This guide walks you through every feature unlocked by Katana’s Advanced Manufacturing add-on and explains how to configure each feature to maximize its benefits.
Who’s this for?
Production and operations managers looking to scale manufacturing by equipping their shop floor teams, tracking performance, and managing complex operations more precisely.
What you’ll unlock with the add-on
The Advanced Manufacturing add-on gives you access to:
Shop Floor app – Empower operators with clear task lists
Manufacturing insights – Track efficiency, cost, and resource usage
Advanced routings & operation types – More control over your production steps
Ingredient picking – Reserve materials to avoid delays
Pre-implementation checklist (optional)
1. Map your current production workflow
Visually outline all the steps for a few key products (use a flowchart or sticky notes), and mark:
Which steps are sequential or parallel
Where quality checks happen
Where delays or confusion typically occur
Try to configure sequences and spot bottlenecks.
2. Review and optimize resource allocation
List all workstations, tools, and teams involved in production.
Identify:
Which resources are used in which steps
Where setup time is required
What can be batched or standardized
This prepares you to assign the correct resources in routings and track real-time usage via the Shop floor app.
3. Audit and standardize your BOMs and production steps
Take the time to review what you’ve built to ensure your foundation is solid.
Review BOMs and production steps, and remove any outdated tasks or gaps.
Spot steps that would benefit from clearer costing (e.g., setup time, per unit work).
Note any products with inconsistent workflows or steps that require enforcement.
Use a stopwatch or mobile timer to capture actual operation times on the floor, obtaining real benchmarks to improve from.
Standardize where possible. E.g. if you are making subassemblies per order, maybe you can make them in batch. This could reduce stockouts and make planning easier.
Accurate operation types and sequencing rely on clean BOMs. Clear, realistic steps ensure better costing and performance insights.
4. Plan operator access
Decide who needs Shop floor app access and for which workstations
Designate a “master user” or internal go-to person for Shop floor app support
This prepares your team for day-one usage and reduces dependency on the production manager.
5. Align what you’ll track
Determine where better data will have the greatest impact. Think in terms of the following:
Are you losing more to material overuse or to inefficient task flow?
Do you need tighter control over ingredient usage, setup time, or delays?
Where do errors or overruns typically happen?
Use Manufacturing insights to focus on what hits your margins or flow the hardest. Keep your goals clear, whether it’s tighter inventory control, fewer delays, or more accurate costing.
6. Clean up open manufacturing orders
Review any open manufacturing orders (MOs). Use Refresh data on open MOs to apply the latest operations and routing so your task list matches your setup.
7. Train your team
Ensure operators are aware of how to initiate pause/complete tasks, accurately report actual quantities, and leave clear notes. Here is a list of resources you can share with the operators:
Using the Shop floor app video guide
Using the Shop floor app written guide
8. Plan a first review
Set a check-in for 1–2 weeks post-launch. Review ingredient usage, task times, and cost breakdowns in the Manufacturing insights tab to identify early wins and needed tweaks.
Advanced manufacturing add-on implementation checklist
Use this checklist to track your progress through the setup to get the most out of the add-on:
Review Manufacturing settings and enable key toggles
Update or build routings with correct operation types
Enable operation sequences for sequential or parallel steps
Optional: Bulk add or update production operations via CSV/XLSX
Add Shop floor operators with login codes and QR setup
Test the Shop floor app with real operator logins
Enable and use ingredient picking to reserve materials
Review Manufacturing insights to track performance and cost
Set up filters or download reports for ongoing review
Phase 1: Review your manufacturing settings
Navigate to Settings → Manufacturing
Here you’ll find toggles for some of the features unlocked by the add-on
Setting | What it does |
Enforces ingredient picking before production starts (recommended for accuracy) | |
Prompts operators to input actual ingredient usage | |
Prompts for confirmation of finished quantities when the final step of production is complete | |
Show manufacturing order deadline / Show sales order deadline | Displays MO or related SO deadlines inside the app |
Suggested default: Turn all toggles ON to maximize control and visibility.
Phase 2: Configure routings with operation types
Use routings to define each stage of the workflow, assign operation types for accurate labor and machine costing, and set task sequences to guide operators through the process in the right order.
1. Set up or review your routings
If you’ve already created your product recipes/BOMs and production operations - great! Now’s the time to enhance them with:
Operation types for smarter cost tracking
Sequenced steps to enforce the right task order on the floor
If you're new to this, start with:
- How to create a BOM/product recipe
- How to create production operations
2. Add operation steps and set sequence
Go to Items → Products
Open a product and go to the Production operations tab
Add or adjust each production step (e.g. Cutting, Assembly, Packaging)
Assign a resource (station, machine, or operator) for each step
Enable Operations are in sequence if your workflow has a defined order. You can choose to:
Run operations consecutively (one must finish before the next begins), or
Group operations in parallel (multiple operations run at the same time)
Enabling task sequence ensures operators only see tasks when they’re ready to start, preventing skipped steps and keeping production aligned with your real-world workflow. If the sequence isn’t enabled, all tasks appear at once, even if earlier steps aren’t finished.
3. Choose the right operation type
Operation types determine how Katana calculates labor or service costs for each task:
Operation type | Best for | How cost is calculated |
Process | Time-based tasks (e.g. assembly) | Time × hourly workstation rate |
Setup | Prep work (e.g. equipment calibration) | Fixed time × hourly rate |
Per unit | Repetitive, per-item tasks (e.g. labeling) | Units × cost per unit |
Fixed cost | Flat-rate or outsourced steps | Fixed cost per operation |
Using the right type avoids over- or underestimating your margins and helps ensure accurate COGS.
4. Bulk update production operations (optional)
Use our templates if you’re managing several products and want to update them in bulk to save time.
1. Export or download operations:
Go to Items → click Export button → Operations (.csv or .xlsx) to get a list of selected existing items' production operations
Or navigate to Settings → Data import → Download “Add new production operations” to get an empty template
2. Edit the file
Update or add new steps, durations, resources, and operation types.
3. Re-upload from Settings → Data import → Add new production operations, and select import behavior:
Replace existing operations: completely overwrite operations for listed products
Add to existing operations: append new steps to current operations. Delete pre-existing operations in the exported file, or they will be duplicated during import when choosing this option.
4. Review errors (e.g. missing SKUs or time values), correct and re-import
5. Apply to open MOs
Open an MO and click Refresh data to sync with the updated routing
Phase 3: Set up the Shop floor app
The Shop Floor app provides your production team with a real-time view of their tasks directly on a tablet or smartphone. Using the Shop floor app, operators can:
View only the tasks assigned to them based on routing sequences
Start and finish their work with one tap
Report consumed ingredients and track finished goods
Leave comments or alerts (e.g. missing stock, quality issues)
1. Add operators
Click on your name (top-right corner in Katana)
Select Team → Add new team member
Choose Shop floor operator
Enter the operator’s full name and a 6-digit login code (numbers only)
Click Add to create the operator account
Use consistent naming so you can match devices to workstations easily later.
2. Set up the operator device
Once an operator is added:
Click Set up operator device
A QR code will be generated
On the operator’s device (tablet or mobile), open: shopfloor.katanamrp.com
Scan the QR code to connect the device to the operator profile
(or save it and send it remotely)Save or print the QR code and post it at the operator’s station. They’ll use the same code + 6-digit login to reconnect anytime.
Click Next to see the 6-digit login code again
Finalize setup on the device
You can test the operator login on your own phone to preview their view and check that everything looks right.
3. Assign tasks to operators (important!)
A task = an individual operation step on an open manufacturing order (MO). To actually display tasks in the Shop floor app, you need to assign operators to tasks in Katana. You can assign tasks in 3 ways:
Option 1: Assign from the MO card (for manual control)
Go to Make → open an MO
Scroll to the Operations table
Under the Operators column, click an empty field, and select the relevant operator from the list
Option 2. Assign tasks from the tasks tab
Go to Make screen→ Tasks tab
Find the task you'd like to assign, or use checkboxes to select multiple tasks.
Use Assign to for adding an operator to multiple tasks, or Assigned to column to assign tasks one by one.
This view displays all open tasks across all MOs, making it ideal for bulk reviews. You can also filter tasks by resources!
Option 3. Map operators to resources (auto-assignment)
Go to Settings → Resources
Add default operators to specific resources
Then, any task linked to that resource will be auto-assigned to the mapped operator when creating new MOs
If you change resource assignments later, mappings won't auto-update past tasks, only new ones going forward.
What happens after task assignment?
Assigned tasks appear instantly in the operator’s Shop floor app
Operators only see tasks they’ve been assigned to
If no operator is assigned, the task won’t show up in the app
If multiple operators are assigned, all of them can view and complete the task
Common pitfalls to avoid
Issue | What to watch for |
Out-of-sequence task execution | Make sure your routing steps are clearly ordered, and “operations are in sequence” enabled on the product card → production operations |
Negative inventory warnings missed | Operators won’t see warnings, apart from red/yellow/green for ingredients in task view. Make sure to check inventory accuracy in Katana beforehand |
Accessibility | Ingredient availability colors are red/yellow/green, be ready to explain verbally if needed |
Phase 4: Use ingredient picking (recommended)
Ingredient picking helps ensure ingredients are available before production begins, reducing mid-task delays and inventory errors.
How it works:
Make sure ingredient picking is enabled: Settings → Manufacturing and enable Picking of raw ingredients is required.
From Make screen → Schedule tab, and open an MO
Click Pick all to reserve available ingredients
Katana picks what’s in stock and shows:
Fully picked – all ingredients reserved
Partially picked – some still missing
Not picked – nothing reserved
As stock becomes available, you can return and click Pick all again
When the MO is completed:
Finished goods are added to stock
Unused ingredients are returned automatically
MO shows updated actual vs. picked usage
If more ingredients are reported than picked, the MO will revert to “Partially picked.”
Phase 5: Monitor manufacturing insights
Manufacturing insights offer a clear view of your production performance, enabling you to reduce costs, track material and resource usage, and enhance efficiency across your shop floor.
To access your manufacturing insights, go to Insights → Manufacturing, where you’ll find three reports:
Report | What it shows | Key questions it helps answer |
Cost Overview | Trends in total manufacturing cost, split by materials and operations |
|
Ingredients | Usage and cost of materials across products |
|
Resources | Usage of resources and related costs |
|
Best practices for using manufacturing insights:
Use filters (date, product, customer) to drill into relevant data
Click directly on charts to cross-filter by time or category
Export data or connect to tools like Easy Insight, PowerBI, or SyncHub for custom dashboards
Schedule regular reviews (weekly or monthly) to spot trends and make proactive improvements
Time is tracked per task, not per operator. If multiple operators work on one task, time is logged collectively. Reassign the task on the MO in Katana to reflect who completed it for better tracking. You can then export Done tasks from the Make screen for further analysis.
Your feedback is invaluable. Let us know your thoughts on this article or anything in Katana you'd like to see improved: [email protected]