In the physical world, manufacturing is the combination of multiple components into one finished product. In the supply chain software world, manufacturing works more like a map. Everything involved in the physical production needs to be mapped in the software.
Imagine you are making an ice cream cone. In the physical world, you take a scoop of ice cream, attach it to a cone, and only then do you have an ice cream cone. You no longer have ice cream and a cone, you just have one ice cream cone. In the system it is different.
You have three items in the system: the ice cream, the cone, and the ice cream cone. The system reads the items like this:
Ice Cream Scoop: Quantity 1
Cone: Quantity 1
Ice Cream Cone: Quantity 0
When you manufacture the final product the Ice Cream Cone quantity jumps to 1 and the component quantities drop to 0. The point is that everything already exists in the system, only the quantity changes. Even when the quantity is 0, the SKU exists. This is the only way to track inventory and quantities across your entire system.
Create a BOM SKU
The very first step in creating a manufacturing workflow is to create a BOM SKU. A BOM, or Bill of Materials/Manufacturing, SKU is the final product. This is the product that your customers purchased and that you need to manufacture. You will also need to create an SKU for each component.
From the OMS account, go to the inventory tab and select “Add SKU”
Fill in the Necessary Information
At this point, you should create the SKU the same as you would any other product. You can also do this by uploading a CSV.
The SKU we’ve selected is BIKE-RED. This is our BOM SKU because it is the final product.
Create a SynSet
1. In the OMS account, go to Inventory dropdown menu and select Synsets.
2. Now select “Add Synset”
Fill Out the SynSet Information
1. Name your Synset.
2. Write a quick description for the warehouse
3. Enter in your BOM SKU (this is the final product SKU)
Add the Components
You now need to add each component and the quantity of each component.
1. Click “Insert” to add an SKU to your Bill of Materials. Each time you click “Insert” you add one unit to the Bill.
2. You can also edit the quantities by selecting “Edit” and typing in the desired quantity.
3. When you’ve added everything, click submit.
Orders with BOM SKUs
Create an Order
For testing purposes we create a pick order. This part of the process usually occurs automatically through Integrations.
Add a Finished Good (BOM SKU) to the Order
1. Select the manufactured item (BOM SKU), enter quantity and click insert.
2. The item will be shown as part of the order to be inserted.
3. Click Continue
Verify and Submit the Order to the WMS
Just verify and click “Confirm Submit”
Your Order Will Go Into Backorder Until the Items Are Produced
The order is now in Backorder status in the Orders tab.
Warehouse Manufacturing Workflow
The Warehouse Takes Over From Here
These steps are for the Warehouse Team. First login to the Warehouse side.
1. Go to the “Pending” tab.
2. They will see a button: “Manufacture” indicating there is work to be done.
After Clicking the “Manufacture” Button, Add the BOM SKU to a Bin
After selecting the manufacture button, you will need to add the BOM SKU to a Bin. If the BOM SKU already has a bin, you can select the bin from a dropdown. Otherwise, select “Add Bin”
Fill Out the Bin Information
After selecting Add Bin, you will see this pop-up. When you start typing a bin, you will get a dropdown of available bins. Select a bin and click Add.
Now Select Process
1. Click the check boxes next to the orders you want to manufacture
2. Click the “Process” button.
Print the Work Order
You now have the option to print the manufacturing work order.
Process the Order
In the Processing tab, select the order you want to process, then select Process.
Start the Picking Process
1. You are automatically directed to the “Processing” tab.
2. Select the order(s) you want to start picking.
3. At this point you can print the packing list or assign the order to user. If you assign the order, the information will be sent to a connected device.
Print Out the Packing Lists and the BOM Lists
1. The packing list has the list of finished goods that can be shared with the client
2. The BOM list is similar to the packing list, but it includes all the parts that make the finished good, so it serves as a checklist.
NOTE: The design of the BOM or Checklist can be improved in the future.
Shipping the Package
Before we get a label, you might need to divide the order into multiple packages. We’ve created a separate order with two manufactured items to show you what this looks like.
1. Click “Divide”
2. If the order does not need to be divided, you can click on Xenvio to get a label and give the package to the truck. All your items are prepared and the finished goods are ready to go! You are done.
Divide an Order (Optional)
Occasionally, you may need to ship a BOM SKU in multiple boxes. If this is your situation, then follow this workflow.
You can split the units of a single line item (SKU) into multiple packages:
1. Enter a number in the “split” text box. (Note: The number in the split text box is the number of SKUs per box – in this case we split by 1. Each box will contain 1 item. Because there are 2 items in this order, there will be 2 boxes. If there were 3 items and we split by 2, then we would have 2 boxes)
2. Click Split
3. Click Continue
Verify Before Dividing
You will see the allocation of the products that go in each box
1. If everything looks good, just click “Submit”
2. If you want to make changes, click “Edit” and you will return to the previous screen
You Now Have 2 Packages Ready to Ship
After dividing the package with more than one unit, you will see a “Multibox” link under the processing status. This lets you know there are more than one package for this order number.
In order to get shipping labels and ship the packages:
1. Select the boxes you need labels for (or Select All)
2. Click on Xenvio to get the labels
These Orders Are Set As Local Pick
Xenvio will produce an additional packing list for local pickups. The packing list can act as BOL if a truck comes to pickup the goods.
Manual “Mark as Shipped” After the Truck Picked Up the Order
Click on the Ship Number or any package to see its contents and further actions/options at the top of the screen. In this case, we can mark the order as shipped.
1. Click on the action “Mark as Shipped”
Fill in Tracking Number and Cost
You only need to fill in the tracking number and final transportation cost.
1. Enter a tracing number or BOL provided by the Trucking Company (LTL)
2. Enter the cost associated with the Shipment (for reporting and accounting purposes)
3. Click Submit
The Order is Now Shipped
1. Go to the “Shipped” Tab
2. The package is immediately shown in the “Shipped” status.
3. You will see the Tracking Number or BOL Number associated with the package.