Manufacturing · Reference

End-to-end workflows

How work moves through Manufacturing from start to finish, who does each step and what the system does in response.

On this page (9)

Engineering to first order: BOM and route to a costed order Make to order: sales order demand, MRP, firm, purchase and order Full production cycle with backflush and cost relief (the worked example)Short components: shortage, purchase request, receipt, release Quality failure: check, non-conformance, deviation and rework Scrap and rework with an approval threshold Subcontracting: send components, vendor service, receive, return unused Shop floor shift on a tablet: queue, downtime, complete, repeat Short-close, cancel and settle the order's cost

Engineering to first order: BOM and route to a costed order

Who: Engineer A (manufacturing.bom.edit / route.edit), Engineer B (bom.approve), Planner (create, plan), cost.view user

#	What the person does	What the system does
1	A: Manufacturing > Engineering > Bills of Materials > New: product OT-1000, Type Manufacture; Save; add TT-01 1, LG-01 4, SC-01 16 (Backflush); Save version	BOM-OT-1000 version 1 Draft; cost column LG-01 4 x 15.00 = 60.00
2	A: Routes > New RT-OT-1000: 10 Cutting at CUT setup 30 / run 12; 20 Assembly at ASM run 18, After 10; Save	Route version 1 Draft with two operations
3	A presses Approve on the BOM version and on the route version	Both refused (segregation of duties): 'The person who drew up a BOM version does not approve it - ask another engineer (segregation of duties).' and the route equivalent
4	B approves, then Activates both versions	Approved by B, then Active from today; BOM side panel roll-up per unit: material 184.00, labour 45.00, machine 21.00, overhead 25.00 = 275.00 (setup spread over 1 unit)
5	Costing > Standard Cost	Row BOM-OT-1000 v1 shows rolled-up cost and the difference against the product cost
6	Planner: New MO for 10 OT-1000, warehouse MAIN, leave BOM empty; Save; Plan	BOM and route picked automatically; components TT-01 10, LG-01 40, SC-01 160; 2 work orders 150 and 180 min; status Planned; estimate 1,840.00 + 247.50 + 75.00 + 216.25 = AED 2,378.75 (237.88 a table)

Make to order: sales order demand, MRP, firm, purchase and order

Who: Sales user (confirm the SO), Production planner (manufacturing.plan, firm), Purchasing user

#	What the person does	What the system does
1	Confirm a test sales order SO for 25 OT-1000; open Planning > Demand > Sales Orders	Row qty 25 (nothing delivered), due date, customer; a draft SO is not listed
2	Planning > MRP: parameters for OT-1000 safety 3, minimum 10, multiple 5, lead time 2; stock on hand 5; Run MRP, scenario base	Production proposal for 25 (3 - (5 - 25) = 23, raised to the multiple 5 = 25), start = due - 2 days, pegged to the SO; component proposals TT-01 25, LG-01 100, SC-01 400 less stock and incoming
3	Planned Orders: Firm the OT-1000 proposal	A Draft->Planned manufacturing order is made (source = the SO), row shows Firmed and 'Became MO-...'
4	Firm the TT-01 purchase proposal that has a supplier; look at a component without a supplier	A draft purchase order at the product's cost; the one without supplier sits in Review with 'No supplier - choose one to firm it.'
5	Reduce the SO demand and run MRP again	Unfirmed proposals are replaced; the firmed supply is kept and flagged '<code>: firmed supply exceeds demand by N (demand M).'
6	Open the order from the Became link; Release it	Order released; SO and MO linked by the smart button; reservations taken for the components in stock

Full production cycle with backflush and cost relief (the worked example)

Who: Planner (release), Supervisor (issue, register), Operator (execute), cost.view user, cost accountant (close)

#	What the person does	What the system does
1	Release the 10-table order; Quick Actions > Material Issue TT-01 10 and LG-01 40; Issue	LG-01 40 reserved then consumed; MI- internal transfer MAIN/Stock -> MAIN/PROD; WIP = 1,200 + 600 = AED 1,800.00; order In Progress
2	Shop Floor, work center CUT: Start Cutting, Complete with Good 10 and 150 minutes	Labour 2.5 h x 45 = 112.50, machine 2.5 x 30 = 75.00, overhead 10 % of (112.50 + 75.00) = 18.75; WIP 2,006.25; Assembly becomes Ready
3	Register Production: Good 4	Backflush 64 SC-01 = 16.00; WIP 2,022.25; receipt for 4 at 202.225 each = 808.90 into finished goods; Produced 4 / 10, progress 40 %
4	Complete Assembly (180 min, Good 6)	Labour 135.00 + overhead 13.50 added; backflush 96 SC-01 = 24.00; the finishing receipt takes the whole remaining WIP 1,385.85; total finished goods 2,194.75
5	Complete Production, then Close; open the Costs tab and the WIP report	Completed then Closed; variance list overhead -184.00 and yield +184.00 settle to 0.00; WIP 0.00; Production Status & Cost (R048) shows 'Reconciles' Yes
6	Inventory > Stock on hand OT-1000	10 tables on hand valued at AED 2,194.75; component stock lower by 10 / 40 / 160

Short components: shortage, purchase request, receipt, release

Who: Planner, Purchasing user, Warehouse user, Supervisor

#	What the person does	What the system does
1	Create and plan an MO for 10 tables when only 25 LG-01 are free (Allow release with short components Off); Release	Refused: 'Components are short. Buy or transfer them, use a substitute, or release with the partial-start policy.' listing 'LG-01: need 40, free 25'
2	Planning > Material Shortages: row LG-01 short 15; Purchase Request: supplier, qty 15; Save	Draft purchase order for 15 LG-01 at its cost with note 'Shortage for MO-...' and a firmed planned purchase pegged to the MO
3	Purchasing confirms the PO due after the MO start; reopen Material Shortages	Expected receipt shown in red with the suggestion '<PO> arrives <date> - after the order starts. Reschedule or expedite.'
4	Reschedule MO for material	Order starts the day after the receipt at 08:00 Dubai
5	Warehouse receives the 15 LG-01 into MAIN; open the order	LG-01 now fully available; the shortage row disappears
6	Release the order	Released; LG-01 40 reserved; first work order Ready

Quality failure: check, non-conformance, deviation and rework

Who: Inspector A (quality.record), Quality approver B (quality.approve), Supervisor, Manager

#	What the person does	What the system does
1	Release an order with a final template (measure 74.5 - 75.5 cm); A records 76.0 and ticks Raise a non-conformance	Check Fail; NCR- opened (Open, severity Major) linked to the order; Complete Production is blocked by the pending / failed check
2	A tries Deviation approval	Refused 'The inspector who failed the check does not approve its deviation.'
3	B records Deviation approval with the note 'Customer accepted'	Check status Deviation approved, note 'Deviation: Customer accepted'; the check no longer blocks completion
4	A records Rework with Qty failed 2 on a second check	Rework request RW- for 2 on the order
5	Investigate the NCR; try Close with no root cause; fill root cause and action; Close as B	First Close refused 'Record the root cause and the corrective action before closing.'; then Closed; later edits refused 'A closed report is not changed.'
6	Complete Production and Close the order	Allowed only after the NCR is closed (otherwise '1 non-conformance report(s) are still open on this order.')

Scrap and rework with an approval threshold

Who: Operator (scrap.record), Quality approver (quality.approve, a different person), Cost accountant

#	What the person does	What the system does
1	Settings: Scrap above this quantity needs approval = 5. Operator records finished-goods scrap qty 1, Normal ticked; then qty 1 Normal unticked	Both Done; scrapped 2; normal scrap 237.88 stays in WIP; abnormal 237.88 leaves WIP to abnormal scrap expense
2	Operator records material scrap of LG-01 qty 2	Done; cost 2 x 15.00 = 30.00; only 38 left to scrap
3	Operator records finished-goods scrap qty 6	Waiting approval; the order's scrapped quantity is unchanged; Close refused 'A scrap record is waiting for approval.'
4	Operator opens Production > Scrap and tries to approve it	Refused 'The person who recorded the scrap does not approve it.'
5	Approver approves it	Scrap Done, order scrapped quantity rises by 6, remaining quantity falls, History 'Scrap SC-... done'
6	Register Good 3, Rejected 1 with Send rejected to rework ticked	Rework RW- Requested for 1; Rework smart button 1; Scrap % tile on the Dashboard moves

Subcontracting: send components, vendor service, receive, return unused

Who: Planner (edit, plan), Supervisor (material.issue, production.register), Purchasing user, Warehouse user

#	What the person does	What the system does
1	Release the 10-table order; Subcontracting > Subcontract Orders > New: vendor, We send the components, price 35.00; Save	SUB- Draft for 10; lines TT-01 10, LG-01 40, SC-01 160; MO estimate gains subcontract 350.00
2	Send components	Transfer MAIN/Stock -> MAIN/SUB-<vendor> (still company stock, value unchanged); reservations released; status Components sent; order In Progress
3	Purchase order	Draft PO for 'Subcontract manufacturing service' 10 x 35.00 = 350.00 + 5 % VAT = 367.50; status Vendor production
4	Vendor WIP as a cost.view user and as one without	Card per vendor with components and value; value hidden without cost.view
5	Receive Good 10 (try 12 first)	'At most 10 is outstanding.'; then receipt: components consumed at the vendor into WIP, service 350.00 added, production registered at full cost, PO line accepted for billing, status Received
6	Close with 2 LG-01 still at the vendor, then Return unused, then Close	First refused 'Components are still at the vendor - return them first.'; after the return the order is Closed

Shop floor shift on a tablet: queue, downtime, complete, repeat

Who: Operator (workorder.view, workorder.execute), Supervisor

#	What the person does	What the system does
1	Shop Floor: pick work center ASM and an operator; scan 'wo-000002'	The WO opens as the current job; choices are remembered on the tablet
2	Start; Pause with the downtime reason 'Machine breakdown'; resume after 20 minutes	Down since shown while paused; a 20 minute downtime stretch is logged with reason BREAKDOWN; labour is costed for it, machine and overhead are not
3	Record Scrap qty 1 with a reason	Process scrap recorded on the order; Save disabled until a reason is chosen
4	Complete: Good 10, Rejected 1 on the last operation	10 good received into stock; a rework request is raised for the 1 rejected; the screen notes 'This is the last operation...'
5	Press Complete again (or replay the same command_key)	Answers 'repeated': one completion, one receipt, one cost entry only
6	Supervisor opens Work Orders and Reports > Downtime	WO shows Completed; downtime 20 minutes counted

Short-close, cancel and settle the order's cost

Who: Manager (close), Planner (edit), Cost accountant (close, cost.view), Auditor reading the WIP report

#	What the person does	What the system does
1	Order of 10 with 8 produced, 2 work orders open: More > Short-close with empty reason, then 'Customer reduced order to 8'	Empty refused 'Say why the order closes short.'; then Completed, open work orders Cancelled, History 'Short-closed: 8 of 10 made.'
2	Issue 50.00 of extra material after the last receipt; Close	A variance row of -50.00 clears WIP; with posting on: Dr Production variance 5310 / Cr WIP 1250 50.00
3	Accounting > Journal entries for the order	Balanced entries for issue, labour, machine, overhead, receipt and the variance (Accounting Entries smart button counts them)
4	Run Production Status & Cost (R048) for the month	'Reconciles' Yes for every order; closed order WIP 0.00
5	On a second order released with reservations and nothing issued: Cancel, then Reopen	Cancel releases reservations, cancels open WOs and deletes pending checks; Reopen returns it to Draft with snapshots cleared
6	On a third order with issued material try Cancel	Refused 'Material has been issued to this order. Return it to the warehouse before cancelling.'

Updated 3 October 2026