Assembly and kitting

A bill of materials defines the component quantity for an explicit output basis. The work order selects the effective bill, routing, output product, standard cost, warehouse and planned quantity. For a distributor preparing a multi-item kit, the output is a reviewed product made from recorded component quantities; the order preserves the component basis used for the kit.

Warehouse Manager reviews release against the frozen work basis. Warehouse Operator records material issues and production entries as actual work occurs. Completion records the eligible output and its cost, leaving any variance visible for the close decision. Partial completion keeps the remaining planned quantity distinct from finished goods already received.

• Version. Decide which bill and routing version applies on the planned date.
• Material. Check component units, allowed loss and stock before release.
• Output. Keep completed quantity and residual variance visible at close.

Set up the output product, standard cost and component units before releasing work. Name the Warehouse Manager who can approve a work order prepared by another person. Agree how a shortage interrupts material issue and how scrap is recorded against the allowed basis. Finance Manager should know which variance requires financial review rather than treating all planned output as completed inventory.

Create a kit order with a planned quantity greater than one partial completion. Release it against an active bill and routing, issue only the first required components and record the first output. Check that the remaining work is still open and that output stock rises only by completed quantity. Attempt to close the work with an unresolved residual variance; require the independent decision or zero residual before close.

A revised bill should take effect for new work without rewriting output already completed under an earlier version. Use the work order revision and stock events to trace which components were actually consumed. If only part of the plan is finished, the team can investigate missing components or scrap before scheduling the rest. Finance can reconcile work cost with finished output and the remaining variance.

Before the next completion, compare the issued component quantity with the output already recorded. The Warehouse Manager can then decide whether more material is needed or whether scrap explains the difference. The work order remains the common reference for both checks.

• Work Orders Awaiting Release — Review planned work before material and output can post.
• Warehouse Availability — Check components and finished output positions.

Follow the operating process and use the data model when mapping source records.