In the Shop Floor App, Operators can report the actual quantity of the product made with a Manufacturing order (MO). They can 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 easily report the actual output.

The actual quantity can ONLY be reported for Manufacturing orders that are Make-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 of a MO 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 a MO 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 always be automatically used as the actual output quantity. If you want to start reporting actual quantities from the Shop Floor App, you need to enable this on the Katana MRP main site.

Operators can also report the actual quantity of ingredients consumed with a MO. 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. On the Katana MRP main site, go to Settings screen > 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 of a MO 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 can't be reported before completing the final step.

  • (optional) If you enabled reporting for actual ingredient quantities consumed in the Shop Floor App, 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 MO.

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

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

This comment will be displayed in the Additional info section of the MO on the Katana MRP main site along with the Operator name. It will not overwrite existing additional info on the MO but will be added at the end of an existing note.

Changing the quantity of the finished product does not change the quantities of ingredients used for a MO. 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 MO.

  • Click Finish.

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

If a product is batch-trackable and the batch number hasn't been assigned to the MO, the MO stays as Work in progress until the batch number is assigned on the Katana MRP main site.

  • The Actual quantity of product made with the MO is added to Stock.

You cannot edit the Actual quantity for a product on a completed MO. You would need to revert the MO back to an Open 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 products made from the Shop Floor App.

  • Stock movements are recorded only when a MO is completed. If the final step of operations for a MO is complete and the actual quantity of the product reported, but the MO remains open for a specific reason, the products are not yet added to Stock. The MO may remain open after completing the final step if other steps haven't been completed or the batch number for a batch-trackable item hasn't been assigned on the MO.

  • As long as a MO is open (not completed), the Expected quantity of the product in Stock is always based on the Planned quantity of the MO.

  • As the Expected quantity of a product in Stock is based on the Planned quantity before the MO is complete, the reported Actual quantity doesn't have an effect on the sales items availability calculations for Sales orders until the MO is completed.

  • When a MO is completed, the Actual quantity of product made will be added to Stock. At this point, it may have an effect on the sales items availability for Sales orders if the actual quantity made is different than the planned quantity.

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