In the Shop Floor App, Operators can report the actual quantity of the product made with a Manufacturing Order. They can either indicate the planned quantity or change the produced quantity if it's different from planned.

In certain industries or situations, it is difficult to assess the exact quantity of output from the manufacturing process. This feature enables you to report the actual output easily.

The actual quantity can ONLY be reported for Manufacturing Orders that are Making to Stock. You cannot report the actual quantity in a Make-to-Order situation, in which case the actual quantity always equals the planned quantity.

The actual quantity of products made is asked at the time of completing the final step for the Manufacturing Order in the Shop Floor App. In this case, the final step means the bottom task on the Operations list, not the last open task.

The Operator can leave additional comments on the quantity of the product made. This will be added to the "Additional info" section of the Manufacturing Order on the Katana MRP main site.

You can choose whether the actual quantity of products made is asked from Operators or should the planned quantity be always automatically used as the actual output quantity. If you wish to start reporting actual quantities from the Shop Floor App, you would need to enable this in the Katana MRP main site.

Operators can also report the actual quantity of ingredients consumed with a Manufacturing Order. Read more

Enabling tracking for actual product quantities made

To enable tracking for actual quantities of products made with Manufacturing Orders from the Shop Floor App:

  1. In Katana MRP main site, go to "Settings" -> "Shop Floor App"

  2. Enable "Ask the quantity of finished products from the operator when a Manufacturing Order is completed".

Reporting the actual quantity of products made

To report the actual quantity of products made via Shop Floor App:

  • An Operator marks the final step for the Manufacturing Order as "Finished" in the Shop Floor App. The final step means the bottom task on the Operations list, not the last open task.

In this example, let's assume that "Quality check" is the final operation step for the T-Shirt.

The actual quantity of products made cannot be reported before completing the final step.

  • (optional) If you have enabled reporting for actual ingredient quantities consumed in the Shop Floor App, then the Operator will be first asked to report the quantities of ingredients. After the ingredients have been reported, the next step will appear.

  • The Operator is asked to indicate the actual quantity of products made with the Manufacturing Order.

By default, the total planned quantity is indicated. You can change the quantity if needed.

You can also leave comments on the quantity of the product made. Click on "+Add a comment" and enter any information.

This comment will be displayed in the "Additinoal Info" section of the Manufacturing Order on the Katana MRP main site together with the Operator name. It will not overwrite any existing additional info on the MO but will be added after a comma at the end of an existing note.

Changing the quantity of the finished product does not change the quantities of ingredients used for the Manufacturing Order. Basically, changing the quantity is indicating that you made more or less of the product with the planned (or actual reported) ingredients.

Note: Katana does not support partial completion of Manufacturing Orders yet. The quantity of finished products entered is the total quantity made with the Manufacturing Order.

  • Click "Finish".

  • When the task is finished, the actual quantity of product made is recorded on the Manufacturing Order. If all the operations for the MO are completed, then the MO is completed.

Only if the product is batch-trackable and the batch number has not been assigned to the Manufacturing Order, then the MO is kept as "Work in progress" until the batch number is assigned on the Katana MRP main site.

  • The Actual Quantity of the product made with the Manufacturing Order is added to your Stock.

You cannot edit the Actual Quantity for the product on a completed Manufacturing Order. You would need to revert the MO back from the "Done" status to change the quantity.

What about Stock movements?

It is important to understand how Stock movements work when Operators report the actual quantity of product made from the Shop Floor App.

  • Stock movements are recorded only when the Manufacturing Order is completed. If the final step of the operations for the MO was completed and the actual quantity of the product reported, but the MO remained open for a specific reason, then the products are not yet added to your Stock. The MO might remain open after completing the final step if some other steps have not been completed yet or the batch number for a batch-trackable item has not been assigned on the MO.

  • Until the Manufacturing Order is open (not completed), the "Expected" quantity of the product in Stock is always based on the Planned Quantity of the Manufacturing Order.

  • As the "Expected" quantity of the product in Stock is based on the Planned Quantity before the MO is completed, then the reported Actual Quantity does not have any effect on the sales items availability calculations for your Sales Orders (before the MO is completed).

  • When the Manufacturing Order is completed, then the Actual Quantity of the product made will be added to Stock. At this point, it might have an effect on the sales items availability for Sales Orders if the actual quantity made was different than the planned quantity.

Did this answer your question?