How to Manufacture Part A Units from Pre-Mixed Stock
Learn how to manually create a works order, allocate components, build part A units, and clear leftover mix using stock takes in your manufacturing software.
By Ben Fotheringham
This guide explains how to manually process and build Part A units using pre-made mix. By following these steps, you will accurately log component allocations, record true yields, and clear any scrap material left in mixing bins.
This process applies to production and manufacturing staff who assemble finished units from existing subassemblies. Use this workflow when a mix is already prepared and waiting to be transferred into individual Part A containers.
Creating the Works Order
1
Head to Manufacturing Module
2
Click Work in progress.
If the work order has already been created it can be found in this list - skip to step 12
3
Click Manufactured Variants.
4
Search for the variant by typing its code (e.g., "hbe-lg-5").
5
Select the desired variant from the list.
6
Click Create Works Order.
7
Type the expected production quantity (e.g., "90").
If the mix has not already been made/in production, keeping include sub assemblies ticked will also create a works order for the Mix and step 8 can be skipped
8
Uncheck Include Sub Assemblies.
9
Click Create.
10
Click OK to confirm the works order creation.
Progressing the Order and Allocating Components
11
Return to the Work In Progress tab.
12
Select the Work Order for the Part-A's we are working on
13
Click Progress and follow the prompts, clicking Yes to confirm progression to the next steps.
14
The description will tell us what to do at each stage
15
Click Save and Progress button to move to the next step.
16
Follow instructions until you get to the Allocate Components stage
17
Click the Components tab.
18
Click Edit Component Allocations at the bottom of the screen.
Do not use the auto-allocate feature. Manually allocate components to maintain strict control over which batches are assigned to the Part A units.
19
Select a component line (like tins) and click Add.
20
Type the amount of product being used directly into the Typed In column, on the row matching the batch/location of product you are using.
Different batches and or different stock locations (bins) will be on different lines
21
Click Save.
22
When allocating the mix component, select the specific batch you prepared (e.g., "Training"). Avoid assigning remnant batches left over from previous mixes.
23
Repeat this allocation process for all other items, including labels, and close the window when finished.
24
Save and Progress
25
Click Yes to progress past the allocation process step.
Adjusting Yields and Building the Order
26
When we hit the Edit work order quantity step; Click Save on the progress screen to pause progression.
27
Double-click the active Works Order.
28
Update the original expected quantity to match your actual output (e.g., updating 90 to 85) to automatically de-allocate unused items.
It is better to over estimate quantity and reduce at this stage - any stock over allocated will automatically be un allocated, when we drop our number here, meaning we don't have to allocate more
29
Save the updated Works Order.
30
Click back into Progress.
31
Save and progress
32
Click Yes to complete the progression and proceed to the Build section.
33
In the labels output options, enter the number of labels to print (you can print extra labels for the lab if needed).
Please throw away any unused labels to avoid confusion at later date
34
Click Build to finalize the order into stock and print your labels.
Clearing Leftover Mix via Stock Take
35
Click the Stock module.
36
Click Stock take.
37
Click Add to begin a new stock take.
38
Select your location (e.g., Featherstone).
39
Click Next.
40
Search for the bin where the mix was held (e.g., "MIX1").
41
Select the bin and click Next.
42
Assign the stock take to the relevant staff member.
43
Highlight the specific batch you used (e.g., "Training") and click to include it in the count.
44
Leave the counted quantity at 0.000. This logs the remaining amount as scrapped or lost material.
The amount we are scrapping is shown in red
45
Click Save and Complete to clear the leftover mix from the system.
Q: Why should I uncheck the "Include Sub Assemblies" box?
A: If your mix is already prepared and waiting, you don't need a subassembly works order. Unchecking this box tells the system you will use pre-existing mix rather than making more.
Q: Why is it important to manually allocate components instead of using auto-allocate?
A: Manually allocating components ensures you maintain strict control over which specific batches are assigned to the Part A units, preventing accidental use of incorrect or remnant batches.
Q: How do I handle a situation where my actual production yield is lower than expected?
A: Before finalizing the build, edit the works order and update the expected quantity to your actual yield (e.g., from 90 down to 85). The system will automatically de-allocate the over-allocated components to balance out your stock.
Q: Why do I leave the quantity at zero during the stock take for the mixing bin?
A: Leaving the stock take quantity at zero clears out any remaining material that was lost during production, such as product stuck to the mixing blade or vessel, ensuring your inventory records remain accurate.
Term
Definition
Works Order
A directive or document detailing the assembly, manufacturing, or processing of specific materials into a finished product.
Subassembly
A pre-assembled unit or mix that is incorporated into a larger final product, such as a bulk mix ready for individual packaging.
Auto-allocate
A system feature that automatically assigns available component stock to a works order, often disregarding specific batch selections.
Stock Take
The process of manually counting and verifying the actual physical inventory present in a specific bin or location.
Discrepancy
The difference between the expected inventory level and the physically counted stock, often representing scrapped or lost material.
