Advanced Manufacturing data

In master data the BOM quantities and the work order quantities are always indicated in production UoM

The unit can be used in which material was actually withdrawn: for example storing in liters, but withdrawal in kg.

In all functions, where required quantity and stock are indicated, the total stock is always displayed in inventory UoM, as otherwise no comparison of planned quantity, posted quantity and stock would be possible.

A special case is single material posting There, the withdrawal quantity can be given in production UoM it will be converted to warehouse units immediately.

The conversion from inventory UoM to production UoM is defined in Quantity units – Conversion

Note:

All other units are managed in Purchase/Sales/Inventory tabs or using the orange arrow in window "Quantity units"

Define the max. Lot size for production in Inventory or Production UoM

See concept Lot size

Limitations

If the lot size produces more than 10 Positions, the system asks if you want to continue.

If the lot size produces more than 200 Positions, the system cancels the process with a message:

" Lot size is set to <losgr>. This corresponds to <summ> Positions created. Max. allowed are however <limit> positions. Creation is aborted (LimitLotSize)"

It is possible to increate the limitation. Please contact our support if needed.

Note on sub-structures:

Lot sizes of order related sub-structures are considered only if activated separately.
See Configuration wizard – Production – Create new.

If the count of the created positions is larger than the limitation, the system ignores the lot size in the last position and displays an error message (LimitLotSize)
Example: 1000 Pcs, Lotsize = 1. 200 Positions created. Position 1-199 for 1 Pcs and Position 200 with 801 Pcs

PreCalculation: Supports Production Lot size

MRP Calculation: Ignores Production Lot size while calculating requirement based on sales order, forecast and other documents.

Only available when Mode of Procurement is defined as “Buy”.

This field is used to define a percentage of the material that is wasted when it is used as raw material for production.

For example:

if Cut-Off (%) is set to “10” and the item is linked to a Bill of Material with the quantity of “50”,

Beas will change the quantity to “55” in the position when a Work Order is created (“50” from Bill of Materials plus “5” from 10% cut-off rate). Cut-Off (%) will also be considered while calculating cost in the pre-calculation functionality.

Video: Scrap on Item Level

see Scrap, Calculated scrap, Option consider cut-off, Production item – cut-off

This value is used for Precalculation. Only available when Mode of Procurement is defined as “Produce”.

Scrap factor for assemblies relates to the material requirement for an assembly rather than the assembly.

Assemblies:

Scrap factor for assemblies is not related to the assembly requirement, but only to the material requirements of this subassembly.

In Precalculation, there are only an information on quantity for BOM item and assembly. This creates an additional requirement for the assembly. If then a work order is created, the behavior may vary.

Phantom assembly

Scrap factor is calculated and entered as "calculated scrap" into the BOM item  and taken into account.

Order related Item

BOM Order related items do not apply the scrap factor, system will generate a work order position for the order related item and scrap factor will be applied to of the sub work order BOMs only.

Purchase part:

The scrap factor is calculated in the work order as total value, added to the cut-off value and other scrap factors and entered to the BOM column calculated scrap.

Precalculation: entered in Master Data > scrap and also taken into account.

Note

using order time receipt function and reporting scrap See Configuration wizard – Backflushing

Video: Scrap on Item Level

see Concept Scrap, Calculated scrap, Option consider cut-off, Production item – cut-off

Define item based scrap on table level.

The Scrap defined in Scrap/Cut-Off Table

The scrap factor affects:

purchase parts: "calculated scrap"

assemblies: material requirement of the subassembly
sub-assemblies: surcharge for scrap in sub-components

Note

Video: Scrap on Item Level

see Concept Scrap, Calculated scrap, Option consider cut-off, Production item - cut-off