Creating a new Manufacturing Order
We suggest reading the following article before proceeding: Understanding Manufacturing Orders.
In short, there are two types of Manufacturing Orders (Make to Order and Make to Stock), which are created in different ways in Katana.
Creating a Make to Stock Manufacturing Order
You can create a new Make to Stock Manufacturing Order either through the global "+" sign and selecting "+ Manufacturing order", selecting "Make in batch" for a Sales Order in the "Sell" screen, or using a quick-add button in the "Inventory" view in the "Stock" screen.
1. Click on the global "+" sign and select "+ Manufacturing order".
2. For a Sales Order with a "Not available" Sales Items availability status, click on "Make" button and select "Make in batch". This will allow you to customize the quantity of missing products based on your desired batch size.
3. In the "Stock" screen, click on the "+" button at the end of a line for a product. This is a quick way to create Make to Stock MOs for products for which the stock level is below the optimal level, taking into account the quantities you have in stock, expected, committed, and the Reorder Point. To enter more details or edit the Manufacturing Order, navigate to the newly created MO in the "Schedule" view.
Creating a Make to Order Manufacturing Order
You can create a new Make to Order Manufacturing Order from the "Sell" screen.
1. Navigate to the "Sell" screen.
2. Click on a "Make" -> "Make to order" button in the Production column for a Sales Order. This will create Make to Order Manufacturing Orders for all the products required by the Sales Order. Those MOs will be permanently linked to the Sales Order.
You can also create Make to Order MOs for each Sales Order line separately by opening a Sales Order and clicking on "Make" -> "Make to order" for a specific Sales Order line.
Each Manufacturing Order has a Production status, which can be manually changed by the user. Statuses trigger specific changes in the inventory and also help to monitor and manage production activities. Read more about Production statuses.
Manufacturing Order card
Manufacturing order # (required) - a unique identifier for the Manufacturing Order. This is auto-generated by Katana. If MO is linked to a Sales Order, then it displays the underlying Sales Order number with a suffix, for example "/ 1". For MOs that are making to stock, order # can be changed manually by the user.
Product (required) - select a product you wish to produce. Note that the field value is a combination of Product Code, Product name and Variant Option values (e.g. "[P-1] MyProduct / White"). You can only add one product or variant to a Manufacturing Order. You cannot change the product for Make to Order Manufacturing Orders that are linked to a specific Sales Order.
Quantity (required) - select a quantity you wish to produce with this MO. The unit of measure for the product can be set and edited on the product card. The maximum of 3 decimal places is allowed. You cannot change the quantity for Make to Order Manufacturing Orders that are linked to a specific Sales Order.
Total cost - shows the total cost of manufacturing the selected quantity of the product. This includes the cost of the ingredients from Product Recipe / BOM and the cost of Production Operations (both can be set and edited on the product card), multiplied by the quantity.
Production Deadline (required) - the expected date for completing the Manufacturing Order. Read more about managing Production Deadlines. Marked red if at least one ingredient required by the MO is not available, the arrival date of an expected ingredient is later than the MO deadline, or if the deadline has passed.
Created date (required) - the date of creating the Manufacturing Order. The default value is set to today but can be changed manually if needed.
Done date - field not visible before completing the Manufacturing Order. This will be automatically assigned to a Manufacturing Order after changing the Production status to "Done".
Ingredients table shows all materials and subassemblies that are required to produce the product.
The ingredients, quantities, and costs are taken from the Product Recipe / BOM (can be set and edited on the product card).
Katana enables you to record waste of ingredients created in manufacturing or account for varying amounts of ingredients in the production process. If you used more or fewer ingredients in production that is defined in the product recipe, you can edit the quantities for ingredients on the Manufacturing Order. Click on the quantity for an ingredient to start editing. These changes are not applied to the default Product Recipe defined on the product card.
Note: Changes to the default Product Recipe for a product will not be applied to any open Manufacturing Orders for that product automatically. You can apply changed Recipes to selected open MOs in bulk with a few clicks or update MOs one-by-one. Read more here.
Ingredients Availability shows whether the required materials and subassemblies for a Manufacturing Order are "In stock", "Expected" or "Not available". Based on the status, you can take necessary actions accordingly. Read more about Ingredients Availability.
The date below to the "Expected" status indicates the arrival date of a related Purchase Order for materials or the Production Deadline of a related Manufacturing Order for subassemblies.
Clicking on the Ingredients availability status opens an Inventory Intel pop-up, which shows additional info about the inventory level of the specific material or subassembly. You can conveniently check the "In Stock", "Expected" and "Committed" quantities of the ingredient and see all the Manufacturing Orders to which this ingredient is booked. In the pop-up window, Manufacturing Orders are ordered by priority (can be edited in the "Schedule" view) and the current Manufacturing Order is highlighted in bold.
Important concept regarding Ingredients Availability:
The ingredients availability status indicates whether the ingredient is available for THIS particular Manufacturing Order. It takes into account the order of priority of Manufacturing Orders (set in "Schedule" view). This means that even when you have some quantity "In stock" for the required ingredient, the Ingredients availability for this particular MO might still show "Not available" if another higher priority MO has already reserved the same ingredient. Changing the order of priority of Manufacturing Orders could also change the Ingredients Availability for Manufacturing Orders. There are no permanent links between any Manufacturing Orders and Purchase Orders.
The table at the bottom of a Manufacturing Order shows production Operations you need to complete to produce the product. The operations, resource, time, and costs are taken from the Production Operations (can be set and edited on the product card). You can edit this information on the Manufacturing Order if needed.
You can also assign Operators (Shop Floor App users) to operations on open Manufacturing Orders. Read more.
If the actual time to complete an operation is different from the default time defined in Production Operations for a product, you can change the "Time" column for each operation on the Manufacturing Order. This is taken into account in cost calculations for the product and enable you to track the actual manufacturing costs for products.
Any changes to the time of operations on the Manufacturing Order are not applied to the default Production Operations on the product card.
Note: If you change Production Operations for a product on the product card, the changes do not apply automatically to existing Manufacturing Orders. You will see a notification at the bottom of the screen on the Manufacturing Order if the Production Operations for the product have been changed and can choose to refresh the operations for the MO.
You can track the production status in more detail for a Manufacturing Order by changing the statuses for production steps. Click on the icon at the end of the operation step line to change the status. Status can also be changed directly from the Shop Floor Control App by Operators. Read more.
Read more about Managing production statuses.
You can add any comments to the Manufacturing Order. For example, specific instructions to production personnel, any production details, any reference numbers, references to the location of relevant files etc.