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Advanced Manufacturing in Ianai ERP

Advanced Manufacturing in Ianai ERP allows businesses to create, customize, and manage manufacturing processes dynamically based on item attributes and options chosen at the time of order. Unlike traditional manufacturing systems that rely on static Bills of Materials (BOMs), this system generates BOMs dynamically, adapting to each order’s unique specifications.

How It Works in the Inventory System​

Item Attributes and Item Options​

  • In the Item Detail Page, users can define attributes (e.g., material, size, color) and options (e.g., add-ons, custom engraving) for products.
  • When a customer places an order, they can select different options for an item (e.g., size, material, color, special features).
  • These selections are saved in the order table as JSON, making it easy to store and retrieve customization details.

Dynamic Bill of Materials (BOM)​

A Bill of Materials (BOM) is like a recipe for building a product, listing all raw materials, components, and instructions required.

  • Instead of having a fixed BOM, Ianai ERP dynamically generates the BOM based on the customer's selected attributes and options.
  • This means that every product can have a customized BOM based on what the customer ordered.

Automated Build Orders in the Work Order​

In the Work Order, where manufacturing takes place:

  • Users can create Build Orders to start production.
  • The system automatically generates builds from dynamically created BOMs.
  • This ensures streamlined and efficient manufacturing, reducing errors and improving speed.

Key Components of Advanced Manufacturing​

1. Bill of Materials (BOM)​

A recipe for manufacturing, specifying:

  • Raw materials
  • Components
  • Instructions required to build the product

2. Routing (The Step-by-Step Path)​

Routing is a predefined sequence of operations needed to manufacture a product.

Example: Routing for a Bicycle​

  1. Cutting → Cut metal tubes into frame pieces.
  2. Welding → Weld the pieces together.
  3. Painting → Apply paint coating.
  4. Assembly → Attach wheels, pedals, and seat.

Each Work Order follows the Routing to complete tasks at the correct Work Centers.

3. Work In Process (WIP)​

Work In Process (WIP) refers to partially completed products still in production. They haven’t reached the final stage yet but are no longer raw materials.

Example: WIP for 100 Bicycles​

  • ✅ 20 frames cut (Work in Process)
  • ✅ 10 frames welded (Work in Process)
  • ✅ 5 frames painted (Work in Process)
  • ❌ 0 bicycles fully assembled (Not yet finished)

WIP is tracked inside Work Orders to monitor progress and costs.

4. Work Centers (Where Work Happens)​

Work Centers are physical or virtual locations where manufacturing operations take place. Think of them as stations in a factory, each specialized for a certain type of work.

Example Work Centers:​

  • Cutting Work Center → Cuts raw materials.
  • Welding Work Center → Joins metal parts.
  • Painting Work Center → Paints finished items.
  • Assembly Work Center → Assembles the final product.

Each Work Center includes:

  • Labor costs
  • Machine costs
  • Overhead costs

5. Build Assembly (Transaction)​

A Build Assembly is a single-step transaction that:

  • Takes component items out of inventory.
  • Converts them into an assembly item.
  • Updates inventory levels accordingly.

Example: Building 100 Bicycles​

  • Materials used: Wheels, frames, pedals.
  • Final output: Bicycles.
  • Cost tracking: Materials, labor, overhead.

🚨 A Build Order does NOT track step-by-step production—that’s where Work Orders come in.

When to Use Build Assembly:​

  • For simpler assembly scenarios without multi-step manufacturing.
  • When tracking partial completions or WIP isn’t required.

Limitations:​

  • No step-by-step production tracking.
  • No multi-stage Work in Process (WIP) tracking.

6. Work Order (Record)​

A Work Order is a detailed instruction sheet for the factory. It is a BOM and Routing-related transaction.

Example: Work Orders for Bicycle Production​

  1. Work Order #1 → Cut 100 metal frames in the Cutting Work Center.
  2. Work Order #2 → Weld the frames together in the Welding Work Center.
  3. Work Order #3 → Paint the frames in the Painting Work Center.
  4. Work Order #4 → Assemble the bicycles in the Assembly Work Center.

Each Work Order has:

  • Line items (steps to complete).
  • Progress tracking per Work Center.

7. Work Plan (Batch Work Orders)​

The Work Plan feature enables the creation of bulk Work Orders linked to Sales Orders. This ensures that production is efficiently scheduled and executed based on demand.

Summary​

Ianai ERP’s Advanced Manufacturing module dynamically adapts to unique orders, allowing:

  • Customizable BOMs based on order specifications.
  • Automated Work Orders that follow Routing and Work Centers.
  • Work In Process (WIP) tracking for detailed production monitoring.
  • Seamless integration with Sales Orders and Inventory.

This system enhances efficiency, reduces errors, and supports businesses in managing complex, customizable manufacturing processes.