Manufacturing Module

Manufacturing

Complete production management from planning through execution. Multi-level BOMs, MRP, work orders, shop floor control, and quality management in one integrated system.

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PRODUCTION
Dashboard
Work Orders
Scheduling
ENGINEERING
BOMs
Work Centers
PLANNING
MRP
Demand
QUALITY
Inspections
NCRs

Production Dashboard

Real-time production overview

Work Orders
24
6 in progress
OEE
87.4%
+2.1% vs target
Yield
98.2%
Above standard
Downtime
1.2%
4.2 hrs today

Active Work Orders

WO #ProductQtyStatusProgress
WO-001Widget Pro A500In Progress
68%
WO-002Assembly Kit B200In Progress
45%
WO-003Component X1000Released
0%
WO-004Part Y Assembly750In Progress
82%
WO-005Module Z300Released
0%
Multi-level
BOM Support
Real-time
Shop Floor Visibility
Integrated
MRP Engine
100%
Traceability

Bill of Materials

Define product structures with multi-level BOMs, version control, and cost rollup calculations.

Bill of Materials
Multi-level BOM structures with version control, effectivity dates, and engineering change management.
  • Multi-level BOMs
  • Version control
  • Effectivity dates
  • Phantom assemblies
  • BOM comparison
BOM Costing
Calculate standard costs with material, labor, and overhead rollup. Simulate cost changes before applying.
  • Cost rollup
  • Material costing
  • Labor costing
  • Overhead allocation
  • What-if simulation
Where-Used Inquiry
Trace component usage across all products. Impact analysis for material changes and substitutions.
  • Component tracing
  • Impact analysis
  • Substitution planning
  • Cross-reference reports
  • Revision tracking

Work Centers & Routing

Define production resources and manufacturing routes with operation sequences and standard times.

Work Centers
Define production resources with capacity calendars, efficiency factors, and cost rates.
  • Machine centers
  • Labor pools
  • Capacity calendars
  • Efficiency factors
  • Cost rates
Routing & Operations
Define manufacturing routes with operation sequences, setup times, and run times per unit.
  • Operation sequences
  • Setup/run times
  • Alternate routings
  • Operation library
  • Routing versions
Routing Costing
Calculate labor and machine costs based on routing times and work center rates.
  • Time × rate costing
  • Setup cost allocation
  • Machine hour rates
  • Labor cost calculation
  • Overhead application

Work Order Management

Create, schedule, and track work orders from release through completion with full material traceability.

Work Order Management
Create, release, and track work orders through the complete production lifecycle.
  • WO lifecycle
  • Material allocation
  • Component issue
  • Quantity reporting
  • WO costing
Work Order Scheduling
Schedule work orders considering capacity, material availability, and due dates.
  • Forward/backward scheduling
  • Finite capacity
  • Resource loading
  • Gantt visualization
  • Rescheduling
Material Picking
Generate pick lists, allocate inventory, and issue components to work orders.
  • Pick list generation
  • Inventory allocation
  • Backflush option
  • Substitute materials
  • Return to stock

Work Order Lifecycle

Track work orders through every stage of production

Draft
Work order created, materials allocated
Released
Released to shop floor
In Progress
Production started
Complete
Production finished
Closed
Costed and closed

MRP & Planning

Material Requirements Planning engine with demand calculation, planned orders, and planner action messages.

MRP Engine
Material Requirements Planning calculates demand, generates planned orders, and provides action messages.
  • Demand calculation
  • Net requirements
  • Planned orders
  • Lot sizing policies
  • Lead time offset
Demand Management
Consolidate demand from sales orders, forecasts, and safety stock requirements.
  • Sales order demand
  • Forecast consumption
  • Safety stock
  • Customer allocations
  • Interplant demand
Action Messages
Automated recommendations for planners: expedite, delay, cancel, or change quantity.
  • Expedite alerts
  • Delay recommendations
  • Cancel suggestions
  • Quantity changes
  • Pegging reports

Shop Floor Control

Real-time production tracking with labor time collection, OEE monitoring, and production reporting.

Time Tracking
Capture setup time, run time, and indirect time against work orders and operations.
  • Labor time entry
  • Setup vs run time
  • Indirect time codes
  • Crew/team entry
  • Overtime tracking
Production Reporting
Report production quantities, scrap, and rework with real-time visibility.
  • Quantity reporting
  • Good/scrap/rework
  • Operation completion
  • Yield tracking
  • Production progress
OEE Tracking
Overall Equipment Effectiveness with availability, performance, and quality metrics.
  • OEE calculation
  • Availability %
  • Performance %
  • Quality %
  • Downtime analysis

Quality Management

Inline quality control, non-conformance tracking, and CAPA workflows for continuous improvement.

Quality Control
In-process and final inspections with test specifications and pass/fail criteria.
  • Inspection points
  • Test specifications
  • Sample plans
  • Pass/fail recording
  • Quality holds
Non-Conformance
Track non-conforming materials with disposition, root cause, and corrective actions.
  • NCR creation
  • Disposition codes
  • Root cause analysis
  • Rework tracking
  • Scrap disposition
CAPA Management
Corrective and Preventive Action workflows for continuous improvement.
  • CAPA workflow
  • Action tracking
  • Effectiveness review
  • Audit trail
  • Trend analysis

Multi-Level BOM Structure

Build complex product structures with unlimited BOM levels, phantom assemblies, and engineering change management.

  • Unlimited Levels

    Build deep BOM hierarchies for complex products

  • Phantom Assemblies

    Components flow through without stocking

  • Version Control

    Track all BOM revisions with full history

  • Cost Rollup

    Automatic cost calculation through all levels

Finished Product ALevel 0
Sub-assembly B (qty: 2)Level 1
Raw Material X (qty: 3)
Raw Material Y (qty: 1.5)
Sub-assembly C (qty: 1)
Component D (qty: 4)
Phantom E (qty: 1)→ flows through

Full Feature List

Multi-level BOMs
BOM versioning
Effectivity dates
Phantom assemblies
BOM cost rollup
Work centers
Capacity calendars
Routing sheets
Operation sequences
Setup/run times
Work orders
Material allocation
Backflush consumption
WO scheduling
Finite capacity planning
MRP engine
Planned orders
Action messages
Pegging reports
Shop floor terminals
Labor time tracking
OEE tracking
Quality inspections
Non-conformance reports

Seamlessly Integrated

Manufacturing connects with every module in Khula ERP

Inventory

WIP tracking & material consumption

Purchasing

Auto POs from MRP planned orders

Sales

Make-to-order from sales orders

Finance

WIP accounting & cost variances

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