Work Orders & Assemblies

The Work Orders & Assemblies module manages light assembly, kit building, and manufacturing. It decomposes multi-component Bills of Materials (BOM), allocates raw material parts, tracks work-in-progress (WIP), and calculates finished goods unit costs.

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Work Order Lifecycle & Costing

stateDiagram-v2
    [*] --> Draft : Create Work Order
    Draft --> Planned : Plan / Allocate Components
    Draft --> Cancelled : Cancel

    Planned --> InProgress : Start Assembly (Issue Components to WIP)
    Planned --> Cancelled : Cancel (Release Component Reservations)

    InProgress --> Completed : Finish Assembly (Stock Finished Units)
    InProgress --> Cancelled : Abort Assembly (Return Unused Components)

    Completed --> [*]

1. Work Order States & Progression

• Draft: Production job created, target assembly selected, and component requirements calculated from BOM.
• Planned: Components checked and reserved from warehouse storage bins. Shortages enter the Purchase Demands queue.
• In-Progress: Production underway. Component stock is physically issued from bins to Work-In-Progress (wip bin).
• Completed: Finished goods verified, unit cost calculated, finished items moved to Putaway staging, and work order closed.
• Cancelled: Job cancelled; reserved or issued components returned to storage.

2. Live Assembly Costing & Valuation

When completing a build (completeBuild), the system calculates total job costs and finished inventory valuation:

Component Materials Cost = Sum(Component Expected Quantity * Component Unit Cost)
Total Assembly Labor Cost = Assembly Cost Per Unit * Target Quantity
Total Work Order Cost = Component Materials Cost + Total Assembly Labor Cost + Additional Cost
Finished Product Unit Cost = Total Work Order Cost / Target Quantity

• Component Materials Cost: Calculated from the snapshotted Bill of Materials components (work_order_components) based on expected quantities and their unit cost / Moving WAC.
• Assembly Cost Per Unit (assemblyCostPerUnit): Variable direct labor or machine running cost entered per finished unit.
• Additional Cost (additionalCost): Fixed lump-sum overhead, machine setup fee, or subcontracting charge for the overall build.
• Inventory Capitalization: Completing the build capitalizes the finished products into warehouse inventory at the new Finished Product Unit Cost, while crediting the consumed raw materials.

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Step-by-Step Workflows

1. Creating and Executing a Work Order

1. Go to Manufacturing → Work Orders (/manufacturing/work-orders).
2. Click New Work Order (/manufacturing/work-orders/new).
3. Select the Assembly Product and enter the Target Build Quantity.
4. The system snapshots component requirements from the active Bill of Materials into work_order_components.
5. Enter any Unit Assembly Cost (labor per unit) and Additional Cost (setup/overhead).
6. Click Plan Work Order to verify and reserve component stock.
7. When assembly begins, click Start Assembly to issue components to WIP.
8. Upon completion, verify output quantities and click Complete Work Order.

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Field Reference

Field	Description
Work Order Number	Production identifier (WO-...).
Assembly Product	Finished item being manufactured.
Target Build Quantity	Planned assembly count.
Components	List of raw materials and sub-assemblies required with unit costs.
Assembly Cost / Unit	Direct variable labor and machine cost per assembled unit (assemblyCostPerUnit).
Additional Cost	Fixed lump-sum setup or overhead fee (additionalCost).
Total Cost	Total build cost (components + assembly labor + additional cost).
Status	Stage (Draft, Planned, In-Progress, Completed, Cancelled).