AccountMate’s Manufacturing module allows you to quickly
and efficiently create work orders and explode jobs into virtually unlimited levels of raw material, labor, machine and subassembly components.

With this module, you can easily monitor inventory levels of the goods that you manufacture, break down large jobs into multiple starting dates and post work-in-process automatically
or manually. You are
able to print work
orders, routing slips, production slips and a wide array of reports as well as track jobs, resource usage and backorders through the posting of finished jobs and the cancellation of any unused allocated resources.

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AccountMate 7 for LAN
Manufacturing Module

Easy to Manage Bill of Materials

At the heart of the Manufacturing module is the bill of materials. Users can easily set up bills of materials for parent items using the inventory, machine and labor records available in the system. They can define the ratio of component items required to produce one unit of a parent item based on the actual production formula or recipe. They can also customize labor and machine production rates on each bill of materials in which the components are used. Best of all, the bills of materials may be updated at any time without affecting the production formula defined on existing work orders.

Bill of Materials Maintenance

Material Requirements Planning for Component Items

To facilitate production scheduling, users can set the system to check inventory on-hand quantities at each production stage. When work orders are exploded, the system calculates how many units of each component items will be required during production and compares the requirement against the available units. This information is available on the Projected Material Requirement Report that can be used in planning the purchase of component items.

Unlimited Notes and Manufacturing Instructions

Each machine, labor and inventory record comes with a NotePad where users can enter unlimited notes. Users can also enter unlimited manufacturing instructions and recipes for each bill of materials. These remarks and instructions are copied onto each work order where the components or bill of materials are used.

Track Availability, Costs and Production Rates of Machine and Labor Resources

Machine and labor costs can be applied to jobs using the bill of materials. Users can enter the following data for each machine or labor record:
  • Production rates

  • Costs

  • Work shifts

  • Time allocated

  • Set-up and/or tear-down time

  • Time used or worked

  • Time before next overhaul (for machine records only)
The foregoing information is used to determine availability of machine and labor resources, and to calculate the machine and labor costs that will be applied to production. This level of detail allows users to closely monitor operations to maximize profitability.

Ability to Copy Data

The Manufacturing module’s copy feature significantly reduces data-entry time and keystroke errors. Components can be copied from an existing bill of materials to a new record where they can be revised, if necessary. Information can be copied from existing inventory, labor or machine records to new ones where they can be edited. Copying bills of materials and component records can be done within the same company or across companies. Line items can also be copied from an existing work order or from an open sales order. For further convenience, users can set the system to include the backorder quantity when creating a work order from an open sales order.

Multiple Start Dates and Request Dates for Jobs

Work orders calling for the production of a master item and some of its components (i.e. subassemblies) are split into several jobs, and each job may start on a different day. Large production orders can also be split into separate work order line items, with a separate request date assigned to each line item to facilitate resource scheduling.

Unlimited Master Items and Job Levels

Each work order can include an unlimited number of master items to be produced. Each master item on the work order can be exploded into an unlimited number and level of jobs, each consisting of its own machine, labor and raw material components.

Automate Work Order Explosion and Work-In-Process Posting

Work orders can be exploded as they are created or they can be exploded at a later time to reduce data entry time. Work orders can also be automatically posted to work-in-process (WIP) as soon as they are saved. Alternatively, users can choose to post finished jobs without posting to WIP. These options give users the flexibility to record the progress of each work order in a manner that best suits their company’s production model.

Expedite Manufacturing by Using Available Subassemblies

Users can save production time by choosing to fill all or part of a job’s subassembly needs from existing stock, rather than manufacturing all subassemblies.

Overbooking of Resources Can Be Prevented

When posting work orders into process and when posting finished jobs, the system allocates the raw materials and subassemblies to each job and compares these allocated resources against what is available in the system. To help prevent overbooking of resources, the Manufacturing module will not allow processing of work orders that use inventory in excess of on-hand quantity unless the “Allow Overuse of Inventory for Component Item” option in the Manufacturing Module Setup is marked. Since users control this setting, they can turn this feature on or off depending on whether the insufficient quantity resulted from delayed recording of material component receipts.

Flexible Posting and Voiding of Work-In-Process

Work order line items can be put into process, and WIP can be voided for any master item on a work order. This saves users time, since the system automatically posts or voids WIP for all subsidiary jobs. Alternatively, jobs can be put into process, and WIP can be voided for a specific job without affecting other jobs in the work order. This kind of flexibility enhances the value of the Manufacturing module as it helps lower data entry costs while still providing detailed status tracking of the company’s work orders.

Flexible Posting of Finished Jobs

Work orders can be posted as finished for a particular master item. This saves time since all subsidiary jobs are simultaneously posted as finished. Alternatively, work orders can be posted as finished by job. This allows users to gradually release finished quantities on a work order without waiting for completion of other jobs that may still be in process. Finished units may be released immediately to inventory for use in sales or for further production, or they may be held until they pass quality assurance checking.

Choice of Calculation Methods

The Manufacturing module provides users with significant flexibility in calculating production and overhead costs. Users can apply either the actual or standard costs to finished goods, or apply actual costs to component items and finished subassembly items, and standard costs to finished master items. They can choose to apply overhead costs to finished items in addition to the applied actual or standard costs. When applying overhead costs, users can assign an amount or apply a percentage of production costs.

Ability to Cancel Work Orders and Backorders

Work orders can be closed without completing a unit of the ordered items. Backorders on partially completed work orders can also be cancelled, returning unused items to inventory and automatically releasing labor and machine resources.

Wide Selection of Documents and Reports

Work orders, routing slips, production slips and bills of materials can be printed for use in production and scheduling. In addition, a wide variety of inventory, machine, labor, work order, production and finished job reports can be generated. These can be used to analyze production variances and inefficiencies in order to help reduce manufacturing costs.

Integration with General Ledger, Inventory Control, Lot Control, Sales Order and Purchase Order Modules
  • Integration with the General Ledger module enables users to easily post accounting entries for manufacturing transactions to the General Ledger either temporarily or permanently using the Transfer Data to GL or Period-End Closing functions, respectively.

  • When integrated with the Inventory Control module, users can take advantage of such features as multiple warehouses and bin locations, assign different cost methods to component and parent items, assign different units-of-measurement to component items on bills of materials, and use serialized items in production.

  • When integrated with the Lot Control module, lot numbers can be assigned to component parts to track the use of these items in production. This tracking mechanism is a powerful tool to address bio-terrorism concerns or to effectively manage perishable components.

  • When integrated with the Sales Order module, users can easily create work orders from sales order data.

  • When integrated with the Purchase Order module, users have access to various purchasing and receipt tracking functions so they can more effectively schedule production around the expected arrival of purchased component items.
Other Features
  • Instant access to inventory information by drilling down on the item number

  • Unlimited system and work order remarks

  • Use an item’s master bin as the default bin during production

  • Completion dates for work-in-process are estimated based on work order start dates and the historical average days to complete the job

  • Component lists can be amended on a work order after they are exploded

  • Work orders can be put on hold until all components are available
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