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Andrey Kolesnikov
2/5/19, 8:30 PM

I understand that Ashley likely already resolved the issue, so this answer is aimed more at Yannick, as I assume you are not satisfied with the original answer.

It appears that 1,125 cans per batch are produced. I can think of 2 ways to set it up (I'd choose option 2).

Alternative 1: You can try to emulate "batching" by setting up a new "unit" (Inventory > UOM) naming it something like "Batch of 1125" and making "Batch of 1125" equal to x1125 of the based "Unit".

  1. Set all the raw materials as individual items that are tracked (units of measure) in grams or kilograms. These would be purchased (or manufactured through sub-operations)

  2. Make your final product - "Can of powdered product", units of measure for it would be "Unit"

  3. For the "Can of powdered product" - setup a BOM, make it a manufactured item, and in the "Quantity" field set it as 1 "Batch of 1125".  Then, select the quantities for all components that are needed in producing the 450 kg batch.

This would let you keep conversions on the scale of the full batch. But it would still count individual cans as the produced units, so I think your users would need to always remember the quantity per batch.

Alternative 2:  you can set up the production as 2 separate manufacturing operations (assembly and subassembly):

  • Set all the raw materials as individual items that are tracked (units of measure) in grams or kilograms. These would be purchased (or manufactured through sub-operations

  • Make an intermediary product - "Batch of powdered product", units of measure for it would be "Unit"

    • Make a BOM for it - 1 "batch" consists of the proper mix of the 10 ingredients so it adds up to 450 kg (or however your recipe requires, if standard "loss" is included or if some material evaporates or otherwise changes mass).

    • This will allow you to have a step where you create 1 "batch" and would make it easier to keep the counts straight - just make them 1 unit at a time (though the system can still auto-generate a manufacturing order with something like 0.345 for you, it would be easy to catch it and just adjust it to 1)

  • Make your final product - "Can of powdered product", units of measure for it would be "Unit"

    • Make a BOM for it - 1,125 cans consists of 1 "Batch of powdered product" (and the cans themselves)

    • This will produce the "final" goods

  • In this setup, you'd have an extra step, but you'd be able to count "batches" (just under 89 batches to process 100,000 cans) and would also count the "cans".  It may work depending on what your actual production process is.

To fulfill an order for 100,000 cans, you can simply run 89 batches and make 100,125 cans, 125 of which would stay in stock (though not as easy if using "make to order" route).  Or you can process 88 full batches, and the 0.889 fraction for the last batch. The system should let you produce fractions of a batch and use up fractions of "component" products.

In setting up, you can consider using real or periodic inventory counts.  If you do monitor inventory, perhaps "real" inventory with FIFO makes sense.  Depending on your accounting reporting/monitoring needs, you have multiple options for internal Product Categories and stock account overrides on the products themselves. Make to order vs reorder rules or manual production management are also the options on the table.

You can also go with Work Orders (using routings) to setup multiple work centers. Depending on the real setup, it may or may not be a better choice.

I hope this helps.

Andrey @ Steersman Company

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Yannick Belot
1/7/19, 1:42 PM

Hello Ashley.

Did you solved your issue? How did you do it?

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