Product overview

Works Order Processing is designed specifically for Sage 200, integrating with BOM and Stock Control.  It provides enhanced functionality to the Sage 200 BOM module and is an ideal addition for clients in manufacturing who need a simplified stock allocation and issuing process with the ability to be amended.

 


1. Works Orders

This section is used to create and amend works orders.  The user has the ability to create a works order using a BOM as a template, create a blank works order, create an estimate works order and create templates.

The user can also copy existing works orders or generate works orders from sales orders.


1.1. New Works Order

Create New Works Order from a Sage BOM

The new works order screen is used to create a new works order based on a Sage BOM as a template.

Sicon Works Order Processing Help and User Guide

To create a works order, do the following:

  • Select a BOM from the drop down list
  • Select warehouses for the finished product(s) and the components
  • Enter the quantity to be made
  • If job costing integration is enabled, select a job from the Job/analysis drop down
  • Click the Create button in the bottom left corner

The works order will now be populated with details from the BOM.  Components, labour, machine and comment lines will be loaded.  An estimate/average total cost for the works order will be shown in the header section

Sicon Works Order Processing


1.2. New Blank Works Order

Creating a New Blank Works Order

The new blank works order screen is used to create a new empty works order with no components or finished items.  All details of the works order will be entered manually.

The name of the works order must be entered, followed by the default warehouse for components and finished items.  The quantity of how many items are to be made should also be entered.

Sicon Works Order Processing New Blank works order

Once the Create button is selected, the empty works order is shown.


1.3. New Estimate Works Order

Creating a New Estimate

The new estimate works order screen is used to create a new estimate.  An estimate is used to calculate an estimate cost of a works order.  An estimate can be converted into a works order using the Create Works Order button when amending the estimate.

When creating an estimate, the name of the estimate is entered, as well as the default wa


1.4. New Estimate

rehouse for finished products and components.  The quantity to estimate on is also entered.  A BOM can be selected as a template, and therefore will pre-populate the estimate with the components on the BOM.

Sicon Works Order Processing New Estimate Works Order

Once the Create button is selected, the new estimate will be shown.


1.5. New Template

Creating a New Template

The new template screen is used to create a new works order template.  Components can be added to the template to form a starting point to works orders generated from the template.

Sicon Works Order Processing New Template

Once the Create button is selected, the new empty template is shown.

To generate a works order from the template, first amend or view the template via the Amend Works Order menu option and selecting the Template Status.  Next select the Create Works Order button at the bottom of the Amend Template screen.

A new works order can also clone a template by selecting the Clone From Template button at the bottom of the amend works order screen.  This option is only available if the works order has a status of New and all component lines will be replace.


1.6. Generate Works Orders from Sales Orders

Generating a Works Order from a Sales Order Line

This screen can be used to create works orders for sales order lines, provided that the stock item on the sales order line is a BOM item and that the sales order is live.  The sales order line must also have an outstanding quantity to allocate.

Sicon Works Order Processing Generate WO from SO

When searching for sales order lines, promised date and sales order document numbers can be used as filters.  The Find button will look for outstanding sales order lines.

A list of items will appear.  Once a line is selected and a default warehouse for components is selected, the works orders can be created by selecting the Create Selected Works Orders button.

Multiple works orders for each sales order line can be created by selecting the tick box at the bottom of the screen.  This will create multiple works orders, each with a quantity of 1, for each item selected.  For example; if the Qty To Make was set to 5, and this option was selected, then 5 works orders will be created.

The works order number used for the generated works orders will match the sales order document number and sales order line.  For example; 5178-001, where the first part of the number is the sales order document number and the second part is the sales order line.

The generated works orders will also be linked to the sales order lines.

Some reasons why a sales order line did not appear in the list could be one of the following:

  • The item on the sales order line is not a BOM item
  • The item on the sales order line has an allocation to it
  • The sales order is complete
  • A works order already exists for the sales order line
  • The stock item is set to Buy on the material planning tab when amending the stock item in stock control.
  • The BOM is not active or is on hold

1.7. Amend Works Order

Amending and Finding Works Orders

The Amend Works Order screen is used to search for and amend, or view works orders.  From here you can edit the works order, change the dates of the works order, delete the works order or link to a sales order line.

Sicon Works Order Processing Amend Works Order

The list of works orders can be filtered by using the Search criteria at the top of the screen.  The status drop down also has options for templates, estimates and completed works orders.

A works order can be edited by double clicking on the works order in the list or by selecting the works order and then the Edit button.

The works order name, dates and area can also be edited in the list itself.


1.8. Works Order Screen Details

Description

The amend works order screen is divided into a number of sections:

  • Header section: Contains details about the works order
  • Finished products section: Lists the finished products as well as transactions for each finished item
  • Components section: List the components used to build the finished item(s)
  • Additional sections: Extra tabs are provided to add non stock items, labour, machine and comments

Sicon Works Order Processing Works order Screen Details

Header Details

The header section is made up of the following fields:

Field Description
Bill of material / Works Order The name of the works order
Version The BOM version number the works order was originally based on
Quantity The original works order quantity to make
Number The unique works order number
Start date The start date of the works order
Due date The due date of the works order
Estimate days req. This is the estimate days required based on the labour and machine items on the works order. This is dependent on whether labour and machine items affect date calculations setup in works order processing settings
Days available This is the number of working days available depending on the start date and due date
Warehouse for finished products The default warehouse to use for finished items
Warehouse for components The default warehouse to use for components
Job/analysis If Sicon job costing integration is enabled, a job can be selected here. This can only be changed when the status of the works order is New. Relevant job costing transactions are then posted to the job during the life of the works order
Area The area the works order is currently in. Areas are setup against the stock item (BOM item) in Stock Control and the areas menu option in works order processing
Comment Any comment relating to the works order
Total cost for WO The total cost for all items on the works order. This cost can be an:

Estimate There are some issued items
Average There are no issued items
Actual All items have been issued

When double clicking on this field, a break down of the cost is given. A further break down of the components is given if the components value is double clicked.

Total issued cost This is the value of all issued components. It also includes labour and machine and non stock items once finished items are booked in. This is dependent on settings.

Materials Tab

A list of components, as well as the finished items for the works order is shown on the materials tab. From here the user can perform a number of functions on the componets and finished items. There is also a list of booking transactions that are filtered for each finished item. Booking transactions record when finished items are booked into stock:

Sicon Works Order Processing Works order Screen Details 2

For details on functions relating to components on the works order, please refer to the Components Section of the Works Order Processing Help and User Guide.

Finished Items

The finished products screen is shown when a finished item is edited and is used to amend the finished item.  The stock item can be changed if no stock has been booked in.  Also, the quantity to book in and the location to book stock into can be amended.  If the finished item is a traceable item, the batch or serial number will have to be entered.

Sicon Works Order Processing Works order Screen Details

Non Stock Items Tab

Here non stock items can be added to the works order.  Non stock items can be added, edited and removed on this tab.  When added or editing a non stock item, the description, quantity, unit price and supplier can be entered and amended.

Sicon Works Order Processing Works order Screen Details

The value of the non stock item can be added to the total cost of the works order if the Add non stock items to cost of works order option is selected on the Calculationstab in settings.  A nominal code will also have to be selected and will be used when booking in the finished item.  For more on nominal posting in works order processing, please visit the nominal posting Works Order Processing Help and User Guide.

Adding Labour Time

The labour tab is used to add labour costs to a works order.  The top list will provide estimate totals for each labour item.  An estimate labour time has to be entered before actual labour time can be entered.  The bottom list provides actual time entries for each labour estimate selected in the top list.

Sicon Works Order Processing Works order Screen Details

When adding an estimate labour entry, the cost item, unit cost and estimate quantity in hours, minutes and seconds are entered.

Sicon Works Order Processing Works order Screen Details 2

When entering an actual labour entry, select the cost item from the top list and then select the bottom Add button to enter the actual hours, minutes and seconds.

Sicon Works Order Processing Works order Screen Details

Cost items are setup in the Sage BOM module in the Manufacturing System Manager.  Please refer to the Sage help guides on how to setup labour and machine items.

Costs of labour items are dependant on settings on the Calculations tab in works order processing settings.

Adding Machine Time

Machine items work in much the same way as labour items, except that all items are filtered for machine items instead of labour items.

Sicon Works Order Processing Works order Screen Details 2

Adding Comments

The comments tab is used to add comments to a works order.

Sicon Works Order Processing Works order Screen Details

History Tab

The history tab will show certain changes to the works order for historical purposes.  These changes could include labour items been added, works order status changes or nominal posting entries.

Sicon Works Order Processing Works order Screen Details

 


1.9. Components Screen

Description

The components section is found on the materials tab on the amend works order screen.  This section lists the components required to build the finished item(s).

Sicon Works Order Processing Components Section

Add Component

To add a component, click the Add button and the following screen will appear:

Sicon Works Order Processing Components Section

Select a stock item code.  Enter the quantity required and the warehouse from where the stock is going to be used from. Then click Save.

If the component item is a BOM, then the user will be asked whether they would like to add a sub assembly for this line.

Sicon Works Order Processing Components Section

If Yes is selected, a sub assembly with all the components will be created and linked to the component line added.  The number of the sub assembly will be the parents works order number followed by a /# where # is the sub assembly number.

Edit Component

To Edit a component, select the line to edit and then select the Edit button.

Sicon Works Order Processing Components Section

The quantity and location can be changed on the component line. All lines that have not been fully issued can be edited. If the quantity required is reduced to the issued quantity on the line, then the line will automatically be marked as ‘Issued’ and therefore cannot be further edited.

Remove Component

To remove a component, select the line to remove and then select the Remove button.  The following message will appear:

Sicon Works Order Processing Components Section

Select Yes and the component line will be removed. Only lines that have not been allocated or issued can be removed.

Allocating a Component Line

To allocate a component line, select the component line to allocate and then select the Allocate button.  When the line is allocated, the quantity in the allocated column will increase by the amount allocated.

A component line can be part allocated by select the line and then selecting the Part Allocate button.  The Part Allocate screen will appear and the user can enter the amount to allocate.

Sicon Works Order Processing Components Section

A bin location can be selected provided that the BinNames setting in work order processing settings is set to *SELECT.  This will allow the user to select a bin during every allocation.

Sicon Works Order Processing Components Section

This will allow the user to select a bin during the allocation process.

Sicon Works Order Processing Components Section

If the stock item on the component line is a traceable item, then the Works Order Allocation screen will appear during allocation

Sicon Works Order Processing Components Section

Select the batch/serial number to allocate against by double clicking on the line.  The quantity to allocate can be changed in the allocation box.  Next select the Applybutton and the total allocated quantity will increase.  Once the whole line is allocated (the allocated quantity matches the required quantity), the OK button can be selected and the allocation will commence.

All lines can be allocated at once if no line is selected and the Allocate button is selected. This will allocate every line possible in the component list.

Issuing a Component Line

Only lines that have been allocated can be issued.  To issue a component lines, select the line and then select the Issue button.  The Issue Allocations screen will appear, where the user can select the quantity to issue based on the amount allocated.

NB: This is if the Allow part issue of components lines settings is selected in Settings, otherwise the total allocation will be automatically issued.

Sicon Works Order Processing Components Section

Once the user selects the Issue Allocations button, the component line will issue.  If all allocated amounts have been issued and there is no outstanding quantity on the line, the line will be marked as Issued.

Sicon Works Order Processing Components Section

If the component line is a traceable item, then standard Sage Batch/Serial Detail screen will appear during the issue process.  Here the user can select the quantity to issue, as well at which batch or serial number to use.

Sicon Works Order Processing Components Section

All allocated lines can be issued at once if no line is selected and the Issue button is selected.  This will issue every allocated line possible in the component list.

Sub Assemblies

Component lines can link to sub assembly works orders.  Line representing a sub assembly are shown in blue.

Sicon Works Order Processing Components Section

To view the sub assemblies, right click the component line and then select Show Works Order for Sub Assembly.

Right Click Menu on Component List

The following menu appears when the user right clicks on the component list.

Sicon Works Order Processing Components Section

 


1.10. Picking Components

Picking

To allow picking of works order lines, the ShowPickedColumn setting has to be set to Yes.

Sicon Works Order Processing Picking Components

A column will appear in the list of components specifing whether a line has been picked or not.  A Pick button will also appear below the list of components to allow the user to pick the line selected.

Picking and Transfer

The user can also transfer stock during the pick process to another warehouse.  The stock allocated on the component line will be unallocated, then reallocated to the stock on the destination warehouse once the stock has been transferred.

To activate the Pick and Transfer process, the PickAndMoceWhenPick setting needs to be set to Yes.

Sicon Works Order Processing Picking Components

When the user selects a component line and then selects the Pick button, the Pick and Transfer screen appears.  The user can enter the quantity picked.  Allocations will be displayed in the list and the user can add extra quantity at the bottom of the list so that the stock to transfer matches the quantity picked.

Sicon Works Order Processing Picking Components

A destination bin location is selected at the bottom of the screen.  When the Pick and Transfer button is selected, the stock is moved and the allocated lines are re allocated.

Sicon Works Order Processing Picking Components

The location on the component line has also been changed to the new location.

Sicon Works Order Processing Picking Components

If the component line is a traceable item, and there is an extra quantity added to the list of stock to transfer besides the allocations, then the standard Sage Batch / Serial details screen is shown after the Pick and Transfer button is selected, allowing the user to select the batch or serial numbers that represent the extra quantity.

Sicon Works Order Processing Picking Components

NB: At this stage, if the Cancel button is pressed, then the Pick will go ahead and only the allocations will be transferred and then reallocated.  The extra amount will be cancelled and will have to be transferred manually.

 


1.11. Finished Products Tab

Description

The finished products tab is used to add more than one finished item to a works order.  This tab will list the finished items and allow the user to add the cost of each finished item.  The UseFinishedProductsTab setting in Settings – All Settings needs to be set to Yes in order to use the Finished Products tab.  This is a global settings and will be applied to all works orders.

Sicon Works Order Processing Finished Products Tab

More than one finished item can now be added to the works order using the Amend Works Order screen as the Add button in the Finished Products section will now be enabled even after adding one finished item.

Sicon Works Order Processing Finished Products Tab

When adding extra finished items, the following message may appear:

Sicon Works Order Processing Finished Products Tab

This means that the quantity of the finished items is more than the quantity originally entered for the works order.  Simply click Yes to add the finished item.

Sicon Works Order Processing Finished Products Tab

When amending the works order, the finished products tab will also now be visible.  On this tab, a list of the finished items for the works order is listed.

On each line, the portion of the total cost can be entered.  The percent of the total cost is shown next to the cost amount entered.  It is advisable to have all components issued before entering the costs for each line, as the total issued cost of the works order may change if there are some outstanding components.

Sicon Works Order Processing Finished Products Tab

Once all the costs for each line have been entered, the finished items can be booked in.  If the total costs entered against the finished items on the finished products tab does not match the total cost of the works order, then no finished items will be allowed to be booked in and a message will appear when trying to book in a finished item.

Sicon Works Order Processing Finished Products Tab

Once a finished item is booked in, the finished item will be marked as booked and a booking transaction line will appear for that particular finished item line.

Sicon Works Order Processing Finished Products Tab


1.12. Copy Works Order

Copying an Existing Works Order

This option is used to copy an existing works order.  The works order to copy is selected and the number of copies to make.

Sicon Works Order Processing Copy Works Order

Once the Create Copies button is selected, the works order is copied the specified number of times and the resultant works orders are shown.


1.13. Completed Works Orders

Description

The Complete Works Order screen can be used in two scenarios:

  • Scenario 1: To complete a works order that does not have a finished item; all components will have to be issued and the status of the works order will have to be issued.
  • Scenario 2: To complete a works order where there is still an outstanding quantity on the finished item; the works order will have to have a status of issued and there must only be one finished item.

Scenario 1

In this scenario, the works order has no finished item and the components have been issued, thus giving the works order a status of Issued.

Sicon Works Order Processing Complete Works Orders

To complete the works order, select Works Order – Complete Works Order in works order processing.  A list of Issued works orders will appear.

Sicon Works Order Processing Complete Works Orders

Select the works order to complete and then select the Complete button at the bottom.  A message will appear asking if you are sure you want to complete the works order.

Sicon Works Order Processing Complete Works Orders

This will now complete this works order.  The works order status will be set to Complete.

Scenario 2

In this scenario, the works order has issued components and the finished item will probably have some items booked in, although there could be non booked in as well.  The quantity booked in however does not equal the original quantity for the works order, and therefore the works order does not complete and remains in a Issuedstate.

Sicon Works Order Processing Complete Works Orders

In order to complete this works order, the Production issues internal area has to be set in Settings.

Sicon Works Order Processing Complete Works Orders

The nominal on this internal area is used on a journal entry to record the difference in cost of the works order when completing the works order.  For more information about the Production issues internal area, see the Settings, Options Tab in the Works Order Processing Help and User Guide.

NB: The setting above the Production issues internal area called Use production issues internal area for works order without a finished item does not have to be set.  The production issues internal area nominal code will be used regardless of this setting.  However, you may have to set this to enable the Production issues internal areadrop down and then deselect it again after selecting the correct internal area.  Also note that internal areas are setup in Stock Control.

To complete the works order, select Works Order – Complete Works Order in works order processing.  A list of Issued works orders will appear.

Sicon Works Order Processing Complete Works Orders

Select the works order to complete and then select the Complete button at the bottom.  A message will appear asking if you are sure you want to complete the works order.

Sicon Works Order Processing Complete Works Orders

This will now complete this works order.  The works order status will be set to Complete.  The finished item quantity will be set to match the booked in quantity.  A new booking transaction will be added to the finished item saying there was a difference in cost.  In the following example works order, there was a difference of 10, as the previously booked in finished items had a cost of 5, and the whole works order had a cost of 15.  Therefore, the finished item transaction has the balance of 10 recorded as the cost.

Sicon Works Order Processing Complete Works Orders

A nominal entry will be posted to record this difference.  This entry will have a credit value in the nominal used for the internal area when booking in finished items, therefore reducing the work in progress and a debit value in the nominal used for the production issues internal area.

Sicon Works Order Processing Complete Works Orders

Sicon Works Order Processing Complete Works Orders

 


1.14. Sub Assemblies

Sub Assemblies Created when Works Order Created

Sub assembly Works Orders will be automatically created if the Create separate works order for each sub assembly option is ticked on the Settings screen.

Sicon Works Order Processing Sub Assemblies

When a works order is created (either manually or from a sales order line) and there is no free stock for the sub assembly, then the sub assembly works order will be created automatically.  If there is free stock, then the user will be asked whether they want to use the free stock, in which case no sub assembly works order will be created.

Once the works order is created, component lines that link to a sub assembly will be shown in blue.

Sicon Works Order Processing Sub Assemblies

A works order sub assembly will have a / in the works order number and the numeric value.  For example; PM/SINK/PACK is a sub assembly of CA\ARIZONA SINK UNIT and CA\ARIZONA SINK UNIT is a sub assembly of BS/ARIZONA/BOM.

Sicon Works Order Processing Sub Assemblies

To view the sub assembly from the Amend Works Order screen, right click on the blue component line and then select the Show Works Order for Sub Assembly.

Sicon Works Order Processing Sub Assemblies

This will open the sub assembly in a new window.

Linking existing works orders to create sub assemblies

It is possible to link an existing works order to a works order that has been amended.  This can be linked on any component line in the works order.

NB: Whilst flexibility is provided, the finished item on the sub assembly may then not match the component line on the header works order.  This is up to the user if they want these to match, however works order processing will continue to function if these items don’t match.

To link a component line to an existing works order, right click the component line and then select the Works Order Links option at the bottom.

Sicon Works Order Processing Sub Assemblies

A new screen will appear and will allow the user to select an existing works order to link to.  A works order can be selected from the drop down or the Show All button can be selected to show all works orders. Once a works order is selected, the Link to Selected Works Order button should be selected to create the link.

Sicon Works Order Processing Sub Assemblies

An existing link can also be removed via the same screen.  If a link exists, then a Remove button will appear at the top of the screen to allow the user to remove the link.

Sicon Works Order Processing Sub Assemblies

NB: Works orders that are linked using this method will not have the same works order numbering structure as mentioned above.  This is because works order numbers are not overwritten when links are created between existing works orders.

 


1.15. Select a Warehouse for a Works Order Line

(NB: this is a new feature added in May 2015 .  As such, this is only available in the Interim Versions of Sicon Works Order Processing.  For further information, please contact your Business Partner Manager)

Step 1: Check default warehouse settings on stock item

In Works Order Settings on the Stock and Warehouse tab, there is a setting that specifies whether to check the default warehouse on the stock item:

WOP Settings
If this is selected, the default component warehouse set on the stock item is used.

WOP Settings

 

If the component works order line is to represent a sub assembly, then there is a setting on the Stock and Warehouse tab to check if the default component warehouse or the default finished item warehouse should be used:

WOP Settings

Based on this setting, the default finished item warehouse may be used instead of the default component warehouse.  The reason for this is that the works order finished items may be built into a finished items warehouse, and therefore the component line representing the sub assembly should pick up the stock from the finished items warehouse, not the component warehouse.

Step 2: Use a manually set warehouse if there is one.

A manually set warehouse may be provided. For example:

1. When creating a works order manually, then the default warehouses are set on the works order screen before creating the works order. These are initially set from the default user settings or the global defaults setup in settings (further details in Step 3 and 4):

WOP Manually Set Warehouse

When Generating Works Orders from Sales Orders, there is an option to set the warehouse for components:

WOP Generating a WO from a SO

Step 3: Default user settings are checked.  If warehouses are setup against the logged in user, then these are used:

WOP Settings
Step 4: Global settings are checked.  Global warehouse defaults is the last check to obtain a warehouse:

WOP Settings

NB: If the warehouse found from the above steps does not exist against the stock item for the works order line, then the warehouse is not set. When the works order is opened, the user will have to set the warehouses on works order lines that have not been set.

When adding sub-assemblies

When creating a works order, and a component line represents a sub assembly, the following screen will appear:

WOP Sub Assemblies

This gives the user an option to create the sub assembly, or select free stock from another warehouse. By default, if there is free stock against the default warehouse, the default warehouse will be selected.


2. Works Order Processing

The WOP Processing section is used to add cost item time entries, move works orders into another area, pick components and back flush works orders.

If manufacturing is enabled, the expediting function is also available in this section.


2.1. Work List

Entering Actual Times and Moving Areas

The work list screen is used to show a list of works order in the area selected.  Areas can be setup from the Areas menu option and the routes are setup against the stock item.  The initial area a works order is in has to be selected when amending the works order otherwise the works order will not appear in any lists below.

Sicon Works Order Processing Work List

The area against a works order can also be set on the amend works order list screen in the Area column.

On the Work List screen, the works order can be moved into another area and actual times for labour and machine items can be entered against the works order

Sicon Works Order Processing Work List

When a works order has been selected from the list, the Amend Times button can be selected to show the actual times screen.  Here actual hours, minutes and seconds can be entered against the works order.

Sicon Works Order Processing Work List

The works order can be moved to the next area by selecting the Next Area drop down in the grid.  Once an area has been chosen, selecting the Move select works order to next area button will move the works order to the next area.

Sicon Works Order Processing Work List

 


2.2. WOP Picking Components

Selecting Components to Pick

This option can be used if picking component lines is required.  Once a works order is selected, a list of component lines to pick is displayed.

WOP Pick Components

To pick the component select, select the Pick button.  The picking processing from this point onwards can vary depending on settings in works order processing.  Please refer to the Picking Components in the Works Order Processing Help and User Guide for further information.

 


2.3. Expediting

Expediting Works Orders

The expediting function is used to examine outstanding component lines on a works order.  Incoming purchase order lines can be viewed for each potentially problem component line.  The expediting report can be filtered by date or by works order number and can include allocated and issued works order lines.

Component lines with potential problems are shown in red, whilst lines in orange may not have free stock at the time it is required.  Lines in green will have enough free stock at the time it is required.  Please note that the term Free Stock here refers to the stock levels at the point when the stock is required for the works order, not current free stock levels.  For example; there may not be current free stock, but future purchase orders coming in may increase future free stock quantities.

Sicon Works Order Processing Expediting

When a component line is selected in the top list, the bottom list is populated with corresponding purchase order lines.  The user can view these purchase orders and can therefore chase the supplier for stock.

The Details button will display the stock movements for the selected component line.  The preferred supplier can also be viewed by selecting the Preferred Supplierbutton.

A print out of the entire component line list, with the respective purchase order lines, can be obtained by using the Print All button.

 


2.4. Back Flush

Completing Works Orders using the Back Flush Utility

The back flash utility is used to complete a works order quickly.  The first step is to select the works order to process from the drop down menu and then the list.

Sicon Works Order Processing Back Flush

After clicking the Next button, component lines will be validated to see if there is enough available stock.  From here, we can amend the works order, add stock for items that don’t have enough stock and revalidate the component lines.

Sicon Works Order Processing Back Flush

On the next screen, component lines are allocated and issued.

Sicon Works Order Processing Back Flush

Following allocation and issuing, the finished item is booked into stock.

Sicon Works Order Processing Back Flush

The last screen completes the back flush process.

Sicon Works Order Processing Back Flush

 


3. Enquiries

The enquiries section is used to view works orders.

 


3.1. View Works Orders

This screen is used to view works orders without the ability to amend them.  The search screen looks very similar to the amend works order list screen.

Sicon Works Order Processing View Works Order

When viewing the works order, the user will not be able to amend anything on the works order.


4. Works Order Maintenance

Works order maintenance section.


4.1. Areas

Setting Up An Area

System areas are setup using the Areas menu option.  The area code and description can be specified.

Sicon Works Order Processing Maintenance Areas

Creating Routes for a Stock Item

Routing from one area to the next is setup against the stock item.  On the Material Planning tab when amending a stock item, a routing list is displayed at the bottom of the screen.  An area is setup in the route by selecting an area in the drop down when clicking in the list.

Sicon Works Order Processing Maintenance Areas

These areas can then be used on works orders based on the finished item of the works order and is set when amending a works order.

Sicon Works Order Processing Maintenance Areas

The area can also be set on the amend works order list screen using the Area column.

 


5. Works Order Processing Utilities

This section has utilities to import works order lines, disassemble works orders and update stock item settings.

The settings for works order processing are also contained in this section.


5.1. Import Works Order Lines

Creating New Works Orders via the Import

The import facility is used to import works orders into works order processing.  An example of the import file is included in the installation package.

When the Import Works Order Lines menu option is selected, an open dialog window is displayed asking for the location of the import file.

Sicon Works Order Processing Import Works Order Lines

Once the import file is selected, the lines in the file are validated.

Sicon Works Order Processing Import Works Order Lines

Following validation, the import button becomes available to import the lines into works order processing.

Sicon Works Order Processing Import Works Order Lines

Finally, a message is displayed stating whether the import was successful or not.


5.2. Disassemble Works Order

Creating a Works Order to Disassemble

A completed works can be created for disassembly.  The completed works order will have all components marked as issued and all finished items set as booked in.

Before creating a works order to disassemble, the stock items, default warehouses and the quantity to disassemble needs to be selected.

Sicon Works Order Processing Disassemble Works Order

Once the Create button is selected, a completed works order is shown.  The process of disassembly involves unbooking the finished item, followed by unissuing the component lines.

When a component line is unissued, the user will be asked to specify the location to add the component stock to.

Sicon Works Order Processing Disassemble Works Order

 


5.3. Update Stock Items

Description – Utility to Update Stock Items

The utility to update stock items is used to set the make or buy options on the stock item for the material planning process.  The screen will appear with a list of BOM items to update.  All items will be ticked to suggest they will be updated.

Sicon Works Order Processing Update Stock Items

There is a tick box above the list to only show items that have not been set yet.  The Refresh button will have to be selected to refresh the list.

Next select the option to apply to the stock items, and then select Update Stock Items.  All items in the list will now be updated with the options selected and a message will appear at the end stating the process is complete.

 


6. Settings

This screen is used to alter various settings for works order processing.  Please refer to the sub menus for details about settings on each tab.

Sicon Works Order Processing Settings

See Sicon WOP Amendable Form Settings document for more details.


6.1. Options Tab

Auto Generate and Number Formats

Sicon Works Order Processing Options Tab

WOP Options Tab

Expand BOM and Sub Assembly Settings

These settings are used during the creation of a works order:

2

WOP Options Tab

General Usage and Functionality

These setting refer to general usage when processing works orders.

WOP Settings

WOP Options Tab

Component Line Allocations and Issues

These settings refer to how component lines are allocated and issued:

WOP Settings

WOP Options Tab

 


6.2. Stock and Warehouse Tab

Internal Area Settings

These are the internal areas to be used when issuing components and booking in finished items.

Sicon Works Order Processing stock and warehouse tab

When issuing a component, the stock nominal (Balance Sheet) on the stock item is credited and the nominal on the internal area is debited (WIP nominal).

Sicon Works Order Processing stock and warehouse tab

When booking in finished items using the finished item internal area nominal code, the stock nominal (Balance Sheet) on the stock item is debited and the nominal on the finished item internal area is credited (WIP nominal).

When booking in finished items and NOT using the finished item internal area nominal code, the stock nominal (Balance Sheet) on the stock item is debited and the issues nominal on the stock item is credited.

The value of these journals will include component costs and labour and machine, and non stock item costs

For further information, please see the Nominal Postings section of the Works Order Processing Help and User Guide

Component Issue when using Production Issues Internal Area

Sicon Works Order Processing stock and warehouse tab

If this setting is turned on, then this internal area is used instead of the components internal area if there are no finished items on the works order.  In this example, the internal area called Production Issues is used and is setup as below:

Sicon Works Order Processing stock and warehouse tab

In this case, when issuing a component, the stock nominal (Balance Sheet) on the stock item is credited and the nominal on the Production Issues Internal Area is debited (probably Profit and Loss and in the region of cost of sales).

Sicon Works Order Processing stock and warehouse tab

NB: The Production Issues Internal Area will also be used when completing an outstanding works order via the Complete Works Order screen when there is a difference in cost of the finished items booked in and the cost of the works order.

Default Warehouses

Here the default component warehouse and default finished item warehouse can be set for new works orders.  Settings on the Default User Settings tab will override these settings.

Sicon Works Order Processing stock and warehouse tab

Quarantine Warehouse

Warehouses can be set as quarantine warehouses.  These warehouses will be excluded from works order allocations and from material planning.

Sicon Works Order Processing stock and warehouse tab

 


6.3. Job Costing Tab

Configuration

The following settings exist for Sicon Job Costing integration with Works Order Processing:

Sicon Works Order Processing Job Costing TabJob Costing Table

 


6.4. Calculations Tab

Date Calculations

These settings are used in the calculation of the start date and due date and the duration between these two dates on a works order when the works order is created.

Sicon Works Order Processing Calculations Tab

Calculations Tab Table 1Calculations Tab Table 2

Labour and Machine Cost Calculations

These settings are used in calculating costs recorded against a works order and thus the cost of the finished item booked into stock.

Sicon Works Order Processing Calculations Tab 2

Sicon Works Order Processing Calculations Tab 2

Non Stock Item Calculations

These settings are used to specify whether to add non stock items to the cost of a works order.  A nominal code has to be selected to record the cost of the non stock items when booking in a finished item.

For further information, please refer to the Nominal Postings section of the Works Order Processing Help and User Guide.

Sicon Works Order Processing Calculations Tab 2

Sub Contract Item

These settings are used to specify whether to add sub contract items to the cost of a works order.  A nominal code has to be selected to record the cost of the sub contract item when booking in a finished item.

Sicon Works Order Processing Calculations Tab 2

Miscellaneous Stock Items

This setting is used to specify whether to add the cost of miscellaneous stock items to the cost of a works order.

Sicon Works Order Processing Calculations Tab 2

 


6.5. Sales Order Work Flow Tab

Activate Work Flow Options

This option activates the sales order work flow when sales orders are saved/closed.  To enable this option, select the tick box below:

Sicon Works Order Processing Works Order Flow Tab

Create Works Order for Sales Order

If this option is enabled, the user will be asked whether they would like to create a works order for a sales order when closing the sales order.  This will create an empty works order and link the works order to the sales order.

NB: This option works best when auto numbering for sales order processing is turned off, as the process will then match the works order number and sales order number together.

The following steps are followed if this option is on:

  • When saving/closing the new sales order, the user will be asked whether they would like to create a works order for the sales order or not.Sicon Works Order Processing Works Order Flow Tab
  • If Yes is selected, a screen will appear asking for the works order / sales order number, as well as the works order name and default warehouse.Sicon Works Order Processing Works Order Flow Tab
  • Next the sales order confirmation screen will appear asking for the customer order no if there is one.
  • Sicon Works Order Processing Works Order Flow Tab

After this, the works order is created and linked to the sales order; the works order number should match the sales order number.  If the user views or amends the sales order, the works order will now appear in the list of works orders for the sales order on the Works Orders tab.

Sicon Works Order Processing Works Order Flow Tab

If the user Edits or Views the works order, the sales order number will appear in the header sections as well as a View Sales Order button in the bottom right corner.

Sicon Works Order Processing Works Order Flow Tab

Create Works Order and Fob for Sales Order

If this option is enabled, the user will be asked whether they would like to create a works order and job for a sales order when closing the sales order.  This option is only available if Job Costing Integration is enabled.  This will create an empty works order and job and link the works order to the sales order.  The works order will also be linked to the new job.

NB: This option works best when auto numbering for sales order processing is turned off, as the process will then match the works order number and job number and sales order number together.

The following steps are followed if this option is on:

  • When saving/closing the new sales order, the user will be asked whether they would like to create a works order and job for the sales order or not.Sicon Works Order Processing Works Order Flow Tab
  • If Yes is selected, a screen will appear asking for the works order / sales order number, as well as the works order name and default warehouse.  In addition, some extra job costing fields are available that will be recorded on the job.Sicon Works Order Processing Works Order Flow Tab
  • Next the sales order confirmation screen will appear asking for the customer order no if there is one.Sicon Works Order Processing Works Order Flow Tab

Create Works Order (and Job) for Each Sales Order Line

These options will allow the the user to create works orders and jobs (depending if job costing integration is enabled) for each sales order line on a sales order.

The following screen appears when the user closes/saves a sales order in Sage:

Sicon Works Order Processing Works Order Flow Tab

This screen displays the status for each line on the sales order whether a works order (and job) has been created.  Click the Create Works Order and Jobs to create works orders (and jobs) for the outstanding lines.

If the sales order line is a standard item line, then the stock item on the line will be added as a finished item on the works order.  If the stock item is a BOM item, then the works order will be populated with the components and cost items from the BOM.

If the sales order line is a free text line, then the new works order will be empty.

If jobs are created as well, then the works orders will be linked to the job.


6.6. Default User Settings

This screen is used to set default warehouse at a user level.  This section will override default warehouse settings in other sections.  A list of users is provided and a default warehouse for the finished item and a default warehouse for the components can be selected using drop downs against each user:

Sicon Works Order Processing Works Default User Settings Tab


6.7. Estimating Costs Tab

When creating works orders or suggested purchase orders, an estimate cost is calculated.  This cost is used on component lines on works orders or as a unit cost of suggested purchase orders in material planning.

These options should be selected if the average buying price should be used first for when there is available stock.

Sicon Works Order Processing Estimate Costs Tab

For details on how the cost of component lines is estimated or how the unit price on suggested purchase orders is calculated, please refer to the Costs section of the Works Order Processing Help and User Guide.


6.8. Material Planning Tab

Material Planning Usage and Functionality

These settings refer to usage and functionality during the material plan run.

Sicon Works Order Processing Material Planning Tab

Material Planning Table


6.9. Other Settings

All Settings

All settings, including extra minor settings, can be accessed through the All Settings button at the bottom left of the Settings screen.  It is advisable to change settings on the normal settings screen; however, if a setting cannot be found, then use the All Settings screen:

Sicon Works Order Processing Other Settings

The following is a list of other settings that may be useful:

Sicon Works Order Processing Other Settings


6.10. Stock Control Settings

These are settings in stock control that will affect the functionality of works order processing.

At this stage, works order processing only works when traceable numbers are specified when allocating.

Sicon Works Order Processing Stock Control Settings

Works order processing will be aware of the integrate stock management with nominal ledger setting.  If this is turned off, no nominal entries will posted to the nominal ledger; this includes labour and machine nominal entries, non stock item entries, issue entries and booking in entries.

Sicon Works Order Processing Stock Control Settings


7. Nominal Postings

Introduction

This document serves as a reminder of which nominal postings and which nominal accounts are involved in certain processing within works order processing.  These examples are using the ACS/TOASTER for a component and finished item:

Sicon Works Order Processing Nominal Postings

The works order internal area is setup as follows:

Sicon Works Order Processing Nominal Postings

The Plumber was used as the labour item and is setup as follows:

Sicon Works Order Processing Nominal Postings

The following diagram shows a summary of nominal movements for a general setup.

NB: Some settings in works order processing will alter which nominals to use; these are mentioned below:

Sicon Works Order Processing Nominal Postings

Dates on Nominal Entries

All dates on nominal entries are based on the UseCurrentDateOnStockMovements setting:

Sicon Works Order Processing Nominal Postings

If this setting is set to Yes, then the current date when the transaction is made will be used.  If this setting is set to No, then the works order start date is used.

Component Issue

In Settings, the internal area to use to components has to be set.  This internal area is used when issuing components.

When issuing a component, the stock nominal (Balance Sheet) on the stock item is credited and the Nominal on the internal area is debited (WIP nominal).

Sicon Works Order Processing Nominal Postings

Component Issue when using Production Issues Internal Area

If this setting is turned on, then this internal area is used instead of the components internal area if there are no finished items on the works order.  In this example, the internal area called Internal is used and is setup as below:

Sicon Works Order Processing Nominal Postings

In this case, when issuing a component, the stock nominal (Balance Sheet) on the stock item is credited and the nominal on the Production Issues Internal Area is debited (probably Profit and Loss and in the region of cost of sales).

Sicon Works Order Processing Nominal Postings 9

Un Issue

An Unissued uses the same technique as an Add Stock, so that the correct cost price can be added.  When unissuing, the stock nominal (Balance Sheet) on the stock item is debited and the nominal on the internal area used is credited.

Sicon Works Order Processing Nominal Postings

Book In

The internal area to use when booking in finished items has to be setup in Works Order Processing Settings.  You can then select whether to use this internal area nominal code when booking in finished items:

Sicon Works Order Processing Nominal Postings

When using Finished Item Internal Area Nominal

When booking in finished items using the finished item internal area nominal code, the stock nominal (Balance Sheet) on the stock item is debited and the nominal on the finished item internal area is credited (WIP nominal).  The value of this journal will include component costs and labour, and machine costs:

Sicon Works Order Processing Nominal Postings

A journal for each labour and machine item will also be created.  In this case, 1 hour’s worth of labour at a cost of 10 pounds was on the works order.  Therefore, the nominal on the finished item internal area will have a positive value (debit WIP nominal) while the nominal on the cost item (plumber) will have a negative value (credit):

Sicon Works Order Processing Nominal Postings

When NOT using Finished Item Internal Area Nominal

When booking in finished items and NOT using the finished item internal area nominal code, the stock nominal (Balance Sheet) on the stock item is debited and the issues nominal on the stock item is credited.  The value of this journal will include component costs and labour, and machine costs:

Sicon Works Order Processing Nominal Postings

A journal for each labour and machine item will also be created.  In this case, 1 hour’s worth of labour at a cost of 10 pounds was on the works order.  Therefore, the issues nominal on the stock item will have a positive value (debit) while the nominal on the cost item (plumber) will have a negative value (credit):

Sicon Works Order Processing Nominal Postings

Labour/Machine

The nominal journals to represent the cost items are only generated if the cost of the labour and machine items is added to the works order.  This is setup in Settings:

Sicon Works Order Processing Nominal Postings

Therefore, the nominal for booking in when labour and machine is excluded on cost of works order will only include the cost of the issued components, for example:

Sicon Works Order Processing Nominal Postings

Non Stock Items

Non-stock items can also be added to the cost of a works order.  This is done by selecting the option button Add non stock items to the cost of works order.  A nominal code for the non stock items has to be selected.

Sicon Works Order Processing Nominal Postings

When the finished item is booked in, a journal entry for the non stock item is represented by a positive value on the nominal of the finished item internal area (debit WIP nominal)* and a negative value on the non stock item nominal set above (credit):

Sicon Works Order Processing Nominal Postings
*This depends on the whether the internal area nominal code is used when booking in finished items.

Values on Nominal’s for Multiple Book Ins

The values on each of the previously mentioned nominal postings are equally divided according to the quantity booked into stock.  Therefore, if a finished item is partially booked in, then the values on the nominal postings will reflect this.

Un-Book a Finished Item of an existing Works Order

When doing an un-book of a finished item booked in the same nominal as above, booking in is used based on the Use internal area nominal code when book in setting.  Therefore, the journal posting is the reverse of when booking in the finished item.

Sicon Works Order Processing Nominal Postings

 

NB: The value of the journal is determined by Sage based on the costing method used and therefore may not be the same value as when the item was booked in.

Nominal entries for labour and machine items will be reversed:

Sicon Works Order Processing Nominal Postings

Nominal entries for non stock items will also be reversed.

 


8. Job Costing Integration

Description

Works Order Processing can integrate with the Sicon Job Costing module, providing job costing is installed.  The integration has to be enabled via the Settings screen on the Job Costing Tab.

Sicon Works Order Processing Job Costing Integration

For details on Settings for this tab, please refer to the Settings Help section on the Job Costing Tab.

Once job costing integration is enabled, a job drop down selection is available on the Amend Works Order screen to link the works order to a job.

Sicon Works Order Processing Job Costing Integration

A works order will have to be linked to the job before any components on the works order are allocated and issued.

When a component line is issued, a transaction will be posted to the job costing module reflecting the cost of the line issued.  The component line will be marked as Issued.

Sicon Works Order Processing Job Costing Integration

In job costing, the transaction will appear in the Stock Issues section and will reflect the cost of the issued component line.

Sicon Works Order Processing Job Costing Integration

The same would occur for labour and machine items when actual times are entered against these.  However, these lines will post a transaction to the Labour/Resources section in job costing.

On the Job Costing Enquiry screen, a Works Orders tab is available to view the linked works orders to the selected job.  From here, it is possible to view the structure of the works order tree if there are sub assemblies, as well as actually opening the Amend Works Order screen to view the works orders.

Sicon Works Order Processing Job Costing Integration

Please refer to the Sub Assemblies section of the Works Order Processing Help and User Guide to find out how to link works orders to create sub assemblies.

Sub assembly lines in works order processing are shown in blue.

Sicon Works Order Processing Job Costing Integration

If a component line on the works order that is linked to a sub assembly (shown in blue) is Issued, then the cost on the transaction in job costing is hidden and excluded from the total cost of the job.  This is to prevent double costing in job costing.

Sicon Works Order Processing Job Costing Integration

 


9. Costs

Estimate and Future Buying Prices

When a new works order is created, each component line is given a future buy price (estimate cost).  This value is calculated using the following algorithm and the value is always in the base currency:

Sicon Works Order Processing Costs

The first decision step is based upon the setting below on the Estimate Costs tab on the settings screen in works order processing.

Sicon Works Order Processing Costs

If the setting is off and the step therefore ignored, then the process of obtaining a cost value will simply move to the Is there a preferred supplier step.

View Costs on a Works Order

On a works order, the header field called Total cost for WO provides the estimate, average or actual cost of the works order.  By double clicking on this field, a summary screen will provide a break down of how this cost is calculated.

Sicon Works Order Processing Costs

By double clicking further on the Cost of components field, a further break down of the components is provided with details.

Sicon Works Order Processing Costs

The future buying price can also be viewed when editing a component line and can also be changed by the user when editing the component line.

Material Planning

The above methodology also applies to suggested purchase order in material planning when setting the unit price.  A description is also supplied next to the unit price field about where the price is obtained from.

 


10. Enable Module

This screen is used to enter module enable string to allow use of the system.

Enter (or paste) the module enable string provided by Sicon, then click OK.

Sicon Works Order Processing Enable Module

NB: When using Sage 200 2009 (and later), it is no longer necessary to enter the enable string for each Sage company.  Earlier versions of Sage 200 will require the enable string to be entered for each Sage company.

 


11. Release Notes

The Release Notes document below shows which release of the Manufacturing & Distribution Manger system includes which new features and for which version of Sage these will work.

The version number indicated in the Distribution Manager Release Notes includes a full release number and a sub version number; e.g. ’6.1′ indicates the full release version number of the software.  Pre-release version builds of the software are available to certain clients requiring new or enhanced features being developed from the wish list.  If these versions are installed on your system, you will see an additional number e.g. 39.113 making up a specific database version and interim build number of 6.1.39.113.

It is unlikely that these features will be documented in this help and user guide until the end of the development phase.

Manufacturing & Distribution Manager Release Notes


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