Production orders and costing
hayaterp.com ↗Run a production order in Hayat Manufacturing — create and release it, issue and return materials (with batches and back-flush), log progress stage by stage with shift, operator and machine, watch WIP on the stage board, receive output and by-products with lot numbers and a QC inspection, record scrap, rejection and rework, complete, then close it to post the cost variances. The cost tab, the cost sheet and the AI variance explanation.
A production order makes a quantity of one item from its BOM. It follows the order's routing stage by stage, and every material, minute and piece is recorded on it. Orders need mfg.produce; closing an order and everything about money need mfg.cost.
| Status | Means | Next |
|---|---|---|
| Draft | Being prepared; can be edited | Release, or cancel |
| Released | Standard cost frozen; ready for the floor | Issue, progress, output |
| In progress | Set by the first issue, progress entry or receipt | Complete |
| Completed | No more output expected (returns and scrap still allowed) | Close |
| Closed | Variances posted; the order's WIP is zero | — |
| Cancelled | Only from Draft or Released, with nothing issued or logged and no live job work | — |
Create and release an order
- Production orders → + Production order.
- Choose the BOM (or the item — its active BOM is used) and the quantity.
- Check the from store (materials) and the to store (finished goods; the branch's location by default).
- Planned start is today; planned end comes from the routing hours ÷ each work centre's capacity, skipping off days. Change them if you like.
- Set the priority (Low, Normal, High, Urgent), back-flush and QC on output (the settings give the defaults) and, if it is made for a customer, the sales order.
- Create draft. The order lists its materials (requirements with scrap %, phantoms already exploded) and its steps.
- Release it. The standard cost of the BOM at this moment is frozen on the order.
While the order is a draft, changing the BOM or the quantity rebuilds its materials and steps. Reschedule moves the planned dates or priority later; Job card prints the order for the floor.
The order list has status tabs (including Open = draft, released and in progress), a late filter and search. Every 12 hours, supervisors (mfg.produce) get one notification for each order past its planned end; rescheduling sets the reminder again.
Issue materials
On the Materials tab each line shows the requirement, what is issued, what remains and what is available in the from store.
- Issue — type quantities per line, or tick issue all remaining; pick the store and, for batch items, the batch (otherwise the earliest expiry goes first).
- Return — unused material back to a store, at the order's average issued cost.
- + Item not in BOM — issue something extra. This, and issuing more than the requirement plus the over-issue % of the settings, needs mfg.plan.
Back-flush (a switch on the order): instead of issuing by hand, materials are issued by themselves as work is logged. Each progress entry issues the materials of that step for the pieces put out and rejected; materials with no step go with the first step. An order without a routing back-flushes everything when output is received.
Every issue and return is a stock movement in Inventory (numbers MFI-…) and moves the cost into Work in progress.
Log progress stage by stage
The Steps / WIP tab is a stage board: per step the pieces in, out, rejected and reworked, the pieces still at the step (WIP) and those waiting for the next step.
- Click Log progress on a step.
- Choose the shift (from the work centre), type the operator and machine.
- Enter the pieces out, rejected (with a reason) and sent for rework, and the minutes worked and labour count.
- Tick done when the step is finished, then save.
Rules that keep the count honest:
- A step cannot put out more than the step before it has put out; the first step not more than the order quantity plus the over-produce %.
- Each entry charges labour, machine and overhead to the order at the work centre's rates (minutes × rate).
- Skip a step with no work logged on it; Reopen a finished step.
The Progress log tab lists every entry with who logged it.
Receive output
On the Output tab, Receive output:
| Field | Fill |
|---|---|
| Quantity | Good pieces now going into the to store |
| Lot | Your lot number; batch items get the order number when left empty |
| By-products | Scaled from the BOM for this quantity; change them if needed |
| QC | Start a quality inspection on this lot (see Quality control) |
| Complete | Mark the order completed with this receipt |
Output goes into stock at the order's standard unit cost (numbers MFR-…). It cannot exceed the order quantity plus the over-produce %, nor what the last step has put out. A failed QC inspection does not block the receipt; the order shows a warning and the receipt links to the inspection.
Scrap, rejection and rework
Scrap / rework → Record: the kind (Scrap, Rejection or Rework), the step, the quantity and a reason. Rejected pieces are charged to Production Scrap & Rejection at standard cost when the order is closed. The yield and scrap % in the reports come from these figures.
Complete
Complete when nothing more will be made. Returns of unused material and scrap entries are still possible. An order can also be completed from the last output receipt.
Close and variances
Close & post variances (mfg.cost) ends the order's costing. It is refused while the order has job work still at a contractor.
The Cost tab shows, side by side:
| Standard (frozen at release) | Actual | |
|---|---|---|
| Material | From the BOM | Issued at stock cost |
| Labour | From the routing | Minutes logged × labour rate |
| Machine | From the routing | Minutes logged × cost per hour |
| Overhead | Overhead % | Overhead % of the actual |
| Subcontract | — | Job-work charges |
with the value received into stock, the WIP balance still on the order, the scrap value and the three variances — a preview until the order is closed.
On close, Hayat posts one journal: rejected pieces to scrap, then the rest of the order's WIP balance split into labour efficiency, overhead & machine and material usage variances (the material variance also takes by-products and rounding). A positive variance means the order cost more than the standard. After closing, the order's Work in progress is zero.
The cost sheet under the Cost tab compares, per material, the quantity the output should have used with what was issued (usage %), and per step the standard and actual minutes and the yield.
✨ Explain variance (if Hayat AI is on) writes a short plain-English explanation of the variances from these figures. It is a suggestion only.