Assembly and kitting

A work order uses an effective bill of materials, routing, output product and cost standard. Required component quantities and operation instructions are frozen for released work. Warehouse Operator records material issue, operation time, good output and scrap against the order.

Warehouse Manager reviews release and close. A completion records accepted terminal output and cost allocation once for the completed scope. For a dealer kit assembled from stocked items, the team can compare required input, actual consumption, output and remaining variance without treating intermediate operation counts as finished goods.

• Plan. Warehouse Manager checks the output product, bill of materials, routing and planned quantity.
• Execution. Warehouse Operator records component issue, operation time, good output and scrap against released work.
• Close. Warehouse Manager reviews remaining material and cost variance before closing the work order.

Choose an output product with active bill and routing versions. Agree the output base quantity, component loss allowance, standard cost and warehouse location. The released work order must retain those versions even if a future master change takes effect.

Assign an operator to each planned operation and a manager to release and close. Decide which observation proves good output and how scrap will be reviewed. A partial completion should leave remaining planned scope and variance visible.

Release a work order for a small kit from stocked products. Verify that the planned quantity is positive and the frozen bill, routing and standard match the intended output. Warehouse Operator issues only the required material tranche, records an operation and posts part of the planned output.

Compare component consumption, good output, scrap and remaining material. Try to close with an unresolved variance; Warehouse Manager should have to resolve or independently approve it. Repeat a completion event and confirm it cannot add finished stock or cost a second time. Trace the final stock position back to the production completion.

A partial production run may consume a different component mix from the plan. Keep each component issue and operation entry with the work order, and show Warehouse Manager the residual variance. The final completion should reflect actual accepted output, not just the quantity the order intended to produce.

• Work order schedule — Released and active work by planned start and end, output product and manager.
• My assigned operations — Operations assigned to the signed-in Warehouse Operator with their planned times.

Continue with the process and the implementation plan.