Manufacturing Module — User Guide

1. Overview

The Manufacturing module plans and executes production: plant master data, BOMs and routings, MPS/MRP planning, shop-floor orders, inventory issues/receipts, batch traceability, optional QC/packaging/pharma controls, and production costing posted to Finance.

Feature flags in manufacturing settings typically control Quality, Quarantine-on-QC, Packaging, Pharmaceutical extension, and Costing.

2. Getting started

2.1 Recommended setup order

1. Ensure Inventory items, UoMs, and warehouses exist.
2. If costing is used, align Finance accounts with manufacturing cost settings.
3. Enable Quality / Packaging / Pharma / Costing as needed.
4. Build plant hierarchy.
5. Create and approve BOMs and routings.
6. Configure inspection plans and packaging BOMs if enabled.
7. Enter demands, run plans/MRP, generate orders.
8. Execute shop floor and close/cost as required.

2.2 Main navigation

3. Plant hierarchy

Routings reference work centers/machines; scheduling uses line capacity; the dashboard can filter by plant and line.

4. BOMs and routings

Manufacturing BOM

Versioned bill of materials for a finished item.

Approve requires at least one line. Approving a version typically obsoletes prior approved versions of the same BOM number. Components must be valid Inventory items.

Routing

Versioned process route with operations: sequence, work center, machine, setup/run time, labor/machine flags, scrap %, quality checkpoint. Approval uses the same Draft → Approved → Obsolete pattern and requires at least one operation.

Packaging BOM

When packaging is enabled: Draft → Active → Inactive. Lines include packaging components (and label flags). Used to create packaging orders from production.

5. Planning

Production demands

Sources: Manual, Sales, Forecast. Manual CRUD plus Import from Sales for open sales demand (skips duplicates).

Production plans (MPS/MRP)

MRP requirements use actions such as Produce or Purchase. Generated production orders often start as Planned. Schedules are managed mainly from the plan detail screen (Scheduled / Confirmed / Cancelled entries).

6. Production orders

Statuses

Key actions

Parent/child orders support multi-level assemblies from MRP.

Operations

Operation statuses: Pending → Running ↔ Paused → Completed | Skipped.
Starting the first operation can move the order to InProduction. Completing all operations moves toward ProductionCompleted (or PartiallyCompleted if some remain). Scrap can be recorded as material, product, or operation scrap.

7. Material issues and outputs

Material issues

Create when the order is Approved or MaterialsRequested. Create from BOM scales components by planned quantity and scrap %. Issue checks stock, posts Inventory ISSUE, moves the order to MaterialsIssued, and supports batch/traceability logging.

Production outputs

Create/post when the order is in production or completed. Posting receipts finished goods, updates genealogy, and if Quality is enabled may set QualityPending and create inspection (and quarantine when configured). Otherwise a completed order may move to Released.

8. Packaging

When packaging is enabled:

1. Activate a packaging BOM.
2. Create a packaging order (optionally from a production order).
3. Issue materials → Start → Complete (receipt finished packaging qty; track reject/waste).

Statuses: Draft → MaterialsIssued → InProgress → Completed | Cancelled.

9. Batches, quarantine, and traceability

Batch lots

Statuses: Open, Closed, Quarantined. Create or generate for an order; optional serials. Lots are often auto-ensured on issue/output. Closing is blocked while quarantined.

Quarantine

Statuses: Active, Released, Rejected. Can be auto-created when QC holds output. Release can free the order; Reject can cancel the linked order. Quarantine management is primarily API/permission-based (dashboard may show active count).

Traceability

Link types such as Consumed in, Produced from, Parent of, Derived from. Use backward/forward batch inquiry and order genealogy; manual links can be added.

10. Quality

Inspection plans

Draft → Active → Inactive. Plans define checks (min/max/expected values).

Inspection requests

Pending → InProgress → Completed | Cancelled.
Results: Pending / Pass / Fail / Conditional pass.
Decisions: Release, Reject, Rework, Hold.

Completing with Release typically sets the order to Released (and releases quarantine). Reject cancels the order. Rework returns to InProduction. Hold keeps QualityPending. You generally cannot Release if any check Failed.

11. Costing

When costing is enabled:

Cost elements: Material, Labor, Overhead, Scrap. Variances: Material, Labor, Overhead, Total.

Calculate uses issued materials, operation labor rates, and overhead settings. Post to GL creates a Finance journal (and optional variance accounts) using configured account codes.

Manufacturing costing is separate from the Cost Accounting module; organizations should avoid inconsistent dual posting.

12. Pharmaceutical extensions

When the pharmaceutical extension is enabled:

Treat destruction/controlled logs as compliance records; confirm inventory impact in your process.

13. Dashboard and reports

Dashboard

Order counts (active/completed/cancelled), yield and scrap, issues/outputs, status breakdown, trends, top lines, pending inspections, active quarantines, cost/variance summary. Filters: date, plant, line.

Reports hub

Production orders, scrap, quality, cost variances, line utilization.

14. Permissions summary

Permission group: Manufacturing.

15. Integration with other modules

Appendix A — Quick procedures

A.1 Engineer a product

1. Create plant hierarchy.
2. Create BOM with components → Approve.
3. Create routing with operations → Approve.

A.2 Plan and generate orders

1. Enter or import demands.
2. Create plan → Confirm → Run MRP.
3. Generate orders / PRs / schedule as needed.
4. Approve and Release production orders.

A.3 Run the shop floor

1. Create material issue (from BOM if possible) → Issue.
2. Start and complete operations.
3. Create output → Post.
4. Complete QC if required → Release.
5. Calculate and post production cost if enabled.
6. Close the order.

A.4 Package finished goods

1. Activate packaging BOM.
2. Create packaging order → Issue materials → Start → Complete.

Appendix B — Operating notes

Appendix C — Document control

This guide describes functional capabilities of the Manufacturing module as implemented in the Vertex ERP codebase. UI labels may appear in English or Arabic depending on language settings.