something to make. Tick phantom when you do not stock it — its components then go straight into the parent order. Badges in the explosion show Make, Phantom or Buy.
Start from template offers four examples — denim (fabric, thread, rivets, labels), hosiery (yarn kg, elastic), towel (yarn by GSM) and bedding (fabric metres, filling) — with their routing. You map each template line to one of your own items, then save.
Suggest with AI (if Hayat AI is on): describe the product, e.g. "5-pocket denim jeans, 12 oz fabric, stone wash", click Suggest, check the draft lines and the items it matched, then Fill the editor. Nothing is saved until you save the BOM.
Versions
Each item can have many BOM versions; one is active and new orders use it. Saving a new BOM for an item that already has one makes the next version number.
- Copy as new version — start a change from the current BOM.
- Activate / Deactivate — switch which version new orders use.
Orders already made keep the materials and routing they were made with. Changing a BOM never changes an existing order.
Standard cost
The Standard cost tab shows the cost of one batch, live: material, labour, machine, overhead, total and unit cost. Roll up & save stores it on the BOM; Roll up all costs on the list does every BOM.
How it is worked out:
| Part | From |
|---|---|
| Material | Each component × (1 + scrap %) at its own BOM's unit cost (sub-assemblies), else the item's standard cost, else the average stock cost, else the last purchase price |
| Labour | (setup + run × output quantity) minutes × labour rate × labour count, per routing line |
| Machine | The same minutes × the work centre's cost per hour |
| Overhead | The work centre's overhead % of labour and machine |
| Unit cost | The batch total less the by-products' cost share, ÷ output quantity |
A by-product's unit cost is its share of the batch ÷ its quantity. With Update item standard cost on in the settings, the roll-up also writes the unit cost to the item in Inventory.
When an order is released, the standard cost of that moment is frozen on the order; variances are measured against it (see costing).
Explosion and where-used
- Explosion — Explode for any quantity shows every level indented: what is made, what passes through as a phantom and what has to be bought, with Totals to buy / stock at the bottom.
- Where used — every BOM (and version) that uses an item, with the quantity and scrap %. Check it before you stop buying a material.
- Print prints the BOM with its components and routing.