Production Reports and Inquiries

Production Reports & Inquiries Guide

Reports Accessed from Production Order Screen

All reports listed in this section can be accessed via the Actions Menu on the Production Order screen. Reports are displayed based on the production order's workflow status. They are also available under the Reports menu in the Production Workspace.

Production Prepost Report

• This report helps determine if the recipe and or production order is setup correctly.
• This report will be available in any production status with the exception of Released.
• If status equals ‘Scheduled’ then report uses planned quantities, otherwise it will use actual quantities for the details of the production order.  It will always use estimated average cost at the time the report run.  
• Totals at the bottom will show an anticipated Per Unit Cost based on the base UOM of the finished good.  Also reflected is the total for the based on the Planned Qty for the entire production run.

Production Order Pick List

• Provides a list of stock items to be pulled for this production order.  Can alternatively be used as a manual entry form for recording actual usage during production.
• If the lot class for the item is set to auto assign the lot numbers, they will show on this form.
• All header and line level production notes will print on this form. 
• Once the Pick List is printed a checkbox on the Production Order screen will be checked identifying that the Pick List has been printed.  If need to reprint, uncheck the box and it will enable the option to print again.

Production Detail Report

• Available to print after a production order is Released.
• Shows Finished Good lot numbers with Expiration Date and lot numbers and quantities used for Stock Components.  If weight is setup at the component stock item it will also calculate the total weight.

Production Cost Report

• Available to print after a production order is Released providing the costing results of what was produced and posted to stock.  All costs are final at this point.
• Shows Total Qty produced, totals for Stocking and Non-Stock component, Unit Cost for the Total Quantity posted to inventory and Total Cost posted to the general ledger.

Production Variance Report

• Available to print after a production order is Released providing the variance between planned an actual on all quantities and costs.

Production Barcode Label

• A generic barcode label is provided that prints based on the finished good data found in the production order.
• The label is customizable to the size needed.
• GS1 application identifiers are embedded in both GS1 barcode formats (code 128 and QR code) and additional application identifiers for quantity and or weight can be added based on GS1 UOM specifications used in your setup.
• The barcode will not contain any data if the GTIN/EAN/UPC/ISBN ‘Alternate Type’ is not defined on the Cross-Reference tab of the Stock Item screen for the finished good.

Reports Available in the Production Workspace

The following reports are accessible from the Reports menu in the Production Workspace.

Production Order Master Pick List

• Lists items that need to be picked but provides a combined list of many production orders based on the criteria selected.  This can be based on a date range or production area.
• The quantity column is a total for all production orders in the range.  The user can enter their picked quantity or their initials in the blank line.
• The items are grouped by the Default Issue From location setup on each stock item.

Track and Trace

This report provides the necessary data for lot traceability in the event of a recall.  This report has its own document with a detailed explanation available here Track and Trace.

Finished Goods Weekly Demand

• Provides a quick review of Sales Order demand vs. Production planned for the next 28 days broken into 4-week blocks.
• Only lists stock items with a type set as Finished Good and marked as a Recipe.
• First section labelled as ‘Demand Thru This Week’ will include any orders not yet shipped or production orders not yet produced from prior to this week, I addition to activity scheduled for this week.
• Red indicates a shortage and will show the quantity short.  Green indicates enough inventory on hand, or items being produced satisfies the demand.  The green will always show zero.
• Report can be run in Summary for all warehouses or in Detail to list out the same information per warehouse.

Order Fulfillment Report

• Lists all details of all Sales Order demand and Production Orders planned, per item, in date order as they are scheduled to identify which date a shortage will occur.
• The data will include orders ‘On Hold’ or transfer orders (‘TR’ order type) based on the checkboxes used in the Material Demand Preferences screen.
• Options to run as Detail which will show all entries for that item and when exactly an item may go negative.  If running in Summary it will basically hide the detail lines and only show one line item per line with the final expected quantity assuming all expected transactions.
• Details represented:
  • Always lists each warehouse quantity and the warehouse name as the first lines in the report.
  • Order # column will either be a Sales Order number or Production Order number. 
  • Date will be either the Requested Ship Date for that SO line item or Production Order Date.
  • Status will come from the SO or the Production Order. 
  • Qty On Hand is always a warehouse value of On Hand or an In Transit Warehouse transaction.
  • Order Qty will always come from a Sales Order.
  • Production Qty will always come from a Production Order.
  • Customer / Warehouse
    • If a Warehouse transaction, it will show the Warehouse name.
    • If a SO or FC type of order, it will show the customer’s name.
    • If a TR type of order, it will show the From and To warehouse names.

o   Running Total is a calculation starts at the top, adds anything in the Qty on Hand column, subtracts anything in the Order Qty column and adds back anything in the Production Qty column.  When this total becomes negative it will show in RED to alert that it will not meet the demand for this date.

Daily Supply and Demand

• Provides a 14-day view of actual production supply and demand with both Finished Goods and Subassemblies.  The details will indicate specifically which day production is not meeting demand.
• Options to run as Detail which will show each warehouse and their respective quantities, or Summary which will show as one line item per inventoried item.
• The demand for finished good items come from Sales Orders or Forecast orders entered as an FC type.  The numbers will include orders ‘On Hold’ or transfer orders (‘TR’ order type) based on the checkboxes used in the Material Demand Preferences screen.
• The demand for subassemblies come from an open production order producing a finished good, that has the subassembly listed as a component.
• The supply for both finished goods and subassemblies is provided from finished good production orders in any status except released.

Production Component Usage

• Lists a rolling 12-month tally of all components used in production. 
• Current month will be in MTD column which could be a partial month.
• Provides AVG/Month and Annual columns which will use the 12 month column and ignore the MTD column.
• Only includes details from production orders, does not include other inventory transactions.

Inquiries Accessed on the Production Workspace

All inquiries found under the Inquiries menu item of the Production Workspace. 

Item Lot Inventory Inquiry

• Lists all the open lot numbers for an item selected, their expiration date if used and the warehouse the item is located.

Production Order Schedule

• Shows a list of all production orders that are open. 
• Filter tabs provide a list by each production status of Scheduled, Picking, Picked or In Production.

Inventory History by Lot Number

• Lookup transaction history on a lot number to see all history.
• Allows a start date to any point in time with other filters for Warehouse, Location or a specific inventory ID.

Material Demand

• This inquiry provides the detail records of what is needed to be purchased or produced.  This inquiry has its own document with a detailed explanation Material Demand.

Recipe Component Details

• Select one recipe at a time and it will show all components in that recipe, including any explosion of components from a subassembly recipe.  If a component is a subassembly, it will show the component highlighted in yellow.
• The component level column will identify multiple levels if a subassembly is used. If your subassembly, has a subassembly it will change the level number and also list the subassemblies in yellow to reflect another level.   
• The In Recipe column will show the original recipe the component is listed under, if the recipe is a subassembly, it will list these recipes in yellow.
• This inquiry is only able to select the recipe that has the ‘Default Revision’ checkbox selected.
• Rolls up the costs for all the components to provide an estimated unit cost based on the base stocking UOM.

Production Cost Review

• Includes all details from every production run created including both information on components and finished goods. 
• List all unit costs, planned and actual quantities and production yields. 
• Provides a Pivot based on a date range of total costs for production item but mostly intended for users to create their own pivots or to export the data for further analysis as needed.

Where Used

• Enter any component or subassembly item and it will show every recipe that the item can be found with the component quantity used for that recipe.

Production Analysis

• Representation of Finished Good output to list production quantities of planned, produced and the production area the item was produced. 
• Data feeds into dashboard widgets of “Planned vs. Produced” and “Batches Per Production Area”.