In the Shop Floor App, Operators can report the actual quantities of ingredients consumed for a specific Manufacturing Order. They can either indicate the planned quantity or change the consumed quantity if it's different from planned.

This enables the Operators to report waste or deviance from the planned consumption for any reason. If the actual quantity is often higher or lower than the planned quantity, maybe the planned quantity should be reconsidered.

The actual quantity of ingredients used is asked at the time of completing a task in the Shop Floor App. It is asked for each task separately. The Operator can leave additional comments on the quantity consumed for each ingredient.

To identify the tracked ingredients the operator can use the shop floor control app barcode scanning option with a smart device camera. Read more

If the ingredients are batch trackable then the batch numbers can be assigned by the operator while tracking the actual quantity of ingredients used. Read more

You can choose whether the actual quantity of ingredients consumed is asked from Operators or should the planned quantity be always automatically used as the actual 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 products made with a Manufacturing Order. Read more

Enabling tracking for actual ingredient quantities consumed

To enable tracking for actual ingredient quantities from the Shop Floor App:

  1. Go to "Settings" -> "Shop Floor App"

  2. Enable "Ask consumed ingredient quantities from the operator when a task is finished"

Reporting the actual quantity of ingredients

To report the quantity of ingredients used in the Shop Floor App:

  • An Operator marks a task as "Finished" in the Shop Floor App.

  • A list of all ingredients for the Manufacturing Order opens in a popup window. Check the ingredients that you have used and report the quantities.

The quantity of the ingredient is the amount consumed for the total product quantity on the Manufacturing Order. For example, if the MO is for 3 pieces of T-Shirt and I performed the task for all 3 T-shirts, I should add the total quantity of fabric used for 3 T-Shirts (for the quantity per one T-Shirt).

In Katana, ingredients are not related to specific tasks or operations, therefore the entire list of ingredients for the MO is displayed.

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

You can also leave comments for the quantity used. Click on "+Add a comment" and enter any information.

This comment will be displayed as a Note for an ingredient on the Manufacturing Order on the Katana MRP main site together with the Operator name. It will not overwrite any existing notes for ingredients on the MO but will be added after a comma at the end of an existing note.

If multiple tasks consume the same ingredient, the actual quantity for the ingredient will be the sum of quantities consumed with all tasks.

  • Click "Finish".

  • When the task is finished, the quantity of materials consumed is recorded for the MO in the Katana MRP main site. Any comments left for ingredients is displayed as Notes for the ingredient on the MO.

  • You can edit the Actual Quantity for each ingredient manually in the Katana MRP main site.

What about Stock movements?

It is important to understand how Stock movements work when Operators report the consumed quantities of ingredients from the Shop Floor App.

  • Stock movements are recorded only when the Manufacturing Order is completed. Reported consumed ingredients quantities from the Shop Floor App are not immediately deducted from Stock in Katana.

  • Until the Manufacturing Order is open (not completed), the "Committed" quantity of ingredients in Stock is always based on the Planned Quantity of ingredients, even if the reported quantities in the production process have been different from planned.

  • As the "Committed" quantity of ingredients in Stock is based on the Planned Quantity before the MO is completed, then the reported Actual Quantities do not have any effect on the ingredient availability calculations for your other Manufacturing Orders (before the MO is completed).

  • When the Manufacturing Order is completed, then the Actual Quantity of ingredients consumed will be deducted from Stock. At this point, it might have an effect on the ingredient availability for other Manufacturing Orders if the consumed actual quantity was different than the planned quantity.

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