Work in Progress – Rajawali Adikarya

What Is?

Work in Progress (WIP) is goods in various stages of completion throughout the plant, including all material from raw material that has been released for initial processing, up to completely processed material awaiting final inspection and acceptance as finished goods inventory.

Within SYSPRO, Work in Progress is used to track the activity of the manufacturing process and manage the performance of the shop floor in order to minimize job costs, utilize production resources efficiently and provide comparative reporting.

Jobs are created with or without material and labor allocations. The job start and completion dates, as well as when material should be ordered, are based on a job’s operations. The system uses both material and labor allocations to calculate the expected cost of a job.

When you start posting material and labor to jobs, actual costs are recorded against the job. You can access the Work in Progress Query and print various reports to view the differences between expected and actual costs.

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SYSPRO Solution

The Work in Progress system enables you to post material usage and labor in real time and in batch mode. It also enables variance reporting to be produced between estimated costs and actual costs of each job. Work orders may be added for stocked items (with a bill of materials) stocked items without a bill of materials or non-stocked items.

These work orders can create a bill of jobs for all relevant sub-assemblies down the BOM chain. Labor transactions can be posted through kit issues, manually or imported into the system from a data collection interface. Material allocations can be issued to a job through kit issues or manually and optionally allow for the substitution of a material allocation when performing kit issues.

Process Flow

Jobs are created for stocked items (with a bill of materials), stocked items without a bill of materials or non-stocked items. After ensuring that all the material needed is in stock, or purchase orders are created to meet the material requirements, the jobs are confirmed.

Floor stock items are issued and the rest of the materials as per allocations. The items are manufactured and the labor gets allocated against the jobs. The job is now complete. The Work in Progress value is zeroized and the job is closed.

Variance reporting is produced between estimated costs and actual costs of each job.

Process Flow for Work in Progress

Integration

The Work in Progress solution can be integrated with other solutions in the SYSPRO system, including:

Inventory

Stock items are issued as material to jobs and job parent items are typically receipted back into stock.

Accounts Payable

For stocked items, the supplier assigned to the item is used to create a purchase order in Trial Kitting when a summary list of components is generated for the job or a standard part.

In the A/P Invoice Posting program when posting the GL Distribution you are able to post invoices for non-stocked items directly to a job.

Cash Book

In the Deposits & Withdrawals program you are able to post payments for non-stocked items directly to a job.

General Ledger

If Work in Progress is integrated to General Ledger then the job material issues, job stock receipts, labor posting and part-billings transactions are posted to the General Ledger.

Purchase Orders

During, Trial Kitting, purchase orders can be created for job components. Also, within the Purchase Order Entry program, purchase order lines can be linked to jobs.

Sales Orders

Within the Sales Order Entry and Backorder Review programs, you can link a sales order line to a job. When the job parent is receipted it updates the sales order line with the quantity.

Lot Traceability

Lot Traceable items are used when allocating material or creating a parent item in the Job Creation and Maintenance program.

Bill of Materials

Used when creating a job in the Job Creation and Maintenance program for a stocked item with a bill of material.

Quotations

During quotation confirmation, jobs can be created to supply the order for the non-stocked items.

Product Configurator

In the Job Creation and Maintenance program you are able to create a job for a configured product via the Product Configurator Wizard.

Projects and Contracts

In the Job Creation and Maintenance program you are able to create a job for a non-stocked item and select to track costs to the hierarchy.

Requirements Planning

Jobs provide input to material supply and demand, as well as operation allocation calculations within Requirements Planning, which, in turn, recommends suggested jobs to meet calculated demand.

Accounts Payable

You can allocate the cost of the items directly to a job in the AP Invoice Posting program, when posting supplier invoices for items that have been purchased specifically for a job.

Bill of Materials

When creating a job for a stocked item, the Bill of Materials for the item is used to define the components, work centers, machines and operators to be used in the manufacturing process.

Cash Book

Whilst posting a withdrawal in Cash Book you can post payments for non-stocked items directly to a Work in Progress job.

Posting to a job can only be performed in the current company. The Cash Book and Work in Progress modules must be in the same period and both must be open.

General Ledger

SYSPRO enables you to determine whether you want Work in Progress to be integrated to the General Ledger and if so, whether the integration is to be in real-time or in batch mode, and whether the transactions are to be posted in detail or in summary (see General Ledger Integration in this document).

The system uses the general ledger account held against the job when processing Work in Progress transactions. This is determined as follows:

the code defined against your Preferences in the Job Entry program is used if this is not defined, then
the code defined against the stock code is used if this is not defined, then
the code defined against the warehouse is used if this is not defined, then
the code specified within the General Ledger Integration program is used
You can change this account for a job that has not been confirmed and against which no transactions have been posted.

If you create a hierarchical job and you use the Hierarchies for Job program to define a WIP ledger code against a head/section of a hierarchy, then work in progress costs are posted to the ledger code defined against the head/section for the hierarchy.

Although work centers derive their default costing rates and units from the cost center to which they are assigned (e.g. costing rates, time and capacity units of measure, run time calculation method and General Ledger productive and non-productive codes) these can be overridden at work center level.

Use the Work Centers program to define the Work Center GL Integration accounts.
Inventory

Using the Job Issues program, you can issue stocked items to a job as components.

You can receipt the finished items into stock using the Job Receipts and the WIP Inspection Maintenance programs.

When both the Inventory and Work in Progress modules are installed, Work in Progress transactions cannot be processed unless both modules are in the same financial period.

Lot Traceability

Lot Traceable items are used when allocating material or creating a parent item in the Job Entry program.

You can use the Component to Parent Tracking Query program to trace a serial or lot from the time it was purchased or manufactured, through to its issue to a job.

Projects and Contracts

In the Job Entry program, you can create a job for a non-stocked item and select to track costs at hierarchy level.

Purchase Orders

When Inventory is installed, the Purchase Order Receipts program Purchase Orders > P/O Receipts uses the Inventory module control record to establish the current period and year. Purchase Order receipts can only be processed if the current month is the same in both the Inventory and Purchase Order modules.

You can create Purchase Orders from the Trial Kitting program when a summary list of components is generated for a job or there is a need to fill a requirement for a component.

Purchase Orders

Purchase Orders integrates with Work in Progress when the receipt of items against a purchase order line linked to a specific job is processed.

Purchase orders can be created for job components from the Trial Kitting program, or you can link a purchase order line to a job when entering the purchase order.

Quotations

During quotation confirmation, jobs can be created to supply the order for non-stocked items.

Requirements Planning

Once the Requirements Calculation program has been run, the Job Review program enables you to update existing live jobs that have not started, according to actions from the plan in the snapshot, or create new jobs from suggested jobs.

Sales Orders

When creating a sales order for which there is insufficient stock, you can select to create a job on acceptance of the line. This job is linked to the sales order line and when the item is receipted into stock it is released to the sales order.

You can create jobs for made-in and subcontract items for a selected sales order line in the Back Order Review program.

Essential and recommended modules

Essential

Inventory

Recommended

Accounts Payable
Cash Book
General Ledger
Purchase Orders
Sales Orders
Lot Traceability
Bill of Materials
Quotations
Product Configurator
Projects and Contracts
Requirements Planning

Work in Progress Integration to other SYSPRO solutions

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